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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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

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Introduction
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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

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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.

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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.

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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.

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3.5.1 Project Planning and Installation
•24 VDC power supply: generate as electrically safely separated low
voltage. Suitable devices include split-winding transformers built in
compliance with European Standard EN 60742 (corresponds to VDE
0551).
•Power breakdowns or power fades: the program structure is to en-
sure that a defined state at restart excludes all dangerous states.
•Emergency-off installations must comply with EN 60204/IEC 204
(VDE 0113). They must be operative at any time.
•Safety and precautions regulations for qualified applications have to
be complied with.
•Please pay particular attention to the notices of warning which, at
relevant places, will make you aware of possible sources of danger-
ous mistakes or faults.
•Relevant standards and VDE regulations are to be complied with in
every case.
•Control elements are to be installed in such a way as to exclude un-
intended operation.
•Lay control cables such that interference (inductive or capacitive) is
excluded if this interference could influence controller operation or its
functionality.
3.5.2 Maintenance and Servicing
•Precautions regulation VBG 4.0 to be observed when measuring or
checking a controller after power-up. This applies to section 8 (Ad-
missible deviations when working on parts) in particular.
•Repairs must be carried out by specially trained Kuhnke staff only
(usually in the main factory in Malente). Warranty expires in every
other case.
•Spare parts:
•Only use parts approved of by Kuhnke. Only genuine Kuhnke mod-
ules must be used in modular controllers.
•Modular systems: always plug or unplug modules in a power-down
state. You may otherwise damage the modules or (possibly not im-
mediately recognisably!) inhibit their functionality.
•Always dispose of (rechargeable) batteries as hazardous waste.

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3.6 Electromagnetic Compatibility
3.6.1 Definition Electromagnetic compatibility is the ability of a device to function satisfacto-
rily in its electromagnetic environment without itself causing any electromag-
netic interference that would be intolerable to other devices in this environ-
ment.
Of all known phenomena of electromagnetic noise, only a certain range oc-
curs at the location of a given device. These kinds of noise are specified in
the applicable standards.
Refer to IEC 61131-4, User's Guideline, for general installation instructions
to be complied with to ensure that hardware interface factors and the ens
u-
ing noise voltages are limited to tolerable levels.
3.6.2 Interference Emission
DIN EN 6100-6-4
3.6.3 General Notes on Installation
As component parts of machines, facilities and systems, electronic control
systems must comply with valid rules and regulations, depending on their
field of application.
General requirements concerning the electrical equipment of machines and
aiming at the safety of these machines are contained in Part 1 of European
Standard EN 60204 (corresponds to VDE 0113).
For safe installation of our control system please observe the information
contained in the next ch
apters (  2.6.4 ff).

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3.6.4 Electrical Immission Safeguard
To bleed electromagnetic interference, connect the controller to operative
earth and ensure best-practice wiring.
Susceptibility to noise
Electromagnetic Compatibility (EMC) - Part 6-2: Generic standards - Immu-
nity for industrial environments (IEC 61000-6-2:2005);
3.6.5 Cable Routing and Wiring
Keep power circuits separate from control circuits:
•DC voltages 60 V ... 400 V
•AC voltages 25 V ... 400 V
Joint laying of control circuits is allowed for:
•shielded data signals
•shielded analogue signals
•unshielded digital I/O lines
•unshielded DC voltages < 60 V
•unshielded AC voltages < 25 V
3.6.6 Location of Installation
Ensure that temperatures, contaminations, impact, vibration or electromag-
netic interference are no impediment to the installation.
3.6.6.1 Temperature
Consider heat sources such as general heating of rooms, sunlight, heat ac-
cumulation in assembly rooms or control cabinets.
3.6.6.2 Contamination
Use suitable casings to avoid possible negative influences due to humidity,
corrosive gas, liquid or conducting dust.
3.6.6.3 Impact and Vibration
Consider possible influences caused by motors, compressors, transfer lines,
presses, ramming machines and vehicles.
3.6.6.4 Electromagnetic Interference
Consider electromagnetic interference from various local sources: motors,
switching devices, switching thyristors, radio-controlled devices, welding
equipment, arcing, switched-mode power supplies, converters / inverters.
3.6.7 Particular Sources of Interference
3.6.7.1 Inductive Actuators
Switching off inductances (such as from relays, contactors, solenoids or
switching magnets) produces surge voltages. It is necessary to reduce these
extra voltages to a minimum.
Throttling elements could be diodes, Z-diodes, varistors or RC elements.
Their rating should conform to the specifications provided by the manufac-
turer or supplier of the actuators.

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4 System Description
4.1 Overview Description of 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 IR
radiators.
Load voltages can be fed through a bus bar. Separate fuses are thus un-
necessary which minimises the amount of space and time needed for instal-
lation.
Super-fast blow-out fuses in the thermo-controller protect both, actuated
outputs and antiphase. Consumers can thus be directly connected without
any need for separate fusing.
Intelligent soft start by phase-fired controller reduces the inrush load on the
mains when energising the unit.
EtherCAT®1fieldbus interface
Ethernet Control Automation Technology
EtherCAT® is the most powerful Ethernet-based fieldbus system currently
available on the market. EtherCAT® puts up the top speed mark, and its
flexible topology and simple configuration make it the perfect means of con-
trolling extremely fast processes. To give you a clue: 1000 I/Os can be ad-
dressed in 30 μs.
Because of its high performance, the simple wiring and its open protocol
support, EtherCAT® is often used as a fast motion control and I/O bus
driven by an industrial PC or in conjunction with control technology on a
smaller scale. EtherCAT® moves beyond the limits of conventional fieldbus
systems. Its interconnections between the controller at one end and both the
I/O modules and drives at the other are as fast as those of a backplane bus.
EtherCAT® controllers thus nearly act like centralised control systems, over-
coming the issue of bus transfer times that conventional fieldbus systems
are burdened with.
Integrated functions
•Extensive diagnostic options provide quick information about the
thermo-controller and the load users need to efficiently locate problems.
- Load failure
- State of fuse
- Power supply failure
•A software function module for CoDeSys controller programs helps us-
ers integrate the controller into the control system.
•Parameter setup and actuation data is exchanged via an EtherCAT®
fieldbus which supports networks of hundreds of thermo-controllers.
•LEDs for optional output status indication help locating faults immedi-
ately at the switching cabinet
1EtherCAT® is a registered trademark and patented technology, licenced by Beckhoff Automation GmbH, Germany.

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4.2 Ventura Thermo-controller Hardware Design
Block diagram

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4.3 Technical Properties
VENTURA Smart Solution
Power controller
9-channel thermo-controller
Load current
9 x 4000 W (each channel carrying max. 10A)
Load type
resistive
Mains voltage
3 x 400 VAC (±10%) without N wire
Mains types
For Europe:
3 x 400 V AC (± 10%) without N conductor, to the TT, TN-C or TN
Network identification / network configurations in the USA
400Y/230 V (solidy grounded wye, 3 phase, 4 wire)
Current consumption
3 phase max. 54 A
Mains frequency
50/60 Hz
Short Circuit Rating
(SSCR)
50 kArms / 400V (see chapter 6.5 for details)
Adjustment range
0% … 100%
Aux supply voltage
24 VDC /18 V - 32 V to electronic circuitry
Current consumption 0.5 A
Cooling
active by two redundant axial fans
Status indication by
LEDs
EtherCAT® RUN / ERROR
POWER
BUS 1 / 2
CPU failure / status
CH1 … CH9 status
Fieldbus
EtherCAT® IN/OUT
PROFIBUS DP, addressable
Serial ports
RS 232 service port
Functions
soft start
multi-cycle control
mains voltage correction
Housing made of
stainless steel
Degree of protection IP20, unit for installation in closed, metal switching cabinets
For use in pollution degree 2 environment only
Power loss
Max. 105 W
Ambient temperature
Operation
vertical installation: 0°C to 55°C
relative humidity 25% to 80% at 25°C (no condensation)
Ambient temperature
In transit and storage
temperature -25...+70 °C
relative humidity 5% to 95% at 25°C (no condensation)
Approval
CE, UL recognized component (E 339947)
Dimensions (H x W x D)
285 mm x 100 mm x 175 mm

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5 Pin Wiring
5.1 Power Heat Controller on EtherCAT®
All plug-type ports are lo-
cated at the front panel of
the thermo-controller.
5.1.1 Connectors
Device status LED
EtherCAT IN
Status LED
Channel status
EtherCAT OUT
Terminals, channels
7..9
Terminals, channels
4..6
Terminals, channels
1..3
24 VDC
power supply

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5.2 Auxiliary Supply "24VDC", X10
The thermo-controller features an on-board power supply unit designed for
an input voltage of 24 VDC (18V ... 32V). The power supply unit is internally
protected against polarity reversal and limits the inrush current. It supplies
power to the thermo-controller's circuitry and is required to measure the
mains voltage.
Be sure to connect the supply voltage to PE since this is required for making
measurements for line voltage compensation. Both the cord and the power
supply unit must have external protection against short circuit and overload.
For UL applications / machines use a listed DC branch circuit protection of
max 4A. The admissible diameter of the cord connecting the 24 VDC power
is between 0.75 mm2 and 2.5 mm2.
Connector 2-pin, male, 2.5 mm2
Use male connector FKC 2.5/ 2-STF-5.08 (1873207)
Connector included in package.
Connector X10 wiring:
X9
Phoenix MSTB
2.5/2-G-5.08
L- external power supply, GND (PE/N potential)
L+
external power supply
24 VDC (18V ... 32V)
Only attach the unit to a 24 VDC power supply source if the source is guar-
anteed to meet safe extra low voltage requirements (SELV)
as defined in
IEC / EN / DIN EN / UL corresponds 60950
-1.
For UL applications / machines:
Please use for the
auxiliary supply a listed DC branch circuit protection of
max 4A
min 30VDC, fuse in accordance with UL 248.
To make the phase fired controller work properly; pin L- must have the same
potential as the neutral point of the power supply.

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5.3 Device with EtherCAT® Fieldbus Port, X7, X8
5.3.1 EtherCAT® Fieldbus Port X7, X8
Connector X7/X8/ wiring:
X7/X8 PIN Function
RJ45
1
TX+
2
TX-
3
RX+
4
75 Ohm
5
75 Ohm
6
RX-
7
75 Ohm
8
75 Ohm
5.3.2 Device and EtherCAT® Status
5.3.2.1 "EtherCAT®" LED (RUN/ERROR)
The LED labelled "EtherCAT®" indicates the state of the EtherCAT® ASIC.
State
LED flash code
Explanation
Init
Red, on
Initialising, no data exchange
Pre-Op
Red/green, 1:1
Pre-operational, no data exchange
Safe-Op
Red/green, 3:1
Safe operation, inputs readable
Op
Green, on
Operational, unrestricted data exchange
5.3.2.2 "POWER" LED
State
LED flash code
Explanation
5.3.2.3 LED "BUS IN" , LED "BUS OUT"
The "In" and "Out" LEDs indicate the physical state of the Ethernet port they
are allocated to.
State
LED flash code
Explanation
Not connected
Off
No Ethernet connection
Connected
Green, on
Connected to Ethernet
Traffic
Green, flashing
Exchanging telegrams
IN
OUT