Kuhnke 610.441.31 User manual

Kuhnke Electronics
Instruction Manual
Ventura Smart Solution
Power Heat Controller
E 774 GB 30.06.2014 / xxxxxx

This technical information is primarily directed to system designers, project engineers and device develop-
ers. It does not contain any availability information. All specifications are only of a descriptive nature and are
not to be understood as warranted
properties in a legal sense. Exact properties and characteristics shall be agreed in the specific contract.
Claims for damages against us
- on whatever grounds - are excluded, except in instances of deliberate in-
tent or gross negligence on our part. Reproduction of any part of this document is allowed with the author's
consent only. We reserve the rights for errors, omissions and modifications. Pictures are similar. Microsoft®,
Windows® and the Windows® logo are registered trademarks of Microsoft Corp. in the USA and other
cou
ntries. EtherCAT® is a registered trademark and patented technology, licenced by Beckhoff Automation
GmbH, Germany. Further information about the PLCopen organisation is available at www.plcopen.org.
CiA® and CANopen® are registered joint brands of CAN in A
utomation e.V. Title to all companies and
company names mentioned herein as well as to products and product names is held by the respective e
n-
terprises.

KUHNKE Automation Table of Contents
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30.06.2014
Table of Contents
1 Modification History.........................................................................................................................................6
2 Introduction......................................................................................................................................................8
3 Reliability, Safety.............................................................................................................................................9
3.1 Intended Use........................................................................................................................................9
3.2 Target Group........................................................................................................................................9
3.3 Reliability..............................................................................................................................................9
3.4 Symbols ...............................................................................................................................................9
3.4.1 Danger..............................................................................................................................................10
3.4.2 Attention...........................................................................................................................................10
3.4.3 Note..................................................................................................................................................10
3.4.4 Under Construction ..........................................................................................................................10
3.4.5 Instruction.........................................................................................................................................10
3.5 Safety.................................................................................................................................................10
3.5.1 Project Planning and Installation......................................................................................................11
3.5.2 Maintenance and Servicing..............................................................................................................11
3.6 Electromagnetic Compatibility............................................................................................................12
3.6.1 Definition ..........................................................................................................................................12
3.6.2 Interference Emission ......................................................................................................................12
3.6.3 General Notes on Installation...........................................................................................................12
3.6.4 Electrical Immission Safeguard........................................................................................................13
3.6.5 Cable Routing and Wiring................................................................................................................13
3.6.6 Location of Installation .....................................................................................................................13
3.6.7 Particular Sources of Interference....................................................................................................13
4 System Description........................................................................................................................................15
4.1 Overview ............................................................................................................................................15
4.2 Ventura Thermo-controller Hardware Design....................................................................................16
4.3 Technical Properties ..........................................................................................................................17
5 Pin Wiring ......................................................................................................................................................18
5.1 Power Heat Controller on EtherCAT®...............................................................................................18
5.1.1 Connectors.......................................................................................................................................18
5.2 Auxiliary Supply "24VDC", X10..........................................................................................................19
5.3 Device with EtherCAT® Fieldbus Port, X7, X8..................................................................................20
5.3.1 EtherCAT® Fieldbus Port X7, X8.....................................................................................................20
5.3.2 Device and EtherCAT® Status.........................................................................................................20
5.4 Output Channel Terminals, X1 … X6.................................................................................................21
5.5 Operative Earth / Protective Earth.....................................................................................................22
6 Mounting - Installation - Start-up ...................................................................................................................23
6.1 General ..............................................................................................................................................23
6.2 Installation..........................................................................................................................................23
6.2.1 Place of Installation..........................................................................................................................23
6.2.2 Preparatory Steps ............................................................................................................................24
6.2.3 Installation Using the Mounting Rail Adapter...................................................................................25
6.2.4 Removing from the Rail Adapter......................................................................................................26
6.3 Power Supply.....................................................................................................................................27
6.3.1 Short circuit Rating (SSCR) .............................................................................................................27
6.4 Protective Earth Conductor................................................................................................................28
6.5 Output ................................................................................................................................................29
6.5.1 Branch Circuit protection according UL 508A..................................................................................29
6.5.2 Lead fuses........................................................................................................................................29

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6.5.3 Requirements for the output lines....................................................................................................30
6.6 Mounting Lid.......................................................................................................................................30
7 Thermo-controller Operation .........................................................................................................................31
7.1 Starting up..........................................................................................................................................31
7.2 Indicators............................................................................................................................................31
7.2.1 Status Indicators...............................................................................................................................31
7.3 Status Signalling by Thermo-controller..............................................................................................33
7.3.1 Module State....................................................................................................................................33
7.3.2 Channel State...................................................................................................................................33
7.4 Power Output Fuses ..........................................................................................................................34
7.4.1 Replacing the Fuses ........................................................................................................................34
7.4.2 Type of Fuse ....................................................................................................................................35
7.4.3 Allocation of Fuses and Output Channels........................................................................................35
7.5 Thermo-controller Operation..............................................................................................................36
7.5.1 Channel Error at Pilot Stage ............................................................................................................36
7.5.2 Soft Start ..........................................................................................................................................36
7.5.3 Error Suppression at Soft Start........................................................................................................36
7.5.4 Half sine wave control......................................................................................................................37
7.5.5 Mains Voltage Correction.................................................................................................................37
7.5.6 Fan ...................................................................................................................................................38
7.6 Malfunctions.......................................................................................................................................39
7.6.1 Faults................................................................................................................................................39
7.6.2 Power Mains Disturbances ..............................................................................................................39
7.6.3 Troubleshooting................................................................................................................................40
7.7 Preventive Maintenance ....................................................................................................................41
7.7.1 Disposal............................................................................................................................................41
8 EtherCAT® Process Data and Parameters...................................................................................................42
8.1 Module State......................................................................................................................................42
8.2 Channel State ....................................................................................................................................44
8.3 Actual Control Values.........................................................................................................................45
8.4 Phase Voltage....................................................................................................................................45
8.5 Mains Frequency................................................................................................................................45
8.6 Output Stage......................................................................................................................................46
8.7 Version...............................................................................................................................................46
8.8 Module Control...................................................................................................................................47
8.9 Parameters.........................................................................................................................................49
9 Maintenance..................................................................................................................................................50
10 CoDeSys Library for the Thermo-controller (EtherCAT®)...........................................................................51
10.1 CoDeSys ........................................................................................................................................51
10.2 Output Variables.............................................................................................................................52
10.3 Input Variables................................................................................................................................52
11 Appendix......................................................................................................................................................53
11.1 Technical Data................................................................................................................................53
11.1.1 Basic Units .....................................................................................................................................53
11.1.2 Accessories....................................................................................................................................53
11.2 Dimensions.....................................................................................................................................54
11.2.1 Power Heat Controller with Bus Bar Adapter.................................................................................54
11.3 Sales & Service..............................................................................................................................55
11.3.1 Malente Headquarters....................................................................................................................55
11.4 Index...............................................................................................................................................56

KUHNKE Automation Table of Contents
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Introduction
6 E 774 GB
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1 Modification History
Version
Date
Subject
E774D
31/08/2010
Initial release based on the tailored power heat controller model
E774D
09/12/2010
Addenda to the installation and change of fuse sections
Details about the PROFIBUS fieldbus interface
E774D
12/05/2011
New / changed functions at migration from software release SW 2.01 to SW
2.02 or SW 1.04 of hardware HW 1.0x
7.5.1 Channel Error at Pilot Stage
7.5.3 Error Suppression at Soft Start
8.1 Module State (ModuleWarning freewheeling)
E774D
01/06/2011
Status indicators
7.5.3 Error Suppression at Soft Start
E774D
01/08/2011
Use of inhibit signal at start-up in units running software 2.03
7.5.3 Error Suppression at Soft Start
E774D 01/08/2011 7.6.2 Power Mains Disturbances
E774D
01/08/2011
0 Half sine wave control is intended to separately control each of multiple
continuously operated IR lamps. After the soft start stage, the thermo-
controller automatically sets itself to the specified heat output.
As opposed to phase-fired control, half sine wave control is based on com-
plete half-cycles. Interconnecting 3 output channels allows complete sine
waves to be picked off the mains, thereby substantially reducing harmonic
perturbations of the electrical power mains.
Load power variation between 0...100% in steps of 1%.
Mains Voltage Correction
E774D
01/08/2011
8.8 Module Control
Information about actively selecting error suppression using the inhibit signal,
cf. 7.5.3 Error Suppression at Soft Start
E774D
01/11/2011
Legibility improved by clearing up the layout and removing errors
E774D 01/11/2011 7.4 Power Output Fuses
Fuse type changed from 16A to 20A
E774D
13/12/2011
7.4 Power Output Fuses
Fuse type changed from 16A to 20A
E774D
13/12/2011
Legal notice added to document:
EtherCAT® is a registered trademark and patented technology, licenced by
Beckhoff Automation GmbH, Germany.
E774D
15/06/2012
5.3 Auxiliary Supply "24VDC", X10
Advanced Instructions for the auxiliary supply in UL applications or machine.
E774D
10/09/2012
6.7 Output
Branch Circuit protection according UL 508A
Call to action for use in UL member territories
E774D
13/12/2011
7.4 Power Output Fuses
Fuse type changed for UL marked units from 20 A to 16 A
E774D
17/01.2013
6.5 Power Supply
Definition of the power supply and power form for USA
E774D
17/01/2013
8.9 Notes on parameter "Voltage Tolerance"
E774D
05.03.2013
6.7.3 Requirements for the output lines
Guidance on minimum requirements.
E774
18.04.2013
5.7 Output Channel Terminals, X1 … X6
7.4.3 Allocation of Fuses and Output Channels

KUHNKE Automation Introduction
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Version
Date
Subject
Correction of the phase assignment at the output terminals
E774
06.08.2013
Extension of the manual with UL requirements
E774
03.03.2014
Extension Accessories, Fuse Adapter
E774
24.04.2014
5.3 Auxiliary Supply "24VDC", X10 (extension "fuse according UL 248)
E774
19.05.2014
7.5.4 Half sine wave control
Improvement of the Declaration on control method of the power outputs.
E774
17.06.2014
6.6 Protective Earth Conductor
Described additional ground connection at the bottom of the unit
E774
30.06.2014
8.9 Parameters
Software 2.05, Mains Voltage extension

Introduction
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2 Introduction
General functionality
The 9-channel thermo-controller is a power controller with the ability to actu-
ate ohmic consumers. Ohmic consumers are normally contact heaters or in-
frared radiators (IR radiators).
The thermo-controller needs less space in the switching cabinet than solid
state relays and is a cheaper alternative to the classic PLC-based control,
specifically when it comes to detecting failing consumers.
Intelligent soft start by phase-fired controller reduces the inrush load on the
mains when energising the unit.
Multi-talented application
Put the thermo-controller to use wherever you need to discretely adapt the
heat from heating panels made up of several radiators or groups of radiators.
Various areas of mechanical engineering will benefit from this application.
Examples:
•thermoforming machine
•PET stretch blow moulding machine
•drying or curing (e.g. of paint)
•discrete heating of materials.

KUHNKE Automation Reliability, Safety
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3 Reliability, Safety
3.1 Intended Use The thermo-controller is designed as operating equipment in industrial envi-
ronments and for connection to non-public mains.
All other applications need to be discussed with the factory first. The manu-
facturer shall neither be liable for any other than the intended use of our
products nor for any ensuing damages. The risk shall be borne by the opera-
tor alone. The use as intended includes that you read and apply all informa-
tion and instructions contained in this manual.
3.2 Target Group This instruction manual contains all information necessary for the use of the
described product (control device, control terminal, software, etc.) according
to instructions. It is written for design, project planning, servicing and com-
missioning experts. For proper understanding and error-free application of
technical descriptions, instructions for use and particularly of notes of danger
and warning, extensive knowledge of automation technology is compulsory.
3.3 Reliability Reliability of Kuhnke products is brought to the highest possible standards
by extensive and cost-effective means in their design and manufacture.
These include:
•selecting high-quality components,
•quality agreements with our suppliers,
•actions to avoid static charges when handling MOS circuits,
•worst case planning and design of all circuits,
•visual inspections at various stages of fabrication,
•computer-aided tests of all assemblies and their interaction in the
circuit,
•statistical assessment of the quality of fabrication and of all returned
goods for the immediate taking of appropriate corrective actions.
3.4 Symbols Despite the actions described in section 2.3, the occurrence of faults or er-
rors in electronic control units - even if most highly improbable - must be
taken into consideration.
Please pay particular attention to the additional notices which we have
marked by symbols throughout this instruction manual. While some of these
notices make you aware of possible dangers, others are intended as a
means of orientation. They are described further down below in descending
order of importance.

Reliability, Safety KUHNKE Automation
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3.4.1 Danger
This symbol warns you of dangers which may cause death or grievous bodily
harm if operators fail to implem
ent the precautions described.
3.4.2 Attention
This symbol draws your attention to information you must take a look at to
avoid malfunctions, possible material damage or dangerous states.
3.4.3 Note
This symbol draws your attention to additional information concerning the
use of the described product. This may include cross references to inform
a-
tion found elsewhere (e.g. in other manuals).
3.4.4 Under Construction
This symbol tells you that the function described was not or not fully avail-
able at the time this document went to press.
3.4.5 Instruction
Wherever you see these symbols in the left margin, you will find a list of
steps instructing you to take the appropriate computer or hardware
actions.
They are intended as a means of orientation wherever working steps and
background information alternate (e.g. in tutorials)
.
3.5 Safety Our products normally become part of larger systems or installations. The in-
formation below is intended to help you integrate the product into its envi-
ronment without dangers to humans or material/equipment.
To achieve a high degree of conceptual safety in planning and installing an
electronic controller, it is essential to exactly
follow the instructions given in
the manual because wrong handling could lead to rendering measures
against dangers ineffective or to creating additional dangers.