PMA KS40-1 User manual

PMA Prozeß- und Maschinen-Automation GmbH
Universal controller for burners
KS40-1 burner
KS40-1 burner
KS40-1 burne
r
Operating manual
English
9499-040-66011
Valid from:8473
expert
li
ne

© PMA Prozeß- und Maschinen-Automation GmbH •Printed in Germany (0207)
All rights reserved. No part of this document may bereproduced or published in any form or by any means
without prior written permission from the copyright owner.
A publication of PMA Prozeß- und Maschinen Automation
P.O.Box 310229
D-34058 Kassel
Germany
Description of symbols
in the text: on the device:
gGeneral information aFollow the operating instructions
aGeneral warning
lAttention: ESD-sensitive devices

3 KS40-1 burner
Contents
1Mounting .............................. 5
2Electrical connections ....................... 6
3Operation.............................. 7
3.1 Front view.............................. 7
3.2 Operating level ........................... 8
3.3 Self-tuning ............................. 10
3.4 Manual tuning ........................... 11
3.5 Operating structure ........................ 13
4Configuration level ........................ 14
4.1 Configuration with qUIC ..................... 14
4.2 Configuration without qUIC (qUIC=OFF) ..........18
4.3 Configuration survey:.................... 18
5Parameter setting level ...................... 24
5.1 Input scaling (only visible with qUIC =OFF)..........26
6Calibration level ......................... 27
7Programmer ........................... 30
8Technical data .......................... 32
9Safety hints ............................ 36
9.1 Resetting to factory setting .................... 38

KS40-1 burner 4

1Mounting
Safety switch:
For access to the safety switches, the controller must be withdrawn from the hou-
sing. Squeeze the top and bottom of the front bezel between thumb and forefinger
and pull the controller firmly from the housing.
1Factory setting 2Default setting: display of all levels
suppressed, password PASS =OFF
aSafety switch 10V imA/Pt always in position left or right. Leaving the
safety switch open may lead to faulty functions!
lCaution! The unit contains ESD-sensitive components.
Mounting
5 KS40-1 burner
or:
%
max.
95% rel.
max. 60°C
0°Cmin.
96 (3.78")
48 (1.89") Loc 10V imA/Pt
min.48 (1.89")
10 (0.4")
1..10
(0.04..0.4")
118 (4.65")
45 +0,6
(1.77" )
+0.02
92
+0,8
(3.62" )
+0.03
125
126
SP.X SG
Err
Ada
*
Ü
*
Ü
Loc 10V mA/Pt
Loc 10V mA/Pt
Loc 10V mA/Pt
Safety switch
F
KS 40-1 burner
10V imA/Pt mA/Pt 1Thermocouple / Pt100 or transducer at InP.1
10V Pressure transmitter (0..10V) at InP.1
Loc open Access to the levels is as adjusted by means of
BlueControl (engineering tool) 2
closed 1all levels accessible wihout restriction

2Electrical connections
* Safety switch INP1 (mA i10V) in position 10V
** Safety switch INP1 (mA i10V) in position mA/Pt
Connection of input INP1
Input for variable x1 (process value)
athermocouple
bresistance thermometer (Pt100/ Pt1000/ KTY/ ...)
cTransducer 50-30-50 W
dvoltage (0/2...10V)
epressure transmitter (3-wire connection)
fpressure transmitter (2-wire connection)
gcurrent (0/4...20mA)
Connection of input INP2
See input INP1.
Connection of inputs di2/di3
Digital input di2 for external switching between SP and SP.2 (SP/SP2).
Digital input di3 for external switching between 3-point-stepping controller and
on/off controller (DPS/SG).
Electrical connections
KS40-1 burner 6
L
N
90...250V
OUT1
di2
di3
OUT2
OUT3
INP2
U(+)
t
1
3
4
5
6
(2)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
10V * 20mA **
INP1
2
3
1
1
2
+
+
ab
b
c
c
edf
g
g
gh
++
--
100%
100%
0%
0%
O
ption
A
P

3Operation
3.1 Front view
gIn the upper display line, the process value is always displayed. At parameter,
configuration, calibration as well as extended operating level, the bottom display
line changes cyclically between parameter name and parameter value.
Operation
Front view 7 KS40-1 burner
125
126.
SP.x SG
Err
Ada
123OK
3
%
1
2
3
7
!
"
4
8
5
6
9
0
$
%
è
§
§
&
KS 40-1 burner
1Status of switching outputs
OuT.1... 3
2Lit with limit value 1 not
exceeded
3Process value display
4Controller works as on/off
controller
5Self-tuning active
6Entry in error list
7Set-point, controller output
8Enter key:
calls up extended operating
level / error list
9Up/down keys:
changing the set-point or the
controller output value
0Set-point SP.2 or SP.E is
effective
!Set-point gradient effective
"Manual mode
§Function key
$Manual-automatic-mode
switching ( ")
%PC connection for BlueControl
(engineering tool)
&Signalization
PArA level (burns)
ConF level (blinks)

3.2 Operating level
The content of the extended operating level is determined by means of BlueCon-
trol (engineering tool). Parameters which are used frequently or the display of
which is important can be copied to the extended operating level.
Operation
KS40-1 burner 8 Operating level
125
126
y21
126
y21
126
Ò
Ò
Ù
Ù
Ù
Ù
125
126
A
utomat
i
c
Extended operating level
M
anua
l
i
i
È
Ì
È
Ì
È
Ì
only
display
126
FbF.1 Err 2
126
Err
switching
display
Errorliste (if error exists)
time
out time
out
time
out

Maintenance manager / Error list
With one or several errors, the extended operating level
always starts with the error list. Signalling an actual en-
try in the error list (alarm, error) is done by the Err LED
in the display. To reach the error list press Ùtwice.
Error list:
Operation
Operating level 9 KS40-1 burner
125
126
SP.X SG
Ada
Err
Err LED status Signification Proceed as follows
blinks Alarm due to existing error -Determine the error type in the error list via the error number
-Remove the error
lit Error removed,
Alarm not acknowledged -Acknowledge the alarm in the error list pressing key Èor Ì
-The alarm entry was deleted.
off No error,all alarm entries deleted
Name Description Cause Possible remedial action
E.1 Internal error,
cannot be
removed
-E.g. defective EEPROM -Contact PMA service
- Return unit to our factory
E.2 Internal error,
can be reset - e.g. EMC trouble - Keep measurement and power supply cables in
separate runs
- Ensure that interference suppression of contactors is
provided
FbF.1
/2Sensor break
INP1 / 2 - Sensor defective
- Faulty cabling - Replace INP1 / 2 sensor - Check INP1 / 2 connection
Sht.1
/2Short circuit
INP1 / 2 - Sensor defective
- Faulty cabling - Replace INP1/ 2 sensor - Check INP1 / 2 connection
POL.1 INP1 polarity
error - Faulty cabling - Reverse INP1 polarity
LooP Control loop
alarm (LOOP) - Input signal defective or not
connected correctly
-Output not connected correctly
- Check heating or cooling circuit
-Check sensor and replace it, if necessary
-Check controller and switching device
AdA.H Self-tuning
heating alarm
(ADAH)
-See Self-tuning heating error
status -see Self-tuning heating error status
LiM.1/
2/3stored limit
alarm1/2/3 -adjusted limit value1/2/3
exceeded -check process
Inf.1 time limit value
message -adjusted number of operating
hours reached -application-specific

Error status (error status 3-9only with error AdA.H /AdA.C ):
3.3 Self-tuning
After starting by the operator, the controller makes a self-tuning attempt. The
controller uses the process characteristics for quick line-out to the set-point wit-
hout overshoot.
gti and td are taken into account only, if they were not set to
OFFpreviously.
Self-tuning start
The operator can start self-tuning at any time. For this, keys Ùand Èmust be
pressed simultaneously. The AdA LED starts blinking.
The controller outputs 0% or Y.Lo, waits until the process is at rest and starts
self-tuning (AdA LED lit permanently).
The self-tuning attempt is started when the following prerequisite is met:
wThe difference between process value iset-point must be ³10% of the
set-point range ( SP.Hi -SP.LO) (with inverse action: process value smaller
than set-point, with direct action: process value higher than set-point).
After successful self-tuning, the AdA-LED is off and the controller continues
operating with the new control parameters.
Self-tuning cancellation by the operator:
Self-tuning can always be cancelled by the operator. For this, press Ùand È
key simultaneously. The controller continues operating with the old parameters in
automatic mode in the first case and in manual mode in the second case.
Operation
KS40-1 burner 10 Self-tuning
Error status Signification
0No error/message not visible, except with acknowledgement
1Stored error Change to error status 0 after acknowledgement in error list
2Existing error Change to error status 1 after error removal
3Faulty control action Re-configure controller (inverse idirect)
4No response of process
variable The control loop is perhaps not closed: check sensor, connections and process
5Low reversal point Increase ( ADA.H) max. output limiting Y.Hi or decrease
(ADA.C) min. output limiting Y.Lo
6Danger of exceeded
set-point (parameter
determined)
If necessary, increase (inverse) or reduce (direct) set-point
7Output step change too
small (dy > 5%) Increase ( ADA.H) max. output limiting Y.Hi or reduce
(ADA.C) min. output limiting Y.Lo
8Set-point reserve too
small Increase set-point (invers), reduce set-point (direct) or increase set-point range (rPArA /SEtp /SP.LO and SP.Hi )
9Impulse tuning failed The control loop is perhaps not closed: check sensor, connections and process

Self-tuning cancellation by the controller:
If the Err LED starts blinking while self-tuning is running, successful self-tuning
is prevented due to the control conditions. In this case, self-tuning was cancelled
by the controller. The controller switches off its outputs (controller output 0%).
Acknowledgement procedures in case of unsuccessful self-tuning:
1. Press keys Ùand Èsimultaneously:
The controller continues controlling using the old parameters in automatic
mode. The Err LED continues blinking, until the self-tuning error was
acknowledged in the error list.
2. Press key Ù:
Display of error list at extended operating level. After acknowledgement of
the error message, the controller continues control in automatic mode
using the old parameters.
Cancellation causes:
rpage 9: "Error status self-tuning heating ( ADA.H) and cooling ( ADA.C)"
Examples for self-tuning attempt 3-point-stepping controller
After the start (1) the controller
closes the actuator (2Out.3).
When the difference between
process value and set-point is
big enough (3), the changing of
the process value is monitored
for 1 min. (4). Afterwards the
actuator is opened (5Out.1).
If the reversal point is reached
(6) or there are made enough
measurements, the parameters
are detected and are adopted.
3.4 Manual tuning
The optimization aid should be used with units on which the control parameters
shall be set without self-tuning.
For this, the response of process variable x after a step change of correcting va-
riable y can be used. Frequently, plotting the complete response curve (0 to
100%) is not possible, because the process must be kept within defined limits.
Operation
Manual tuning 11 KS40-1 burner
W
X
1 min
t
t
12
3
456

Values Tgand xmax (step change from 0 to 100 %) or Dt and Dx (partial step re-
sponse) can be used to determine the maximum rate of increase vmax.
y =correcting variable
Yh= control range
Tu = delay time (s)
Tg = recovery time (s)
Xmax = maximum process value
Vmax=Xmax
Tg ={
{
x
t=max. rate of increase of process value
The control parameters can be determined from the values calculated for delay
time Tu, maximum rate of increase vmax, control range Xhand characteristic K ac-
cording to the formulas given below. Increase Xp, if line-out to the set-point os-
cillates.
Operation
KS40-1 burner 12 Manual tuning
Tu
Tg
t
x
y
100%
0%
t
Yh
Xmax
{X
{t
Parameter adjustment effects
Parameter Control Line-out of disturbances Start-up behaviour
Pb1 higher increased damping slower line-out slower reduction of duty cycle
lower reduced damping faster line-out faster reduction of duty cycle
td1 higher reduced damping faster response to disturbances faster reduction of duty cycle
lower increased damping slower response to disturbances slower reduction of duty cycle
ti1 higher increased damping slower line-out slower reduction of duty cycle
lower reduced damping faster line-out faster reduction of duty cycle
Formulas
K = Vmax * Tu controller behavior Pb1 [phy. units] td1 [s] ti1 [s]
With 2-point and
3-point controllers,
the cycle time must be
adjusted to
t1 /t2 £0,25 * Tu
PID 1,7*K 2*Tu 2*Tu
PD 0,5 * K Tu OFF
PI 2,6 * K OFF 6*Tu
PKOFF OFF
3-point-stepping 1,7 * K Tu 2 * Tu

3.5 Operating structure
After supply voltage switch-on, the controller starts with the operating levels.
The controller status is as before power off.
gPArA - level: At PArA - level, the right decimal point of the
upper display line is lit continuously.
gConF - level: At ConF - level, the right decimal point of upper
display line blinks
All levels are accessible only by entering the Password (PASS). If
the safety switch Loc is open all levels are disabled
aTo get access to the configuration and the parameters the saftey switch Loc must
be closed (factory setting).
Safety switch
Loc Password entered with BluePort® Function disabled or enabled with BluePort® Access via the instrument front panel:
closed OFF / password disabled / enabled enabled
open OFF / password disabled disabled
open OFF enabled enabled
open Password enabled enabled after password entry
Operation
Operating structure 13 KS40-1 burner
Ù
Ù
Ù
Ù
End
126
CAL
126
ConF
126
125
126
PArA
126
Ù
Ì
Ì
Ì
3sec.
PASS
PASS
PASS
PASS

4Configuration level
4.1 Configuration with qUIC
At configuration level, the controller function is determined by changing configu-
ration word Con1 .Con1 and the code adjusted for Con1 are displayed al-
ternately on the lower display line.
Code signification:
Configuration level
KS40-1 burner 14 Configuration with qUIC
125
126
SP.X SG
Err
Ada
r
Ì
È
Ì
Ù
3sec.
rPArA
ConF rÙrqUIC Ù
rCon1
rrÙ
r
123.8
1520
ABCD
123.8
Con1
A0Reaction at sensor break as process value higher than set-point.
1Reaction at sensor break as process value smaller than set-point
2Only P30/W connection, always process value smaller than set-point *
B0Potentiometric transducer 50-30-50 [/ pressure sensor 0..10V, display range
0,0...100,0 (%)
1Potentiometric transducer 50-30-50 [/ pressure sensor 0..10V, display range
0,00...1,00 (bar)
2Potentiometric transducer 50-30-50 [/ pressure sensor 0..10V, display range
0,0...16,0 (bar)
3Potentiometric transducer 50-30-50 [/ pressure sensor 0..10V, display range
0,0...40,0 (bar)
4Resistance thermometer Pt 100 [, range 0...200°C
5Resistance thermometer Pt 100 [, range 0...400°C
6Thermocouple type L, range 0...900°C
7Thermocouple type K, range 0...1350°C
C0Signaller with switching
13-point signaller
23-point stepping controller (DPS) switchable to signaller (SG)
33-point stepping controller (DPS) switchable to 3-point signaller (SG)
D0Not changeable
* Only possible with A = 2and B = 0…3

After exit from the configuration level (see page 43, the controller is re-initiali-
zed (all display elements are lit) and changes over to normal operation (operating
level).
gLeading zeros are not displayed (ex.: display 400 with code 0400)
Configuration example 1 (code 0400):
KS40-1 as a signaller with
switch-over contact for 2-stage burner:
Measuring range 0...200°C,
Resistance thermometer Pt 100,
Reaction at sensor break
as process value higher than set-point.
Configuration example 2 (code 2120):
KS40-1 as 3-point stepping controller:
Connection to pressure transmitter P30/W,
Measuring range 0,00...1,00 bar,
Reaction at sensor break as process value
smaller than set-point.
Function: Signaller with switch-over contact
CAUTION: The two relays
1 and 2 are coupled, i.e.
the contacts have
switch-over function. En-
sure that the two relays are
not energized or de-energi-
zed simultaneously. Ex-
ception: de-energized
condition.
Settings:
Switching differences: Sd1: in physical values
Limit value OUT3: The relay is de-energized when exceeding the limit.
Upper limit value H.1 : in units of phys. quantity.
Switching difference HYS.1 : in units of phys.quantity
Signalling LEDs: LED1: lit when OUT1 is energized
LED2: lit when OUT2 is energized
LED3: lit when OUT3 is energized
OK-LED: lit, unless the limit value is reached
Parameter: see chapter 5 “Parameter level”
Configuration level
Configuration with qUIC 15 KS40-1 burner
123.8
400
123.8
Con1
123.8
2120
123.8
Con1
HYS.1
Limit OUT3
OUT2
-XWXW
W
Sd1 Sd2=
OUT1
ON
ON
OFF
OFF
ON
H.1
OFF

Function: 3-point signaller
Settings:
OUT1: Switch-on point is coupled with the set-point.
Switching difference Sd1: in units of phys. quantity.
OUT2: Switch-off point is always below the set-point!
Adjustment range d.SP : in units of phys. quantity
Switching difference Sd2: in units of phys. quantity.
Limit value OUT3: With the limit value exceeded, the relay is de-energized.
High limit value H.1: in units of phys. quantity.
Switching difference HYS.1: in units of phys.quantity.
Signal LEDs: LED1: lit, when OUT1 is energized
LED2: lit, when OUT2 is energized
OK LED: lit, when limit value not reached
Parameters: see chapter 5 “Parameter level”
Configuration level
KS40-1 burner 16 Configuration with qUIC
HYS.1
Limit OUT3
OUT2
-XWXW
W
Sd1
Sd2
OUT1
ON
ON
OFF
ON
H.1
OFF
OFF
d.SP

Function: 3-point stepping controller
Settings:
Controller: SH: in units of phys. quantity
Response threshold A: 0,5 wSH
Switching difference XSd : 0,06 wSH + 0,08
Actuator travel time tt: 3...9999 s
Min.duty cycle: fixed, TEmin = 100 ms
Control parameters: Pb1 = 0,01...9999 : in unit of phys. quantity °C or °F
(number of digits behind the decimal point is determined
by CON1)
Ti = 1...9999 s ( OFF = no I-action)
td = 1...9999 s ( OFF = no D-action)
Limit value OUT3: With exceeded limit value, the relay is de-energized.
High limit value H.1 : in units of phys. quantity
Switching difference HYS.1 : in units of phys. quantity
Signalling LEDs: LED1: lit when OUT1 is energized
LED2: lit when OUT2 is energized
OK LED: lit, unless limit value is reached
De-energized condition: all relays de-energized, contacts open
Parameters: see chapter 5 “Parameter level”
Configuration level
Configuration with qUIC 17 KS40-1 burner
HYS.1
Limit OUT3
OUT2
-XWXW
W
XSd
-A A
OUT1
ON
ON
OFF
ON
H.1
OFF
SH

4.2 Configuration without qUIC (qUIC=OFF)
When key Ùis kept pressed during controller supply voltage switch-on, the
configuration is switched off with qUIC.
Now, all configuration settings are available to the user.
For changing back to configuration with qUIC , the two keys ÌÈmust be
kept pressed during controller supply voltage switch-on.
aHereby, the controller is reset to the factory-set default values !
4.3 Configuration survey:
Configuration level
KS40-1 burner 18 Configuration without qUIC (qUIC=OFF)
Con1
Name Value range Description Default Own
setting
Con1 0000...2330 qUIC - Configuration 0000
Wire hook switches (on electronic card)
Name Value range Description Default Own
setting
Loc open or closed Wire hook switch for locking the ConF- and PArA- level (if
enabled with BlueControl) closed
InP.1 mA/Pt or 10V Wire hook switch for chosing InP.1 signal type mA/Pt
Cntr
Name Value range Description Default Own
setting
SP.Fn Basic configuration of setpoint processing 0
0 set-point controller can be switched over to external set-point (->
LOGI/SP.E)
1 programmer
8 standard controller with external offset (SP.E)
C.Fnc Control behavior (algorithm) 0
02-point signaller
1PID controller (2-point and continuous)
2D/ Y/Off, or 2-point controller with partial/full load switch-over
32 x PID (3-point and continuous)
43-point stepping controller
73-point signaller
83-point stepping controller switchable to signaller
93-point stepping controller switchable to 3-point signaller
mAn Manual operating permitted 1
0no
1yes (see also LOGI/mAn)
C.Act Method of controller operation 0
0Inverse, e.g. heating
1Direct, e.g. cooling

Configuration level
19 KS40-1 burner
Name Value range Description Default Own
setting
FAIL Behavior at sensor break 1
0Controller outputs switched of
1y=Y2
2y=meanoutput. The maximum permissible output can be adjusted with
parameterYm.H.To preventdeterminationofinadmissible values, mean value
formationis only if the controldeviationislower than parameter L.Ym.
rnG.L -1999...9999 X0 (low limit range of control) 10
rnG.H -1999...9999 X100 (high limit range of control) 1100
1rnG.L and rnG.H indicate the control range to which e.g. self-tuning is related.
InP.1
Name Value range Description Default Own
setting
S.tYP Sensor type selection 50
0Thermocouple type L (-100...900°C) , Fe-CuNi DIN
1Thermocouple type J (-100...1200°C) , Fe-CuNi
2Thermocouple type K (-100...1350°C), NiCr-Ni
3Thermocouple type N (-100...1300°C), Nicrosil-Nisil
4Thermocouple type S (0...1760°C), PtRh-Pt10%
5Thermocouple type R (0...1760°C), PtRh-Pt13%
20 Pt100 (-200,0 ... 100,0 °C)
21 Pt100 (-200,0 ... 850,0 °C)
22 Pt1000 (-200,0...200,0 °C)
23 KTY 11-6 (special 0...4500 Ohm)
30 0...20mA / 4...20mA 2
40 0...10V / 2...10V 2
50 Potentiometer 0...160 Ohm 2
51 Potentiometer 0...450 Ohm 2
52 Potentiometer 0...1600 Ohm 2
S.Lin Linearization (only at S.tYP = 30 (0..20mA) and 40
(0..10V) adjustable) 0
0None
1Linearization to specification. Creation of linearization table
with BlueControl (engineering tool) possible. The characteristic
for KTY 11-6 temperature sensors is preset.
Corr Measured value correction ( scaling 2
0Without scaling
1Offset correction (at CALlevel)
22- point correction (at CALlevel)
3Scaling (at PArA level)
2With current, voltage or potentiometer input signals, scaling is required (see section 5.1).

Configuration level
KS40-1 burner 20
InP.2
Name Value range Description Default Own
setting
I.Fnc Function selection of INP2 0
0No function
2External set-point SP.E (switching -> LOGI/SP.E)
S.tYP Sensor type selection 30
20 Pt100 (-200,0 ... 100,0 °C)
21 Pt100 (-200,0 ... 850,0 °C)
22 Pt1000 (-200,0...200,0 °C)
30 0...20mA / 4...20mA 1
50 Potentiometer ( 0...160 Ohm) 1
51 Potentiometer ( 0...450 Ohm) 1
52 Potentiometer ( 0...1600 Ohm) 1
Corr Measured value correction / scaling 0
0 Without scaling
1 Offset correction (at CALlevel)
2 2-point correction (at CALlevel)
3 Scaling (at PArA level)
1With current or potentiometer input signals, scaling is required (see section 5.1).
Lim
Name Value range Description Default Own
setting
Fnc.1
Fnc.2
Fnc.3
Function of limit1/2/3 1/0/0
0Switched off
1Measured value monitoring
2Measured value monitoring + alarm status storage. A stored
limit value can be reset via error list, Ò-key or a digital input (
-> LOGI/Err.r)
Src.1
Src.2
Src.3
Source of limit1/2/3 1/0/0
0Process value = absolut alarm
1Control deviation Xw (process value - set-point) relativ alarm
2Control deviation Xw (relativ alarm) with suppression after
start-up and set-point change
6Effective set-point Weff
7Correcting variable (controller output)
LP.AL Monitoríng of control loop interruption 0
0Switched off
1LOOP alarm active