PMA KS800 Operating and installation instructions

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completely despite utmost care. Any hints are welcome and gratefully accepted.

Multi-Temperature-Controller KS 800
Contents
1 Introduction ..................................................... 7
1.1 Basic structure .............................................. 7
1.2 Input ...................................................... 7
1.3 Functions .................................................. 8
1.4 Output .................................................... 8
2 Input signal processing ............................................ 9
2.1 Measurement value pre-processing ............................... 9
2.2 Measuring frequency .......................................... 9
2.3 Sensor types ................................................ 9
2.3.1 Thermocouples ......................................... 9
2.3.2 Resistance thermometer ................................. 10
2.3.3 Resistance ........................................... 10
2.3.4 DC voltage ........................................... 10
2.4 Measurement value correction .................................. 11
2.4.1 Application examples ................................... 12
2.5 Digital input signal pre-processing ............................... 12
2.5.1 Input signal distribution .................................. 12
2.5.2 Analog input signals .................................... 12
2.5.3 Digital input signals ..................................... 13
3 Controller block diagram .......................................... 14
3.1 Sequence control ........................................... 14
4 Set-point functions ............................................... 15
4.1 Set-point control ............................................ 15
5 Function block protocol .......................................... 16
5.1 Data structure ............................................. 16
5.2 Structure of configuration words ................................. 17
5.2.1 Function block instrument ............................... 17
6 Controller statuses and status priorities .............................. 21
6.1 Priority 0 automatic ......................................... 21
6.2 Priority 1 Tune, run ......................................... 21
6.3 Priority 2 Tune, error ........................................ 22
6.4 Priority 3 Sensor break ....................................... 22
6.5 Priority 5 Manual ........................................... 22
6.6 Priority 7 Y_Track .......................................... 23
6.7 Priority 8 Controller off ....................................... 23
7 Automatic - manual switch-over ..................................... 24
8 Self-tuning for single-loop controllers ................................ 25
8.1 Preparation for controller self-tuning: ............................. 25
8.1.1 Process at rest ........................................ 25
8.1.2 Selecting the stable correcting variable ...................... 25
8.1.3 Start from automatic mode ............................... 26
8.1.4 Start from manual mode ................................. 26
8.2 Self-tuning procedure with heating (2-point and three-point stepping
controller) ................................................ 26
8.3 Self-tuning procedure with heating and cooling processes: (3-point
controller) ................................................. 26
8.4 Set-point monitoring ......................................... 27
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8.5 Self-tuning several controllers in a group .......................... 27
8.5.1 Starting the group self-tuning .............................. 27
8.5.2 Group self-tuning stop ................................... 27
8.5.3 Common start of the heating attempt for all controllers of a group . . . 27
8.5.4 Common start of the cooling attempt for all 3-point heating/cooling
controllers ........................................... 28
8.5.5 Signification of self-tuning messages ....................... 28
9 Controlled adaptation ............................................. 29
9.1 Control function parameters .................................... 30
10 Signaller ....................................................... 31
11 Two-point controller .............................................. 32
12 Three-point DPID controller ........................................ 34
13 Three-point stepping controller ..................................... 36
14 Forcing of switching outputs ....................................... 39
15 Continuous controllers ........................................... 40
16 Water cooling ................................................... 42
16.1 Water cooling controller self-tuning ............................... 44
17 Cascade control ................................................. 45
17.1 Configuration of a simple cascade ............................... 45
17.2 Controller behaviour with switch-over ............................. 46
17.2.1 Master controller switch-over from .......................... 46
17.2.2 Slave controller switch-over : .............................. 46
17.3 Interruption of cascade operation ................................ 46
17.4 Example of cascade control with up to 7 slave controllers .............. 47
18 Start-up circuit .................................................. 49
19 Mean value formation for the output hold function ...................... 51
20 Heating current monitoring ........................................ 52
20.1 Heating current monitoring ..................................... 52
20.2 Monitoring cycle ............................................ 52
20.2.1 Heating current alarm, reset and quick test ................... 53
21 Evaluation of heating current measurement ........................... 54
21.1 Leakage current monitoring .................................... 54
21.2 Heating current scaling factor ................................... 55
22 Alarm handling .................................................. 56
23 Configuration ................................................... 58
23.1 General .................................................. 58
23.2 Main configuration groups ..................................... 58
23.2.1 C100 main controller configuration .......................... 58
23.2.1.1 C101 additional controller configuration ........... 59
23.2.2 Control loop monitoring (loop alarm) ........................ 60
23.2.3 C150 Heating current and output monitoring .................. 61
23.2.3.1 C151 additional heating current configuration ....... 62
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23.2.4 C180 analog signal allocation ............................. 62
23.2.5 C190 digital signal allocation .............................. 63
23.3 Inputs .................................................... 64
23.3.1 C200 main configuration ................................. 64
23.3.2 Input scaling .......................................... 65
23.3.2.1 C201 input scaling start ....................... 65
23.3.2.2 C202 input scaling end ....................... 65
23.3.3 C205 additional configuration ............................. 66
23.3.3.1 C210 external temperature compensation .......... 66
23.3.3.2 C213 sensor failure .......................... 67
23.3.3.3 C214 filter time constant ...................... 67
23.4 Configuration examples ....................................... 68
23.4.1 Thermocouples ........................................ 68
23.4.2 Resistance thermometer ................................. 68
23.4.3 Voltage ............................................. 68
23.4.4 C302 heating current input ............................... 68
23.5 Outputs ................................................... 69
23.5.1 C500 signal inputs/outputs ............................... 69
23.5.2 Alarm outputs ......................................... 70
23.5.2.1 Action C530 ............................... 70
23.5.3 Analog outputs ....................................... 71
23.5.3.1 C600, C602, C603, C604 type of alarms .......... 72
23.5.3.2 C601 alarm target ........................... 73
23.5.4 C700 controller self-tuning ............................... 74
23.5.5 Additional functions ..................................... 75
23.5.5.1 C900 Baud rate COM1 PC interface .............. 75
23.5.5.2 C901 COM1 address ......................... 75
23.5.6 COM2 interface ....................................... 76
23.5.6.1 C902 Baud rate COM2 bus interface ............. 77
23.5.6.2 C903 COM2 address ......................... 77
23.5.7 C904 mains frequency, alarm and current output configuration ..... 78
24 Special functions ................................................ 79
24.1 Selective mean value formation ................................. 79
24.1.1 Configuration ......................................... 81
24.2 Safety limiter with holding function ............................... 82
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Multi-Temperature-Controller KS 800
1 Introduction
The functions of multiple controller KS 800 are described in this document. Not all functions are
applicable to all versions, since some hardware and software functions are mutually precluding
due to the controller configuration (e.g. 8-channel three-point stepping controller and digital in-
puts).
1.1 Basic structure
The basic KS 800 structure for control function handling is shown below. The unit is divided into
four main groups:
input
functions
output
user interface
(The user interface function is not described in this manual.)
User Interface
Interface Signals
Input Output
Functions
Meas. value
aquisition
Signal pre-processing
Signal distribution
Alarm processing
Controller functions
Closed loop
control
Signal output
Signal post-processing
Sequence control
Signals
from the
field
Signals
to the
field.
Set-point
processing
Operating and
display Diagnosis and
production
Interface selection
1.2 Input
Measurement value acquisition
The input signals from the field are acquisitioned and converted according to adjusted sensor
type.
Measurement value correction
This block is used for measurement value corrections (zero offset, suppression, gain adjustment).
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Signal distribution
The conditioned input signals are passed to the controller cyclically (together with the relevant
control parameters).
1.3 Functions
Sequence control
The sequence control describes the statuses and priorities in the control algorithm and the condi-
tions and signals for other function statuses.
Closed-loop control
The correcting variable is calculated dependent of selected controller configuration and adjusted
control parameters.
Set-point processing
Dependent of controller configuration, various functions for generation of the valid (effective) set-
point (Weff) are selected for the control functions.
Alarm processing
Each individual controller has different alarm functions, each with four trigger points. The alarms
can be allocated to various alarm functions by configuration.
1.4 Output
Signal post-processing
The controller calculation result is subject to (user-defined) post-processing: e.g. compliance with
a minimumn duty cycle.
Signal output
Output and storage of the controller output value until the next cycle.
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2 Input signal processing
2.1 Measurement value pre-processing
All measurement signals must be conditioned accordingly, before they are used in the controller
functions. Measurement value processing converts the hardware signals into numeric values,
which are converted into physical signals (°C, °F, ...) by linearization/scaling also during mea-
surement value processing. Sensor monitorings (break, overflow, wrong polarity) are also part of
measurement value processing.
2.2 Measuring frequency
As the analog-digital converter of the input circuit is common for all 8 controllers, the individual
controller inputs are measured cyclically. Each controller input is measured twice per second.
2.3 Sensor types
The sensor type can be determined (also differently) for each controller during configuration.
Analog measurement value acquisition includes the following values:
Actual value measurement for 8 controllers.
thermocouple,
resistance thermometer,
DC voltage.
2.3.1 Thermocouples
The following thermocouple types acc. to DIN/EN 60584 can be connected:
TC type TC material
type Ident. colour neg. wire Range
L Fe/Cu-Ni blue 0....900°C
J Fe/Cu-Ni black 0....900°C
K Ni-Cr/Ni green 0...1350°C
N Nicrosil/Nisil pink 0...1300°C
S Pt-10Rh/Pt orange 0...1760°C
R Pt-13Rh/Pt white 0...1760°C
T Cu/Cu-Ni brown 0....400°C
W*) W5Re/W26Re not determined 0...2300°C
E Ni-Cr/Cu-Ni violet 0...1000°C
*) not acc. to DIN
The lower measuring limit of KS 800 is 0 mV for all thermocouple types, i.e. 0°Cor32°F. The
upper measuring limit is the upper operating temperature of the relevant thermocouple type.
The thermocouples are monitored for wrong polarity and break.
Monitoring for wrong polarity responds, when the wrong polarity voltage corresponds to a tempe-
rature of -30°C.
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2.3.2 Resistance thermometer
Resistance thermometers of type PT 100 to DIN/IEC 751 can be connected in 2 or 3-wire circuit.
The lower measuring limit is -100°C.
The upper measuring limit is +850°C.
The thermometer current is approx. 0,25 mA.
The resistance thermometer is monitored for lead break and short circuit. A short circuit is with a
resistance (thermometer incl. leads) < 48 Ω(-130°C).
2.3.3 Resistance
Variable resistances within 0 ... 400 Ohm can be used as input signal.
Circuit type: variable resistor, no potentiometer circuit.
Span start and end can be selected freely within the limits specified above.
The sensor current is approx. 0,25mA.
Only lead break monitoring is provided.
Note: Unless used in conjunction with a 2-stage cascade controller, this resistive input cannot be
used as position feedback for a 3-point stepping controller: the master controller gets e.g. the
temperature as input, the slave gets its set-point by the master and the process value is the
resistance at the motor actuator.
2.3.4 DC voltage
DC voltages of -100mV ... +100mV can be processed.
Lead monitoring for short circuit or wrong polarity is not possible.
Lead break detection is provided.
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