KFM 903K Series User manual

Programmable industrial controller KFM 903K / 93 B 903K E
Page 1 of 20
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data subjects to alterations 903K_BE / 201119
1 Display for relay function
2 Descriptive text for relay functions
3 Descriptive texts and digital value displays
4 Unit of display
5 Key for setpoint and parameter mode
6 Setpoint adjustment
certifications: DIN, GL, BV
General:
KFM 903 is an industrial microcomputer-based controller series in control panel format 96 x 96 mm
with a performance range of up to 9 relay outputs (changeover), various signal inputs and outputs
as well as numerous possible optional extras. Communication with control systems is also possible.
Additional contacts can be switched time dependent using the integrated real time clock.
Controllers of the series 903 can be delivered with the type extension K in a freely programmable
version and then available functional packages can be added arbitrary within the hardware, using a
graphical workspace, so that a separate control system is often not necessary.
The belonging module software 99pkm provides beside ready to use controller modules a large
number of control functions and logical operations compact within the individual device, furthermore
expansion modules, an external malfunction alarm unit or a second freely programmable
controller 903K can be added to it by using the standard interface.
Alternatively, the delivery can be done unprogrammed with hardware in various types. In this case
the programming is provided by the customer or at extra cost by the factory.
The transmissive colour TFT indication is easy to read in both light and dark environments.
Parameter set, TFT- configuration, data logger recordings and fault history can be transferred by
means of conventional USB stick. Irrespective from that, the continuous logger data is automatically
saved on a regular basis if the USB stick is inserted.
The touch operation of the TFT- display is optionally available.
Depending on version, the industrial controller can configured and read out via USB stick.
F903-tft110202
1 2
56
Vorlauf / Supply
Rücklauf / Return
Brenner +
Brenner -
Grundlast
RL-Min-Alarm
VL-Max-Alarm
Kaltstart-Begr.
Sollwert

Programmable industrial controller KFM 903K / 93 B 903K E
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data subjects to alterations 903K_BE / 201119
Content
Hardware- types (unprogrammed)................................................................................................... 3
Intended use..................................................................................................................................4
Personnel qualification .................................................................................................................. 4
Installation..................................................................................................................................... 4
Electrical safety ............................................................................................................................. 4
Electrical wiring.............................................................................................................................. 5
Putting into operation..................................................................................................................... 5
Maintenance.................................................................................................................................. 5
Operating status ............................................................................................................................. 6
Setpoint value setting..................................................................................................................... 7
Manual operation............................................................................................................................ 7
Parameter level 1 ............................................................................................................................ 8
Parameter level 2 ............................................................................................................................ 9
Configuration level ....................................................................................................................... 10
Manual optimization.....................................................................................................................12
Self- adaption (optional) .............................................................................................................. 13
Additional contact –type of function .......................................................................................... 14
Additional contact –special functions..........................................................................................15
Software ........................................................................................................................................ 16
PKS.............................................................................................................................................16
PKM ............................................................................................................................................16
PKD.............................................................................................................................................16
PCS.............................................................................................................................................16
Error messages............................................................................................................................. 17
Technical data............................................................................................................................... 18
Wiring diagram.............................................................................................................................. 19
About KFM-Regelungstechnik GmbH..........................................................................................20
REFERENCE!
This symbol refers to further information in other sections, chapters or other manuals.

Programmable industrial controller KFM 903K / 93 B 903K E
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data subjects to alterations 903K_BE / 201119
Hardware- types (unprogrammed):
Type
Measuring inputs
Binary inputs
Analogue outputs
Relays
903K2223
2
2
2
3
903K2C46
2
12
4
6
903K5828
5
8
2
8
903K5K28
5
20
2
8
903K5K64L
5
20
6
4 (+2 Logik outputs)
903K8223
8
2
2
3
Depending on version, RC elements for external mounting are enclosed, only in exceptional cases
internal RC elements are wired on terminals for the selective connection.
versions 903K.. (type suffix)
Measuring inputs * for potentiometer: _*w,
Analogue outputs * voltage: _*u
* = Number in case of several in- and outputs
Special versions depending on quantities possible.
Hardware- expansion modules: see sheet 852..
External malfunction alarm display: see sheet 826..

Programmable industrial controller KFM 903K / 93 B 903K E
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data subjects to alterations 903K_BE / 201119
Intended use
The device is intended, in accordance to the technical data, for measuring- and control functions in
industrial environments.
Any other use or usage beyond this scope is not considered as intended.
The device is constructed in accordance to the current standards and directives and complies with
safety regulations.
Nevertheless, improper use can result in danger to life or property damages.
In order to avoid risks, the device must be used for the intended use in a proper safety condition
and in compliance with the delivered technical documentation. Application- related dangers can
occur also if the device is appropriate or intended used caused for example by missing safety
devices or wrong adjustments.
Personnel qualification
This document includes all information necessary for the intended use of the device described
therein.
It has been written exlusively for technically qualified personnel who have been specially trained
with expertise in automation technology. Understanding these informations and the technically
correct implementation of the delivered documentation are required for safe installation,
commissioning as well as for safety during operation. Work on the device and the electrical wiring
must only be carried out to the extent described by qualified personell.
Installation
Before installation: Inspect the controller for any visible signs of damage caused during transport.
Check power supply according to name plate.
Push the housing from the front into the DIN- panel cut-out and secure from behind with the
fastening devices supplied.
Electrical safety
•All electrical lines of the device must be disconnected during installation/dismantling,
service- and repair work.
•Load circuits must be fused for the maximum load (see technical data).
•The device is not suitable for installation in areas with an explosion hazard.
•In addition to a faulty installation, also incorrectly (for example by self- adaption) or wrong set
parameter values on the device could affect the correct process.
•Safety devices independently from the device should be provided always.
The corresponding safety regulations must be observed.
•The operator must be electrostatic discharged (for example by touching a grounded metal
object) before plugging or pulling of the connecting cables.
•During commissioning, the delivery defaults of the device can be different from the
designated application. The plant constructor is generally responsible for commissioning.

Programmable industrial controller KFM 903K / 93 B 903K E
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data subjects to alterations 903K_BE / 201119
Electrical wiring
•Plug bar on the back face of the controller; connect up the controller following the wiring
diagram on the device.
•Only the terminal blocks supplied are to be used. Replace existing old terminal blocks.
•For connecting power supply phase wire and neutral wire must not be transposed.
•Wire cross section max. 1,5 mm2
•Lay input-, output and supply cabling physically seperated and not parallel to one another.
•Use shielded and twisted cables for the measuring-, control- and interface circuits to avoid
interferences; Ground the shield properly. Do not lay close to components or cables through
which current is flowing.
•Do not loop through ground wires, but connect to a common grounding point in the control
cabinet; furthermore, a professional potential equalization must be noted and the lines must
be kept as short as possible.
•The DIN VDE 0100 “construction of low-voltage systems” respectively the appropriate
country specific regulations (for example on basis of IEC 60364) must be followed for the
wiring material, the installation and the electrical wiring.
•Depending on version and application, possibly mount the enclosed RC-elements (external)
or the jumper (internal RC-elements) in accordance to the wiring diagram.
See chapter RC-elements on page 19
Putting into operation
Switch on power supply. Digital display and control lamps (if available) will light up according to the
setpoint after some seconds. Adjust set value and check other adjustments.
Maintenance
All electronic controllers in the product range of the manufacturer are virtually maintenance-free.
Provided that the controller is correctly installed and put into operation and is protected against
mechanical damage and inadmissible operating conditions, it should give years of trouble-free
service. In case of faults repair work by the customer should be restricted to the externally
accessible leads, connections and components the customer is expressly permitted to deal with
himself (bridge circuits, fuses).
All further work, especially on internal components will terminate warranty, makes subsequent
inspection and fault repair more difficult and can cause considerable damage to the circuitry.
For repair remittance remove plug board with connected leads on the rear side,
loosen fastening devices and remove controller from the panel.
In case of remittance please give precise details of the fault to reduce time and cost of repair.
see chapter error messages on page 17

Programmable industrial controller KFM 903K / 93 B 903K E
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data subjects to alterations 903K_BE / 201119
Operating status:
Sollwert Kanal 1
RL-Min-Alarm
VL-Max-Alarm
Kaltstart-Begr.
SP= 250
Vorlauf / Supply
Rücklauf / Return
Brenner +
Brenner -
Grundlast
Sollwert
Sollwert
Sollwert Kanal 1
RL-Min-Alarm
VL-Max-Alarm
Kaltstart-Begr.
SP= 250
Vorlauf / Supply
Rücklauf / Return
Brenner +
Brenner -
Grundlast
Übertemperatur
Niveau-Min
Analog values: Depending on the configuration, up to three values in 10
mm size or two values in 10 mm and two values in 3 mm size can be
displayed. A dedicated unit for each value can be configured if desired. The
corresponding descriptive texts are changeable by means of the PKS PC
software.Depending on equipment, the status of the relays is shown at the
left side of the display via a coloured circle icon.
In conjunction with the option of binary input messages, the corresponding
texts are shown in the two lower 3 mm display lines if the binary inputs are
activated. The corresponding value displays are hidden during this time.
Message list#: Briefly press the - button (do not hold)
The display now shows a list of message texts for all activated binary
inputs in the order of their occurrence with date and time. Operating
messages are displayed by a circle icon coloured green.Pre- alarm
messages are displayed by a circle icon coloured yellow. Messages which
are configured to the collective relay are marked with a circle icon coloured
red. This flashes until the message has been confirmed by means of binary
input 1 (reset).
History# : Briefly press the - button (do not hold)
As message list, but the display shows a list of optionally saved messages
(max. 40, oldest one will be overwritten). Furthermore, gone pre- alarms
and malfunction messages are marked with a yellow respectively with a red
check mark.
Graphical representation#: - Briefly press the - button (do not hold)
Actual- and setpoint values of the controller are displayed as a continuous
diagram. The actual recording cycle is signalised by an ongoing red dot.
Vertical yellow lines with grey background for date and time represent
recording interruptions.
optional: To switch on the cursor press -button briefly:
The cursor is moved along the time axis with the (earlier) / (later)-
buttons, the values of the cursor position are shown in accordance to the
date and time.
- briefly press the - button to switch off the cursor
Custom specific representations# : briefly press the - button each (do not
hold)
# if existing
Note: The configuration of the graphical- and custom specific display is
possible with the pc- software PKS only, see manual 99pks respectively
chapter software on page 16.
Sollwert
Sollwert Kanal 1
VL-Max-Alarm
Kaltstart-Begr.
SP = 250
Alarm! Grenzwert überschritten
SP = 245
Sollwert Kanal 1
SP
Brenner +
RL-Min-Alarm
Brenner -
Grundlast Vorlauf / Supply
Istwert 1 (198)
Istwert 2 (181) Sollwert (200)
100
11:00 12:00 13:00 14:00
22.05 14:25:26
200
400
300
15:00
22.05 11:30:05
Vorlauf / Supply
Rücklauf / Return
Brenner +
Brenner -
Grundlast
RL-Min-Alarm
VL-Max-Alarm
Kaltstart-Begr.
SollwertSollwert
Sollwert Kanal 1
SP = 250
Vorlauf / Supply
Rücklauf / Return
Übertemperatur
Niveau-Min
RL-Min-Alarm
VL-Max-Alarm
Kaltstart-Begr.
Alarm! Grenzwert überschritten
24.11.02 Wassermangel08:26:53
24.11.02 Rauchgas Übertem.09:34:02
24.11.02 Übertemperatur Dampf11:01:32
25.11.02 Umwälzpumpe Stufe 106:26:55
24.11.02 Druckbegrenzer12:59:56
25.11.02 Brenner Betrieb06:00:53
25.11.02 Brenner Vollast06:26:53
25.11.02 RL-Min-Alarm12:26:53
25.11.02 Umwälzpumpe Stufe 206:26:57
Alarmmeldungen S.1 / 2 25.11.02
14:01:45
Vorlauf / Supply
Rücklauf / Return
Brenner +
Brenner -
Grundlast
RL-Min-Alarm
VL-Max-Alarm
Kaltstart-Begr.
SollwertSollwert
Sollwert Kanal 1
SP = 250
Vorlauf / Supply
Rücklauf / Return
Übertemperatur
Niveau-Min
RL-Min-Alarm
VL-Max-Alarm
Kaltstart-Begr.
Alarm! Grenzwert überschritten
24.11.02 Wassermangel08:26:53
24.11.02 09:34:02 Wassermangel
24.11.02 Übertemperatur Dampf11:01:32
25.11.02 Umwälzpumpe Stufe 106:26:55
24.11.02 12:59:56 Übertemperatur Dampf
25.11.02 Brenner Betrieb06:00:53
25.11.02 Brenner Vollast06:26:53
25.11.02 RL-Min-Alarm12:26:53
25.11.02 Umwälzpumpe Stufe 106:26:57
Historie S.1 / 4 25.11.02
14:01:45
L
L
L

Programmable industrial controller KFM 903K / 93 B 903K E
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data subjects to alterations 903K_BE / 201119
Note: The parameters are shown partially, for full listing see sheet 99pkm_m
(module overview).
Setpoint value setting:
Sollwert
Sollwert Kanal 1
RL-Min-Alarm
VL-Max-Alarm
Kaltstart-Begr.
SP= 250
Vorlauf / Supply
Rücklauf / Return
Brenner +
Brenner -
Grundlast
SP = 245
Sollwert Kanal 1
SP
optional:
*SPB
*SP
SP2 / 3 / ..
SPE
SP-F
- Briefly press the - button (do not hold)
A flashing frame with the description SP shows the activated setpoint
level and the parameter name “SP=”, the adjusted value as well as an
description text optionally.
The displayed value can now be changed using the (lower) and
(higher) buttons.
A setpoint change is effective immediately, without any further operational
steps.
‘Arrow’ button acceleration effect: longer pressing causes faster
changing.
return to operating mode:
briefly press the - button (or automatic after > 30 sec)
Briefly press the - button again each time:
Bus setpoint, forced by an external bus adapter (e.g. 99spde..)
setpoints of additional control loops (*=no)
additional setpoints for the control loop
external setpoint (display only);
flashing description signifies: value is presently not active.
Switch over menu SP / SPE
(only in case of adjustment SPEF=MENU (Conf-level))
Manual operation:
(if existing):Press and hold the -button, then additionally press the - button, then
release both. (Option: Switch on and off using the extra button )
A summary of the existing controller channels and their manual state is
displayed.
The requested channel is marked blue using the ... buttons,
press the - button briefly to continue.
Then, select the status "manual" or "automatic" with the ... buttons,
press the - button briefly to continue.
The status "manual" provides now a manual control using the ...
buttons, the control function is deactivated.
The control function is activated in the status "automatic".
Press the - button briefly to select a channel again.
Note: Marking "all manual" respectively "all automatic" and pressing the -
button briefly choose for all channels in common.
The corrective signal and the actual value are displayed for each channel.
return to operating mode: only with marking "return" and entering -
button briefly (respectively ), no automatic switching back!
Note: The deactivated control function is signalised on the operation
display by the display "Manual operation" on yellow background.
optional: Self- optimisation (see on page 11):
Marked channel -button >5 sec: the display switches to "-Ad-
Sollwert
Sollwert Kanal 1
SP = 250
Alarm! Grenzwert überschritten
Channel
all automatic
all manual
return
State Output Act. val
1
2
3
Manual
Automatic
Automatic
0%
OFF
OFF
150
0
0
Sollwert
Sollwert Kanal 1
RL-Min-Alarm
VL-Max-Alarm
Kaltstart-Begr.
SP = 250
Vorlauf / Supply
Rücklauf / Return
Alarm! Grenzwert überschritten
Brenner +
Brenner -
Grundlast
SP = 245
Sollwert Kanal 1
SP
Manual operation

Programmable industrial controller KFM 903K / 93 B 903K E
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data subjects to alterations 903K_BE / 201119
Parameter level 1
Sollwert
Sollwert Kanal 1
RL-Min-Alarm
VL-Max-Alarm
Kaltstart-Begr.
SP= 250
Vorlauf / Supply
Rücklauf / Return
Brenner +
Brenner -
Grundlast
COD2 = 0
2. Codezahl
PAR1
Access from the operating level
After polling (see instructions for level PAR 1 / 2), a flashing frame with the
description PAR1 / PAR2 shows the activated parameter level.
The upper text display shows the first parameter name and the adjusted
value, the lower text display optionally shows a description text.
continue to the next parameter and/or confirm entry:
briefly press each time the - button
To change the setting displayed: Press the ... buttons
Settings in detail: (existence depends on version and type):
PAR1 Polling: press and hold the - button >5 sec,
release it after the display reacts.
Factory setting:
COD2 Code number 2 (password) for parameter levels (1...9999) 1
USB Stick Menu (only) with equipment USB-host and inserted USB stick:
Functions for data transmission
The requested function is marked blue with the ... buttons,
briefly press the -button to confirm
"Load parameter only", "Load TFT-project",
"Load complete configuration"
Parameter set, TFT-project or the complete configuration will be
transferred from the USB stick into the device, mark the desired file
and confirm with the -button.
"Save parameter only", "Save TFT-project", "Save complete configuration"
Parameter set, TFT-project or the complete configuration will be
transferred from the device into the USB stick.
"Cancel" To exit the menu See sheet 903susb for
additional information
CH.. (only) for multi-channel controllers: Selection of desired channel (no.)
PProportional range Xp (%) (for more details, see “Optimisation”) 25,0
IIntegral action time Tn (min) (for more details, see “Optimisation”) 7,0
DRate time Tv (min) (for more details, see “Optimisation”) 0,2
SH Response sensitivity (“dead zone”) Xsh (%) 0,1
SA. (ZA.)** Setpoint distance (absolute) for following switching contact no. 5,0*
SP. Independent setpoint for switching contact no. 0,0
SD. (ZD.)** Hysteresis (switching difference on/off) for switching contact no. 3,0
Only with configuration time dependent additional contacts:
tSt. Start time for switching contact no.., (weekday, hour, minute) daily/0/0
tL. Switching time for switching contact no.., (days, hours, minutes) 0/0/0
(*..201,701/SA3 :10,0)
**= Je nach Ausführung
return to operating mode:
briefly press the - button (or automatic after > 30 sec)

Programmable industrial controller KFM 903K / 93 B 903K E
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data subjects to alterations 903K_BE / 201119
Parameter level 2
PAR2 Polling: press and hold the - button, additionally press the - button,
hold both buttons for >5 sec, release them after the display reacts.
Factory setting:
COD2 Code number 2 (password) for parameter levels (1...9999) 1
Time adj. Submenu time adjustment, Polling: press and hold the - button >5 sec.
Date Weekday, calendar day, month, year (actual selection marked white) -
Time Hour, minute, second (actual selection marked white) -
Unit Switch over of the display unit (cSt / mPas) cSt
1BLO/1BHI input 1 (viscosity): start / end of display range 0 / 50
2BLO/2BHI input 2 (temperature): start / end of display range 0 / 400
1SLO/1SHI (only) for information signal output: start / end of range 0 / 50
1/2NST Number of decimal places of the display (0 / 1 / 2, depending on range) 1/0/0
1Lo / 1HI Setpoint setting range 1 (viscosity), lower / upper limit 0/50
2Lo / 2HI Setpoint setting range 2 (temperature), lower / upper limit 0/200
FA weighting factor pulses per liter (0,001 .. 99,999) 1,000
BRGH Brightness Display (30 ... 100) 50
DSP1/2/3/4 Variable shown in display line 1-4 (10mm) (OFF/SP/Y/IST*/text**/time**) 1=IST1
Note: display line 1 to 3: 10mm, if DSP4 = “OFF“ 2=IST2
otherwise display line 1 and 2: 10mm, display line 3 and 4: 3mm 3=Y
(SP = setpoint,Y=setting var.,Ist*=actual value channel*/meas. input*) 4=AUS
EIN1/2/3/4 Unit of measurement for display line 1-4
(°C/ °F/ %/ bar/ mbar/ mPas/ cSt/ Kgm3/ mm/ Kpa/ L/ m3/h/ “ “)
Note: no conversion! cSt/°C/%
TEXT1/2/3/4 Desription text for corresponding display line1..4: 1= VISCO
choose from a predefined list: 2= TEMP
(ACT.VAL..,SETPOINT, SUPPLY,RETURN), 3=OUTPUT
resp. 1 additionally editable text.. ,changeable by PKS-software 4=OFF
DSPT Configuration message text OFF
Txt (internal messages in lines 3 and 4, value indication is deactivated),
Txtl (internal messages list only),
Txi (external messages in lines 3 and 4, value indication is deactivated),
Txil (external messages list only),
OFF
Hist. Submenu delete history,
Polling: press and hold the - button >5 sec.
Del Delete history (NO / YES) NO
return to operating mode: briefly press the - button
(or automatic after > 30 sec)
*= ID number in case of several meas. inputs/ control loops. # = corresp. range
**= display line 4 only

Programmable industrial controller KFM 903K / 93 B 903K E
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data subjects to alterations 903K_BE / 201119
Configuration level
Access from the operating level
Polling: press and hold the - button, additionally press the - button,
hold both buttons for >5 sec, release them after the display reacts.
A flashing frame with the description CONF shows the activated parameter
level. The upper text display shows the first parameter name and the
adjusted value, the lower text display optionally shows a description text.
continue to the next parameter and/or confirm entry:
briefly press each time the - button
To change the setting displayed:
Number values: Press the ... buttons, text values:press the - button
Settings in detail (existence depends on version and type):
Factory setting
CODE Code number for configuration level (1...9999), 1
Alternatively: Hold the button for more than 10 sec after code entry:
COD1 Possibility of setting the code number for the configuration level(option). 1
COD2 Possibility of setting the code number for the parameter levels(option). 1
LNG Language selection of the menu texts (Deutsch,English,User def, Off) Deutsch
CONF Selection of the configured controller function (if existent)
Note: when continuing after changing a function, the display first flashes for a
few seconds, only then does the desired switching over or back take place
return to operating mode: Briefly press the - button
or: continue to the following settings:
press the -button and hold it > 5 sec
Sollwert
Sollwert Kanal 1
RL-Min-Alarm
VL-Max-Alarm
Kaltstart-Begr.
SP = 250
Vorlauf / Supply
Rücklauf / Return
Alarm! Grenzwert überschritten
Brenner +
Brenner -
Grundlast
CODE = 1
Codezahl
CONF