Siemens Expert Series Quick start guide

PMA Prozeß- und Maschinen-Automation GmbH
Temperature controller KS 50-1
KS50-1
KS50-1
TCont
TCont
Operating Note
English
9499-040-64411
Valid from: 8403
expert line for tempering units and hot runners

© PMA Prozeß- und Maschinen-Automation GmbH •Printed in Germany (0307)
All rights reserved. No part of this documentation may be reproduced or published in any form or by any
means without prior written permission from the copyright owner.
Subject to alterations without notice.
A publication of PMA Prozeß- und Maschinen- Automation
Postfach 310229
D-34058 Kassel
Germany
Contents
1Introduction ............................3
1.1 Definitions..............................3
2Hints on operation .........................4
2.1 Electrical connections ........................4
2.2 Bus interface.............................4
2.3 Connection example.........................5
3Operation ..............................6
3.1 Front view ..............................6
3.2 Behaviour after power-on ......................7
3.3 Functions for tempering units ....................7
3.4 Functions for hot-runner ......................10
4Configuration extensions .....................11
5Parameter extensions .......................13
6Communication protocol .....................14
6.1 Data format.............................15
6.2 Protocol structure .........................15
7Protocol for tempering equipment................16
7.1 Master telegram ..........................16
7.2 Slave telegram ...........................17
7.3 Error messages ...........................18
7.4 Alarm Reset ............................19
8Protocol for hot-runner systems .................20
8.1 Master telegram ..........................20
8.2 Slave telegram ...........................21
9ORDERING INFORMATION .................22
10 TECHNICAL DATA .......................23
11 Index ................................27

1Introduction
Thank you for buying a KS 50-1 TCont.
This expert line unit offers special functions for tempering and hot-runner
equipment. An optional 20mA current loop or an RS485/422 interface are
available for easy connection of peripheral units including a KS 50-1 TCont to a
machine control system.
The protocol is widely used in the plastics industry and supported by many
injection moulder and extruder manufacturers, e.g. Arburg, Engel and
Krauss-Maffei. Another name for it is ”ARBURG protocol”.
This operating note describes the extended functions and features of
KS 50-1 TCont. For all other functions, refer to operating manual
9499-040-62811 for KS 50-1 Industrial Controller.
1.1 Definitions
A current loop interface transmits serial data by switching on and off a 20mA
current in a conductor loop at the data bit clock. During the rest condition, or
during transmission of ”1” bits, a constant 20 mA current is flowing, whilst the
current flow is intermittent with ”0” bits.
Another name for 20mA current loop interface is TTY interface
(TeleTYpe(writer)).
lCaution! The unit contains ESD-hazarded components.
ARBRUG is a registered trademark of ARBURG GmbH + CO, D-Loßburg.
.
Introduction
Operating note KS 50-1 TCont 3 Definitions

2Hints on operation
2.1 Electrical connections
* Safety switch mA iV turned left
gThe controller is provided with flat-pin terminals 1 x 6,3mm or 2 x 2,8mm to
DIN 46 244. Or with screw terminals depending on ordering code.
2.2 Bus interface
1Connection of the TTY bus interface (example)
Hints on operation
Electrical connections 4 Operating note KS 50-1 TCont
U
Logic
di2
di3
UT
L
N
90...250V
24V AC/DC
+24V DC
24V GND
mA
mA
0..10 V*
HC
di1
INP1
INP2
OUT3
OUT2
OUT1
1
2
3
4
7
5
8
6
9
10
11
12
13
14
15
1
3
4
5
6
7
8
9
10
11
12
13
14
15
17
(2)
(16)
OUT5
OUT6
TTY
+ 20mA
20mA GND
RXD-B
GND
RXD-A
TXD-B
TXD-A
RS485 / RS422
RGND
DATA B
DATA A
alternativ
12
13
14
15
17
(16)
11
12
13
14
15
10
12
13
14
15
17
(16)
11
12
13
14
15
10
12
13
14
15
17
(16)
11
12
13
14
15
converter
TTY -RS232
PC +20mA
20mA GND
J
max. 1000m
(”Twisted Pair”)
10
+20mA
+20mA
20mA GND
20mA GND
-T
+R
+
-

2Alternative connection of the RS485/422 bus interface (example)
2.3 Connection example
Hints on operation
Operating note KS 50-1 TCont 5 Connection example
12
13
14
15
17
(16)
11
12
13
14
15
10
12
13
14
15
17
(16)
11
12
13
14
15
10
12
13
14
15
17
(16)
11
12
13
14
15
RGND RGND RGND
RT
converter
RS485-RS232
PC
DATA A
DATA B
DATA A
DATA B
DATA A
DATA B
J
max. 1000m
”Twisted Pair”
10
RT
R=100 Ohm
RGND connection optional
R = 120...200 OhmT
R = 120...200 OhmT
OUT1
OUT2
OUT3
STL
heating
cooling
pump
INP1
INP2
heating
current
process
value
di1
di2
di3
STL
L.start
L.stop
remote/local
TTY
mould
tempering unit

3Operation
3.1 Front view
LED colours :
LED 1, 2, 3: yellow
LED OK: green
other LEDs: red
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.
gLED REM -6displays the remote/local mode. In mode remote this LED lights
and value changes via front keys are locked.
Operation
Front view 6 Operating note KS 50-1 TCont
1Status of switching outputs
OuT.1... 6
2Lights with limit value 1
(PArA /Lim) not exceeded
3Process value display
4Set-point, controller output
5Signals ConF and PArA level
6Device in remote mode
7Self-tuning active
8Entry in error list
9Set-point SP.2 or SP.E is
effective
0Set-point gradient is effective
!Manual/automatic switch-over:
Off: Automatic
On: Manual
(changing possible)
Blinks: Manual
(changing not possible)
(rConF/Cntr/MAn))
"Enter key:
calls up extended
operating level / error list
§Up/ Down keys:
changing the set-point or the
controller output value
$Manual mode /spec. function
(→ConF /LOGI)
%PC connection for
BlueControl (engineering
tool
&Remote/local-switch /
spec. function
(→ConF /LOGI)
KS 50-1 TCont
180
178.
SP.x Rem
Err
Ada
123OK
3
m
%
1
2
3
4
0
5
!
6
"
7
8
§
9
$
9
!
%
§
è
è
è
&

3.2 Behaviour after power-on
After supply voltage switch-on, the unit starts with the remote mode and goes
then into the standby mode. The controller mode is switched off. (SP =OFF).
3.3 Functions for tempering units
KS 50-1 TCont has a lot of possibilities to connect signals coming from and
going to the tempering unit.
wThe process value is connected to INP1.
wAn output signal of a safety temperature limiter (STL) can be attached
alternatively to di1 to di3. When responding the STL the controller goes into
the switching off mode (stop). The signal is passed on in the protocol (see
page 18).
wThe operation of the controller can be accomplished in the remote or in local
operation. For the change-over the inputs di1 to di3 or the F-key are
available. In remote mode values can be given only over the attached
interface; inputs via the front are blocked. Vice versa in local mode set-point
operations over the interface are not permitted. As answer the device
supplies a NAK message.
wFor local starting and stopping of the tempering unit push-buttons or
switches can be selected and attached at the inputs di1 to di3. The function
start or stop is released with the change of 0 to 1, independently of the
configuration of di.Fn as push-button or switch.
wSelected signals for sensor mode, level alarm or flow alarm can be connected
to di1 to di3. They are only through-handed in the device, but indicated in
the protocol (see page 17).
wThe alarm for safety temperature - monitoring can be determined with limit 1
(Lim.1).
wKS 50-1 TCont supplies a continuous signal to control a pump, which can be
connected to OUT1 to OUT6.
wAfter a stop command the pump is only switched off, if the return flow
temperature is fallen below the adjusted limit, which is defined over the
set-point SP2.
gIf the inputs for start and stop are not wired, then the same functionality can be
achieved in local mode by switching on and off the controller function (for
switching off put the set-point SP to OFF; for switching on enter a valid
set-point). The start instruction corresponds to the control command (r) in the
remote mode, the stop command to the control command (p).
Operation
Operating note KS 50-1 TCont 7 Behaviour after power-on

Signal connection types
Signal Connection types Remarks
Pt100 / TC – sensor, internal or external INP1
Heating current input, if applicable INP2
STL input from safety temperature limiter di1...3 
remote – local – switch-over di1...3, F-Key 
local – start; push-button function di1...3 
local – stop; push-button function di1...3 
Sensor operating mode: 0= internal; 1= external; di1...3  
Input for alarm “level”: 0= ok; 1= alarm di1...3  
Input for alarm “flow”: 0= ok, 1= alarm di1...3  
Output heating relay OUT1..3, OUT5..6 
Output cooling relay OUT1..3, OUT5..6 
Output pump relay OUT1..3, OUT5..6 
alarm safety temperature LiM.1
Set-point for return flow temperature SP.2
Signals are only transferred in communication protocol.
Alternative connection types
The function flow is described in the following state diagram.
The implemented actions executed at a change-over of states are shown in the
following table.
Operation
Functions for tempering units 8 Operating note KS 50-1 TCont
Power down
Standby /Rem Standby/ Loc
Controlling / Rem Loc
T1
T2 T3 T4 T5 T6
T7
T8
T9
T10
T11 T12
T13
T14
Controlling /

Transi
tion previous state following state event condition action
T1 Power down Standby/Rem Power on none - start-initialization
- controller switched off
- remote mode
- no self-tuning
T2 Standby/Rem Controlling/
Rem Control command
(r)
remote - switch on pump
- switch on controller
- start self-tuning, if applicable
- control to set-point
T3 Controlling/
Rem Standby/Rem Control command
(k)
remote - if X > SP2: cooling
- then switch off controller
- switch off pump
T4 Controlling/
Rem Standby/Rem Control command
(p)
remote - if X > SP2: cooling
- then switch off controller
- witch off pump
T5 Standby/Loc Controlling/
Loc local start signal local as T2
T6 Controlling/
Loc Standby/Loc local stop signal local as T4
T7 Standby/Rem Standby/Loc r/l-switch-
over local toggle to local
T8 Standby/Loc Standby/Rem r/l-switch-
over remote toggle to remote
T9 Controlling/
Rem Controlling/ Loc r/l-switch- over local toggle to local
T10 Controlling/
Loc Controlling/ Rem r/l-switch- over remote toggle to remote
T11 Controlling/
Rem Standby/Rem STL active remote as T4
T12 Controlling/
Loc Standby/Loc STL active local as T4
T13 Standby/Rem Controlling/
Rem identifier (R) remote -Acknowledge/delete the existing alarms
- continue with T2
T14 Controlling/
Rem Controlling/ Rem identifier (R) remote - Acknowledge/delete the existing alarms
- continue with T2 (however
without self-tuning)
Operation
Operating note KS 50-1 TCont 9 Functions for tempering units

3.4 Functions for hot-runner
To operate with the protocol extension for hot-runners only a few additional
inputs and outputs are needed.
wThe operation of the automatic controller can be switched over from remote
to local operation. Therefore the inputs di1 to di3 or the F-key are available.
In local operation a start-/stop functionality can be achieved by switching on and
off the controller (for switching off put the set-point SP to OFF; for switching
on enter a valid set-point). The start command corresponds to the control
command (r) in the remote mode, the stop command to the control command (a).
Operation
Functions for hot-runner 10 Operating note KS 50-1 TCont

4Configuration extensions
The KS 50-1 TCont configuration values are extended by the following settings
compared with the standard version.
qProtocol selection
In configuration menu othr, item Prot is available for definition of the
protocol to be used.
othr
Name Range Description Default
Prot Protocol selection for rear interface 1
0 MODBUS RTU
1 Protocol for tempering unit
2 Protocol for hot runner
qOutput selection
Control of a pump can be selected via parameter PumPin the configuration menu
for OUT.1,OUT.2,OUT.3,OUT.5 or OUT.6 . The default is an active OUT.3.
OUT.1,OUT.2,OUT.3,OUT.5,OUT.6
Name Range Description Default
PuMP output pump 0
0 Not active
1 Active
qSelf-tuning start
For KS 50-1 TCont, the self-tuning behaviour during start-up was changed.
Self-tuning is suppressed during power-on and called up only when starting
control operation, if permitted (see OrEL).
Cntr
Name Range Description Default
Strt Self-tuning start 0
0 Manual self-tuning start via the front panel, or when starting
control operation, if permitted.
1 Manual self-tuning start via the front panel, when starting
control operation, if permitted, and when detecting
oscillation.
Configuration extensions
Operating note KS 50-1 TCont 11

qInput selection
For configuration menu LOGI additional menus for selecting typical digital
inputs for tempering equipment are available.
LOGI
Name Range Description Default
StB Source for safety temperature limiter signal 0
0 interface only
2 di1 switches
3 di2 switches
4 di3 switches
L.Sta Source for local function start 0
0 interface only
2 di1 switches
3 di2 switches
4 di3 switches
L.Sto Source for local function stop 0
0 interface only
2 di1 switches
3 di2 switches
4 di3 switches
SEnS Source for sensor operating mode (internal, external) 0
0 interface only
2 di1 switches
3 di2 switches
4 di3 switches
LEvL Source for level alarm 0
0 interface only
2 di1 switches
3 di2 switches
4 di3 switches
Flo Source for flow alarm 0
0 interface only
2 di1 switches
3 di2 switches
4 di3 switches
Configuration extensions
12 Operating note KS 50-1 TCont

5Parameter extensions
The KS 50-1 TCont parameters are extended by the following settings compared
to the standard version.
qSelf-tuning switch-off
For Cntrcontrol and adaptation, parameter OrEl is used to permit self-tuning.
Cntr
Name Range Description Default
OrEl Enable self-tuning at control operation start 0
0 Self-tuning permitted
1 Self-tuning not permitted
+Hints on self-tuning
To meet the special requirements of fast control loops, e.g. with tempering units,
the following information should be taken into account.
gBy setting the input filter for measurement input 1 ( Para /InP.1 /t.F1)toa
filter time ≥15 s, input variable fluctuations can be reduced, i.e. earlier settling of
the input variable.
gTo improve the optimization result, the control range should be limited to the
actual range. For this purpose, the min. and max. control range limit must be
matched, e.g. with a range of 20°C ... 150°C, value rnG.L =20and rnG.H =
150 in Conf /Cntrmust be set.
gThe minimum cycle times t1 and t2 should be as low as possible. If a defined
min. pulse duration must not be exceeded, changing during self-tuning can be
prevented via configuration parameter Adt0 =1. Please, note that the shortest
pulses result from ¼ x t1 or¼xt2.
Parameter extensions
Operating note KS 50-1 TCont 13

6Communication protocol
KS50-1 TCont supports a simple protocol for injection moulders and extruders
widely used in the plastics industry, which is used for connecting peripheral
equipment and easy simple data exchange. This protocol, which is also called
”ARBURG” protocol, is designed according to the specification of the Arburg
company.
gThis protocol is also supported by other machine manufacturers, e.g. Engel,
Krauss-Maffei, etc. Any adaptation required can be done by changing the
Baudrate or the parity.
Communication is according to the master / slave principle. KS 50-1 is always
slave and polled for a message by the machine control system. Exchanging
messages is done in half-duplex operation.
The transmission parameters are adjustable via the front panel or via
BlueControl.
qBaudrate (bAud):
w2400 ,
w4800,
w9600,
w19200 Bits/s
qParity (PrtY):
wEven,
wOdd,
wNone
qAddress settings (Addr):
w1to32
qByte format (fixed):
wNumber of data bits: 8
wNumber of stop bits: 1
wNumber of start bits: 1
The LSB is sent first.
Exchanging messages is subjected defined time conditions:
wCharacter delay time T1:< 50 ms
(The max. possible time which can pass between sending of the start bits of
two successive bytes a message)
wAcknowledgement delay time T2: <100ms
(The max. possible time which can pass between the end of an inquiry sent by
the master and reception of the first character of the slave reply)
Communication protocol
14 Operating note KS 50-1 TCont

6.1 Data format
For transmission of block length and checksum, the hexadecimal format is used,
whilst set-points and process values are transmitted in BCD format. For
transmission, hexadecimal values are converted into ASCII. For simplification,
values above 9 (A-F) are coded as 3Ah - 3Fh instead of 41h-46h (ASCII A-F).
6.2 Protocol structure
1 2 3 4 5 6 ... n n+1 n+2
Address Length Identificaton Message Checksum
Byte 1: Device address of instruments 1 – 32, default 1
•Master →slave (range: B1h...D1h, B0h: reserved)
•Slave →master (range: 31h...51h, 30h: reserved)
Byte 2-4: Block length; each message contains 3 bytes, which include
(ASCII-coded) the binary number of bytes of the overall message
(including checksum bytes). When receiving, the correct number of
bytes is checked
(range: 30h,30h,37h ... 3Fh,3Fh,3Fh)
Byte 5: Identification marks the message type,(range: 41h, 7Fh), see below
Byte 6-n: Information bytes, see below
Byte n+1,n+2: Checksum; every message is completed by 2 checksum bytes, which
are also counted in the block length bytes. The checksum bytes are the
(ASCII-coded) 8 bit wide sum of all bytes of the message including
block length bytes, checksum bytes not included.
(range: 30h,30h...3Fh,3Fh)
gHexadecimal numbers are coded in form xxh, e.g. 41h means decimal 65 or ‘A’
in ASCII.
Communication protocol
Operating note KS 50-1 TCont 15 Data format

7Protocol for tempering equipment
The protocol for tempering equipment is selected via parameter ProT =1.
7.1 Master telegram
The following telegrams sent by the master are supported by KS 50-1 TCont.
… 4 5 6 ... 12 13+14
... Identification Message Check sum
Byte 5: Identification: 41h (‚A‘) and 52h (‚R‘) is supported.
Byte 6-9: Set-point (= SP) in 0,1 degrees Celsius
(3 digits before, 1 digit behind the decimal point);
negative temperatures up to –99 degrees Celsius are possible
(1st byte = 2Dh)
Range: -99,9 ... 999,9 °C
Examples: 12,3 °C→30h 31h 32h 33h
-5,6 °C→2Dh 30h 35h 36h
Byte 10: Mould type = parameter set:
60h (`): is supported (self-tuning acc. to KS 50-1 TCont setting)
61h (a)...6Ah(j): commands are accepted; function as 60h
Byte 11: Control commands = operating mode:
61h (a), 6Bh (k): Switch-off function;
cooling down to return flow temperature, switch off
feedback signals: (k) cooling, (p) switched off
70h (p): Switch-off function;
heating off, cooling down to return flow temperature,
cooling off, pump off, switch off
feedback signals: (k) cooling, (p) switched off
72h (r ): Switch-on function;
pump on, self-tuning on (if permitted),
closed-loop control (normal operation)
feedback signals: (r ) closed-loop control
73h (s): Switch-off function;
cooling down to return flow temperature, switch off
feedback signals: (s) cooling, (p) switched off
Byte 12: Reserved, always 20h
Byte 13,14: Checksum
Protocol for tempering equipment
Master telegram 16 Operating note KS 50-1 TCont

7.2 Slave telegram
With correctly received master telegram, the following reply telegram is sent by
KS 50-1 TCont :
...4 5 6 ... 17 17+18
... Identification Message Checksum
Byte 5: Identification: 41h (‚A‘) and 72h (‚r‘) are supported.
Byte 6-9: Process value (= In.1)in0,1°C
(3 digits before, 1 digit behind the decimal point);
Negative temperatures up to –99 °C are possible (1st byte = 2Dh)
Range: -99,9 ... 999,9 °C
Examples: 12,3 °C→30h 31h 32h 33h
-5,6 °C→2Dh 30h 35h 36h
Byte 10-13: Duty cycle in%(=Ypid);
negative polarity sign for cooling (1st byte = 2Dh)
Range: -100 ... 100 %
Examples: 12 % →30h 30h 31h 32h
-34 % →2Dh 30h 33h 34h
Byte 14: Status bit feedback
Bit 0: controller mode 1: local 0: remote
Bit 1: sensor mode 1: internal; (selection via SEns)
Bit 2: inadmissible
set-point 1: fault
Bit 3: (fixed) 0
Bit 4: 1: common alarm occurred
(see status alarms1)
Bit 5, 6, 7: (fixed) 1, 1, 0
Byte 15: Status alarms 1
Bit 0: sensor break 1: sensor break detected (FbF.1)
Bit 1: heating defective 1: HCA error (HCA or Loop)
Bit 2: cooling defective 0, not supported.
Bit 3: level alarm 0, (optionally adjustable
via LEvL )
Bit 4: flow alarm 0, (optionally adjustable via Flo)
Bit 5: temperature >
safety limit 1: yes (optional Stb or Lim.1)
Bit 6, 7: (fixed) 1, 0
Protocol for tempering equipment
Operating note KS 50-1 TCont 17 Slave telegram

Byte 16: Status alarms 2
Bit 0: pump defective: 0; not supported
Bit 1: phase failure: 0; not supported
Bit 2: system error 1: input STL has responded
(Stb) or instrument error (E.1,E.2)
Bit 3, 4, 5, 6, 7: (fixed) 0, 0, 0, 1, 0
Byte 17: Status feedback
6Bh (k) switch-off: cooling down to return flow temperature
6Fh (o) during control operation: self-tuning busy
70h (p) switch-off: heating, cooling, pump switched off
72h (r ) control operation
73h (s) switch-off: cooling down to return flow temperature
Byte 18-19: Checksum
7.3 Error messages
With parity or framing errors, or with undefined characters, no reply is provided.
If the checksum in the master telegram is faulty, or with an error in the message,
KS 50-1 TCont sends a NAK message.
Not Acknowledge message structure:
1234567
Address Length Identification check sum
Byte 1: device address, e.g. 31h device no. 1
Byte 2-4: length (message is 7 bytes long: 30h, 30h, 37h)
Byte 5: identification: 7Fh “Not Acknowledge”
Byte 6-7: checksum
gThe message is also sent, if an invalid value was sent, because e.g. set-point
changing via the interface is not possible during local mode.
Protocol for tempering equipment
Error messages 18 Operating note KS 50-1 TCont

7.4 Alarm Reset
During remote mode, a pending STL alarm can be acknowledged and deleted via
command ”Alarm Reset”..
qMaster telegram:
Structure of the alarm reset message:
...4 5 6 ... 12 13+14
... Identification Message Checksum
Byte 5: Instead of identification 41h (‚A‘), identification 52h (‚R‘) Alarm Reset
is sent. Sending and handling of the remaining parameters are as in the
standard protocol (see page 16)
qSlave telegram
...4 5 6 ... 17 18+19
... Identification Message Checksum
Byte 5: Identification 72h (‚r‘) instead of 41h (‚A‘) is sent. The remaining
functions are as in the standard protocol (see page 17 ).
Protocol for tempering equipment
Operating note KS 50-1 TCont 19 Alarm Reset

8Protocol for hot-runner systems
Selecting the hot-runner protocol is done via setting ProT =2.
With a hot-runner system, KS 50-1 TCont covers one channel.
8.1 Master telegram
The structure of the inquiry telegram is:
...4 5 6 ... 10 11+12
... Identification Message Checksum
Byte 5: Identification: 41h (‚A‘) is supported.
Byte 6-9: •Set-point with command for closed-loop control: (= SP)in0,1 °C
(3 digits before, 1 digit behind the decimal point);
Negative temperatures up to –99 °C are possible (1st byte = 2dh)
•Output value with command for positioning: in % (= Yman)
(3 digits before, 1 digit behind the decimal point)
Byte 10: Control commands
72h (r): closed-loop control (normal operation),
in °C; instrument in automatic mode;
after control function switch-off, self-tuning is done,
if permitted
73h (s): positioning,
in %; instrument in manual mode
61h (a): switch off channel
control function switched off
Byte 11-12: Checksum
gSpecial case: first message after control system start-up: system can read up to 25
channels per device address. Therefore, the message contains up to 25 times the
set-point or output value, and the control command.
However, a KS 50-1 TCont only uses the values for channel 1 from the message,
and indicates in the reply that only one channel is provided.
Protocol for hot-runner systems
Master telegram 20 Operating note KS 50-1 TCont