PMA KS 98 User manual

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KS 98 and KS 98plus
Multi-function unit
Functional description
9499 040 50611
Valid from: 8474

Symbols on the instrument
àEC-conformity marking
aCaution, Follow the operating instructions!
All rights reserved. No part of this document may be
reproduced 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 GmbH
P.O.Box 310 229
D-34058 Kassel
Germany
2

3
Content
1. Description .............................................7
1.1 Construction ...................................................7
2. Important technical data .....................................9
2.1 Analog inputs rsections 3 and 6.9 .....................................9
2.2 Digital inputs...................................................9
2.3 Outputs rsection 6.10.............................................9
2.4 Control outputs .................................................9
2.5 Supply voltage..................................................9
2.6 Further "modular" in- and outputs .......................................9
2.7 Further external in- and outputs .......................................9
3. Versions ..............................................11
3.1 I/O-modules - for units with modular option c basic card ........................11
4. Front view .............................................13
5. Mounting..............................................15
6. Electrical connections......................................17
6.1 Safety hints...................................................17
6.2 Electromagnetic compatibility ........................................17
6.3 Measurement earth (for grounding interference) .............................17
6.4 Connecting diagram..............................................17
6.5 Analog inputs (rconnecting diagram) ..................................19
6.6 Versions with integrated supply voltage ..................................20
6.7 Digital inputs and outputs (rconnecting diagram).............................20
7. Menu ................................................21
7.1 Short-form dialogue ..............................................21
7.2 Complete dialogue...............................................22
7.3 Selection (switch-on and operating pages) ................................22
7.4 Language selection ..............................................23
7.5 Selection (other pages) ............................................23
7.6 Adjusting values ................................................23
7.7 Calibrating ...................................................24
7.8 Operating modes ...............................................24
8. Maintenance ...........................................25
8.1 Behaviour in case of trouble .........................................25
8.2 Shut-down ...................................................25
8.3 Cleaning ....................................................25
8.4 Further information ..............................................25
9. Scaling and calculating functions ...............................27
9.1 ABSV ( absolute value )............................................27
9.2 ADSU ( addition/subtraction ) ........................................28
9.3 MUDI ( Multiplication / division ) ......................................29
9.4 SQRT ( square root function ) ........................................30
9.5 SCAL ( scaling ) ................................................31
9.6 10EXP (10s exponent) .............................................32
9.7 EEXP (e-function) ...............................................33
9.8 LN (natural logarithm).............................................34
9.9 LG10 (10s logarithm)..............................................35
10. Non-linear functions .......................................37
10.1 GAP (dead band)................................................37
10.2 CHAR (function generator) ..........................................38

4
11. Trigonometric functions .....................................39
11.1 SIN (sinus function) ..............................................39
11.2 COS (cosinus function) ............................................40
11.3 TAN (tangent function) ............................................41
11.4 COT (cotangent function) ...........................................42
11.5 ARCSIN (arcus sinus function)........................................43
11.6 ARCCOS (arcus cosinus function) ......................................44
11.7 ARCTAN (arcus tangent function) ......................................45
11.8 ARCCOT (arcus cotangent function) ....................................46
12. Logic functions ..........................................47
12.1 AND (AND gate) ................................................47
12.2 NOT (inverter) .................................................48
12.3 OR (OR gate) ..................................................49
12.4 BOUNCE (debouncer) .............................................50
12.5 EXOR (exclusive OR gate) ..........................................51
12.6 FLIP (D flipflop).................................................52
12.7 MONO (monoflop) ...............................................53
12.8 STEP (step function for sequencing) ....................................55
12.9 TIME1 (timer)..................................................57
13. Signal converters.........................................59
13.1 AOCTET data type conversion ........................................59
13.2 ABIN (analog ibinary conversion) ....................................65
13.3 TRUNC (integer portion) ...........................................67
13.4 PULS (analog pulse conversion).......................................68
13.5 COUN (up/down counter)...........................................70
13.6 MEAN (mean value formation)........................................72
14. Time functions ..........................................75
14.1 LEAD ( differentiator ) .............................................75
14.2 INTE ( integrator ) ...............................................77
14.3 LAG1 ( filter ) ..................................................79
14.4 DELA1 ( delay time ) ..............................................80
14.5 DELA2 ( delay time ) ..............................................81
14.6 FILT ( filter with tolerance band ) ......................................82
14.7 TIMER ( timer ) .................................................83
14.8 TIMER2 ( timer ) ................................................84
15. Selecting and storage ......................................85
15.1 EXTR ( extreme value selection ) ......................................85
15.2 PEAK ( peak value memory ) .........................................86
15.3 TRST ( hold amplifier ).............................................87
15.4 SELC ( Constant selection )..........................................88
15.5 SELP ( parameter selection ) .........................................89
15.6 SELV1 ( variable selection ) .........................................90
15.7 SOUT ( Selection of output ) .........................................91
15.8 REZEPT ( recipe management ) .......................................92
15.9 2OF3 ( 2-out-of-3 selection with mean value formation ) .........................94
15.10 SELV2 ( cascadable selection of variables ) ................................96
16. Limit value signalling and limiting ...............................97
16.1 ALLP ( alarm and limiting with fixed limits ) ................................97
16.2 ALLV ( alarm and limiting with variable limits )...............................99
16.3 EQUAL ( comparison ) ............................................101
16.4 VELO ( rate-of-change limiting).......................................102
16.5 LIMIT ( multiple alarm ) ...........................................103
16.6 ALARM ( alarm processing ) ........................................104

5
17. Visualization ...........................................105
17.1 VWERT ( display / definition of process values ) .............................105
17.2 VBAR ( bargraph display )..........................................107
17.3 VPARA ( parameter operation ).......................................109
17.4 VTREND ( trend display ) ..........................................111
18. Communication .........................................113
18.1 L1READ ( read level1 data ) .........................................113
18.2 L1WRIT ( write level1 data ).........................................114
18.3 DPREAD ( read level1 data via PROFIBUS ) ................................115
18.4 DPWRIT ( write level1 data via PROFIBUS ) ...............................116
19. KS98+ I/O extensions with CANopen .............................117
19.1 RM 211, RM212 and RM213 basic modules ................................118
19.2 C_RM2x (CANopen fieldbuscoupler RM 201) ...............................119
19.3 RM_DI (RM 200 - (digital input module) ..................................120
19.4 RM_DO (RM 200 - digital output module) .................................121
19.5 RM_AI (RM200 - analog input module) ..................................122
19.6 Potentiometer connection and calibration ................................124
19.7 RM_(RM200 - analog output module) ...................................125
19.8 RM_DMS strain gauge module.......................................126
20. KS 98+ -KS98+ cross communication.............................129
20.1 CRCV (receive mod. block no's 22,24,26,28 no.56) ............................130
20.2 CSEND (Send mod. blockno.'s 21, 23, 25, 27 - No. 57) ..........................131
21. Connection of KS 800 and KS 816 ...............................133
21.1 C_KS8x (KS 800 and KS 816 node function - no. 58) ...........................134
21.2 KS8x (KS 800/ KS 816 controller function - no. 59) ............................135
22. Description of KS98 CAN bus extension ...........................137
22.1 CPREAD (CAN-PDO read function) ....................................141
22.2 CPWRIT (CAN-PDO write function) ...................................142
22.3 CSDO CAN-SDO function .........................................143
23. Programmer ...........................................145
23.1 APROG ( analog programmer ) / APROGD ( APROG data ) .......................145
23.2 DPROG ( digital programmer ) / DPROGD ( DPROG data ) ........................153
24. Controller.............................................159
24.1 CONTR (Controllerfunction with one parameterset) ...........................159
24.2 CONTR+ (Controllerfunction with six parametersets) ..........................160
24.3 PIDMA ....................................................161
24.4 Parameter und Konfiguration für CONTR, CONTR+ und PIDMA. ....................163
24.5 Small controller ABC ...........................................166
24.6 Controller behaviour .............................................169
24.7 Optimizing the controller ..........................................181
24.8 Self-tuning rcontroller adaptation to the process ...........................182
24.9 Controller characteristics and self-tuning with PIDMA .........................187
24.10 Empirical optimization ............................................192
24.11 Set-point functions..............................................193
24.12 Process value calculation..........................................199
25. Inputs ...............................................205
25.1 AINP1 ( analog input 1) ...........................................205
25.2 AINP3...AINP5 ( analog inputs 3...5 )....................................211
25.3 AINP6 ( analog input 6 ) ...........................................212
25.4 DINPUT ( digital inputs ) ..........................................216
26. Outputs ..............................................217
26.1 OUT1 and OUT2 ( process outputs 1 and 2 )................................217
26.2 OUT3 ( process output 3 ) ..........................................218
26.3 OUT4 and OUT5 ( process outputs 4 and 5 )................................219
26.4 DIGOUT ( digital outputs ) ..........................................220

6
27. Additional functions ......................................221
27.1 LED (LED display)...............................................221
27.2 CONST ( constant function ) ........................................222
27.3 INFO ( information function ) ........................................224
27.4 STATUS ( status function ) .........................................225
27.5 SAFE ( safety function ) ...........................................227
28. KS98 I/O extension modules ..................................229
29. Modular I/O - extension-modules...............................231
29.1 TC_INP (analog input card TC, mV, mA)..................................231
29.2 F_Inp (frequency/counter input) ......................................233
29.3 R_Inp (analog input card )..........................................234
29.4 U_INP (analog input card -50...1500mV, 0...10V) .............................236
29.5 I_OUT (analog output card 0/4...20mA, +/-20mA) .............................238
29.6 U_OUT (analog output card 0/2...10V, +/-10V)...............................239
29.7 DIDO (digital input/output card) ......................................240
30. Function management .....................................241
30.1 Memory requirement and calculation time ................................241
30.2 Sampling intervals ..............................................242
30.3 EEPROM data .................................................242
31. Examples .............................................243
31.1 Useful small engineerings..........................................243
31.2 Controller applications ...........................................244
31.3 Standard engineerings ...........................................245

1Description
1.1 Construction
KS98 is a compact automation unit with freely configurable functionality using function blocks.
Each instrument contains a function library from which selection, configuration, parameter setting and combination of
up to 150 function blocks is possible by means of an engineering tool. This permits realization of complex mathematical
calculations, multi-channel control structures and sequencing in one instrument. Various pages are displayed by means
of an LCD (64x128 dots): input and output for analog and digital signals, bargraphs and trends. Communication with
other instruments and systems is possible via an optional digital interface.
Additionally, the introduction of a CANopen interface completes the basic version of KS98 multifunction unit by
wlocal I/O extensibility by means of the PMA RM 200 modular I/O system
wconnection of PMA KS800 / KS816 multiple-channel temperature controllers with CANopren interface
won-site data exchange with other KS98+ units (cross communication)
If necessary, connection of further sensors, actuators, transmitters, burner control systems or machine units, etc. with
CANopen protocol is possible.
9499 040 50611 Description
7 Construction

Description 9499 040 50611
Construction 8

2Important technical data
2.1 Analog inputs rsections 3 and 6.9
INP 1: universal input, configurable for thermocouples, resistance thermometers, tem
perature difference, resistance transducers, DC current and DC voltage
INP 3 and INP 4 (option C): DC current, INP 5: DC current and DC voltage
INP 6: resistance transducer and DC current
2.2 Digital inputs
Opto-coupler for 24 V DC, current sink to IEC 1131 type 1, logic 0 = -3...5 V, logic 1 = 15...30 V, approx. 5 mA
di1 and di2:in all versions,
di3...di7:in option B,
di4...di12:in option C.
2.3 Outputs rsection 6.10
Relay contact rating: 500 VA, 250 V,2Aat48...62 Hz
OUT1,OUT2, relay or current or logic dependent of version,
OUT4,OUT5:
OUT 3 (option C): current
2.4 Control outputs
Opto-coupler, grounded load with common positive control voltage, power 18...32 V DC ß100 mA.
do1...do4:in option B,
do5 and do6:in option C
2.5 Supply voltage
90...260V AC, 48...62 Hz, power consumption approx. 10 VA (equipped with all possible options)
For detailed technical data, see data sheet 9498 737 32133.
2.6 Further "modular" in- and outputs
Further analog and digital inputs and outputs can be provided on the "modular C card"
rsee KS98 I/O-extension modules on page 225 ff
2.7 Further external in- and outputs
Further analog and digital inputs and outputs can be connected via CANopen.
rsee KS98+ I/O extensions with CANopen page 117 ff
9499 040 50611 Important technical data
9 Analog inputs rsections 3 and 6.9

Important technical data 9499 040 50611
Further external in- and outputs 10

3Versions
Order no. 9407-9 - 1
Basic unit standard 6
with integrated supply voltage 7
KS98+ with CANopen I/O *1) 8
90...250 V AC with 4 relays 3
Power supply and 90...250 V AC with 2 relays + 2 current outputs 5
process outputs 24 V UC with 4 relays 7
24 V UC with 2 relays + 2 current outputs 9
Option B
no option B 0
TTL interface + di3...7 / do1...4 1
RS 422 + di3...7 / do1...4 + real-time clock 2
PROFIBUS-DP + di3...7 / do1...4 3
INTERBUS + di3...7 / do1...4 4
Option C
no option C 0
INP3 / INP 4 / OUT 3 / di8...12 / do5 / do6 1
INP3 *2) / INP 4 / OUT 3 / di8...12 / do5 / do6 2
modular option c basic card (not with KS98+) *1) 3
modular option c basic card with modules *1) 4
Engineering
single-channel controller (basic unit) 0
cascade controller 1
flow controller 2
program controller 3
heat-energy counter 4
flow calculator 5
Setting standard setting 0
setting to specification 9
*1) The combination KS98+ (CANopen I/O) and modular option c is not possible! Either KS98+ or modular option c!
*2) INP3: With type = 0...20 mA the input is scaled to -50...1300 mV. If output INP3 shall be used with this scaling,
x0 must be set to -50 and x100 to 1300.
3.1 I/O-modules - for units with modular option c basic card
Order no. 9 407-998-0 1
Plug position
Separate order 0
Fitted on KS98 slot 1 }galvanically
connected
1
Fitted on KS98 slot 2 2
Fitted on KS98 slot 3 }galvanically
connected
3
Fitted on KS98 slot 4 4
Module type
Analog inputs
Pt100 / 1000, Ni 100 /1000, resistance, pot 20
Thermocouple, mV, 0/4...20mA 21
-50...1500mV, 0...10V 22
Module type-
Analog outputs
0/2...10V, 0..._10V 30
0/4...20mA, 0..._20mA 31
Module type
Dig.inputs/outputs
Digital I/O (universal) 40
Frequency/counter input 41
9499 040 50611 Versions
11 I/O-modules - for units with modular option c basic card

Versions 9499 040 50611
I/O-modules - for units with modular option c basic card 12

4Front view
LED 2 e.g. cooling LED 3 e.g. alarm 1
LED 1 e.g. heating LED 4 e.g. alarm 2
Locking screw
Display e.g. trend
Selector key
PC interface Increment key (z)
Manual/automatic key Decrement key (u)
qLocking screw: locks the controller module in the housing.
qLEDs: indicate the statuses of the LED function (r219).
qDisplay: LCD dot matrix with (64x128 dots, back lighting). The relevant display is shown in
sections 4 Menus, 6.12 Visualization, 6.14 Programmer and 6.15 Controller.
qKeys HDIM: The relevant function is described in section 4 Menus.
qPC interface: PC connection for structuring/wiring/configuring/parameter setting/operating
with the engineering tool.
9499 040 50611 Front view
13

Front view 9499 040 50611
14

5Mounting
Mount the unit with min. 2 fixing clamps (diagonally at top and bottom).
Protection type IP65: use 4 fixing clamps. Insert the instrument module firmly and block it using the locking screw.
S.I.L. switch S: its switching status is signalled by function STATUS and can be used in the engineering. After delivery,
the switch is open. For closing, release the fixing screw, withdraw
the instrument module from the housing, close the S.I.L. switch. In-
sert the unit and lock it with the screw.
SIL switches DP: PROFIBUS terminating resistor
Every Profibus network must be terminated. This means that the first
and the last node on the bus must be provided with a terminating re-
sistor.
(rsee KS98 PROFIBUS-DP interface description 9499-040-52711).
In KS98, the bus terminating resistor can be activated by 2 SIL
switches (DP). Both switches must always be closed or open (closed
= terminating resistor is active).
SIL switch for CAN: for CANbus terminating resistor,
rsee chapter 22
aTake care that the unit is tight!
lCaution! The unit contains electrostatically sensitive components.
9499 040 50611 Mounting
15

Mounting 9499 040 50611
16

6Electrical connections
6.1 Safety hints
aFollowing the enclosed safety hints 9499 047 07101 is indispensable! The instrument insulation meets standard
EN 61 010-1 (VDE 0411-1) with contamination degree 2, overvoltage category III, operating voltage range 300 V
and protection class I.
aWith horizontal installation, the following rule is applicable additionally: with the instrument module
withdrawn, a facility which prevents conducting parts from dropping into the open housing must be provided.
aIf the unit is switched to off-line, the outputs keep the status from the time of switch-over!!!
6.2 Electromagnetic compatibility
The unit meets European guideline 89/336/EEC. The following European generic standards are met:
Electromagnetic radiation: EN 50081-2 and Electromagnetic immunity: EN 50082-2. The unit is suitable for use in indus-
trial areas (in residential areas, RF interference may occur). The electromagnetic radiation can be reduced decisively by
installing the unit in a grounded metal switch cabinet.
6.3 Measurement earth (for grounding interference)
aInterference voltages, e.g. high-frequency interference, acting on the unit from outside may cause functional
trouble. For grounding the interference voltages and ensuring interference suppression, a measurement earth
must be connected.
Terminal A11 must be connected to ground potential by means of a short cable (approx. 20 cm, e.g. at control
cabinet ground)!
This cable must be kept separate from power supply cables. On instruments with current outputs at OUT1 and
OUT2 proceed accordingly with terminal P13.
6.4 Connecting diagram
wPower supply cables must be kept separate from signal and measuring cables.
wWe recommend using twisted and screened measuring cables (screening connected to measurement earth).
wConnected motor actuators must be provided with protective circuitry to manufacturer specifications. This
avoids high voltage peaks, which may cause trouble to the instrument.
wThe units must be protected with a fuse individually per unit or in common according to a max. power
consumption of 10 VA (standard fuse ratings, min. 1 A)!
9499 040 50611 Electrical connections
17 Safety hints

aIn measuring and signal circuits, the max. potential against ground may be 50 Veff,
Between power supply circuits, the max. potential may be 250 Veff.
*with 24 V DC / AC connection of the protective earth is also necessary, the polarity it is uncritical.
For devices with modular option C see according chapter
Electrical connections 9499 040 50611
Connecting diagram 18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
24 V
di 8 ( )
di 9 ( )
di 10 ( )
di 11 ( )
di 12 ( )
do 5
do 6
GND
+
_
+
_
+
_
-
+
+
+
+
+
+
.C
INP4
INP3
OUT3
0/4...20mA
0/4...20mA
0/4...20mA
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P
OUT4
OUT5
OUT2
OUT1
0/4...20mA
+
_
ßßß500VA, 250V, 2A ßßß500VA, 250V, 2A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
di (-)
di1 (+)
di2 (+)
+Volt
+mA
_Volt / mA
Volt
mA
A
INP5
INP6
INP1
0/4...20mA
100%
0%
0%
100%
}
}
2
1
+
_
+
_
+
_
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
B-
+
+
+
+
+
+
24 V
di 3 ( )
di 4 ( )
di 5 ( )
di 6 ( )
di 7 ( )
do 1
do 2
do 3
do 4
RXD-B
GND
RXD-A
TXD-B
TXD-A
RS422 RS485 TTL PROFIBUS -DP
+5V
GND
TRE
TXD
RXD
VP
GND
RxD/TxD-N
RxD/TxD-P
RGND
DATA B
DATA A
100 [
abcdef
ABCP
1
16
1
16
(Option)
(Option)
OUT
IN
INTERBUS
AB
0/4...20mA
+
_
oder
or/ou
1
1Nur bei Geräten mit Transmitter-Speisung
1For instruments with built-in transmitter power supply
1Seulement pour les appareils avec alimentation transmetteur

6.5 Analog inputs (rconnecting diagram)
Thermocouples (a)
No lead resistance adjustment is necessary.
Internal temperature compensation: the compensating lead must be taken up to the instrument terminals.
In AINP1 STK = int.TC must be configured.
External temperature compensation: use a separate cold-junction reference with fixed reference temperature. The com-
pensating lead is taken up to the cold-junction reference, whilst the lead between cold-junction reference and instru-
ment can be of copper.
In AINP1 STK = ext.TC and with TKref = the reference temperature must be configured.
Resistance thermometer Pt 100 in 3-wire connection (b)
No lead resistance adjustment is necessary, provided that RL1 = RL2.
Resistance thermometer Pt 100 in 2-wire connection (c)
Lead resistance adjustment is necessary: make Ra equal to RL1 + RL2.
Two resistance thermometers Pt100 in difference connection (d)
Compensating the lead resistances: proceed as described r24 .
Resistance transducer (e)
Calibrating the measurement: proceed as described r24 .
Standard voltage signals 0/2...10V (g)
Input resistance: ?100 k[, Configure scaling and digits behind the decimal
point. INP5 is a difference input, the reference potential of which is connected
to terminal A9. With voltage input, A6 must always be connected with A9.
Standard current signals 0/4...20 mA (f)
Input resistance: configure 50 [, scaling and digits behind the decimal point.
Supply voltage -50...1300mV DC
(only INP3 on instruments with order no. 9407-9xx-x2xx1):
With type =0...20mA, the input is designed for -50...1300 mV. For using the INP3 output with this scaling, set x0 to -50
and x100 to 1300.
aInputs INP1 / INP6 are interconnected. This must be taken into account, if both inputs must be used for standard
current signals. If necesary, a galvanic isolation must be used.
9499 040 50611 Electrical connections
19 Analog inputs (rconnecting diagram)

6.6 Versions with integrated supply voltage
The potential-free supply voltage can energize a 2-wire transmitter or max. 4 control inputs. The output connections
can be selected with 3 S.I.L. switches:
Connections Ü* Ö Remarks
14(+) 12 (-) T open closed Only available, if INP1 is configured for current or thermocouple
4 (+) 1 (-) D closed open The voltage input of INP5 is not available
Factory setting: Ü=T,*= open, Ö= closed (T).
The unit must be withdrawn from the housing for changing
the switch positions.
The S.I.L. switches are located on the circuit board shown right.
* If A14/A12 is used for di1/di2, A12 must be connected with A1
6.7 Digital inputs and outputs (rconnecting diagram)
The digital inputs and outputs must be energized from one or several 24 V DC sources. The current consumption is
5 mA per input. The max. load is 0,1 A per output. Examples:
Digital inputs (connector A) Digital inputs and outputs at one voltage
source (e.g. connector B)
Digital inputs and outputs at two voltage
sources (e.g. connector B)
Electrical connections 9499 040 50611
Versions with integrated supply voltage 20
Energization of digital inputs (e.g. di1...di4)
2-wire transmitter connection (e.g. INP1)