WIKA CS4S User manual

D
GB
Operating instructions
Betriebsanleitung
Temperature controller, model CS4S
Temperature controller for mounting into control panels
Model CS4S
Temperaturregler für den Einbau in Schalttafeln
Typ CS4S

2
WIKA operating instructions model CS4S
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Operating instructions model CS4S Page 3 - 46
Betriebsanleitung Typ CS4S Seite 47 - 90
Further languages can be found at www.wika.com.
© 2013 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
WIKA®is a registered trademark in various countries.
WIKA®ist eine geschützte Marke in verschiedenen Ländern.
Prior to starting any work, read the operating instructions!
Keep for later use!
Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch aufbewahren!

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1. General information 4
2. Safety 5
3. Specications 8
4. Design and function 10
5. Transport, packaging and storage 13
6. Commissioning, operation 14
7. Conguration 18
8. Descriptions of the operating characteristics 32
9. Control mode 38
10. Maintenance and cleaning 41
11. Faults 41
12. Dismounting, return and disposal 44
Appendix: EC declaration of conformity 46
Contents
Declarations of conformity can be found online at www.wika.com.
Contents

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1. General information
■
The temperature controller described in these operating instructions has been
manufactured using state-of-the-art technology. All components are subject to stringent
quality and environmental criteria during production. Our management systems are
certied to ISO 9001 and ISO 14001.
■
These operating instructions contain important information on handling the instrument.
Working safely requires that all safety instructions and work instructions are observed.
■
Observe the relevant local accident prevention regulations and general safety
regulations for the instrument's range of use.
■
The operating instructions are part of the product and must be kept in the immediate
vicinity of the instrument and readily accessible to skilled personnel at any time.
■
Skilled personnel must have carefully read and understood the operating instructions
prior to beginning any work.
■
The manufacturer's liability is void in the case of any damage caused by using the
product contrary to its intended use, non-compliance with these operating instructions,
assignment of insuciently qualied skilled personnel or unauthorised modications to
the instrument.
■
The general terms and conditions contained in the sales documentation shall apply.
■
Subject to technical modications.
■
Further information:
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: AC 85.02
- Application consultant: Tel.: [phone]
Fax: [phone]
[e-mail]
Explanation of symbols
WARNING!
... indicates a potentially dangerous situation that can result in serious injury or
death, if not avoided.
CAUTION!
... indicates a potentially dangerous situation that can result in light injuries or
damage to equipment or the environment, if not avoided.
1. General information

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Information
... points out useful tips, recommendations and information for ecient and
trouble-free operation.
DANGER!
...identies hazards caused by electric power. Should the safety instructions
not be observed, there is a risk of serious or fatal injury.
2. Safety
WARNING!
Before installation, commissioning and operation, ensure that the appropriate
temperature controller has been selected in terms of measuring range, design
and specic measuring conditions.
Non-observance can result in serious injury and/or damage to the equipment.
WARNING!
This is class A equipment for emissions and is intended for use in industrial
environments. In other environments, e.g. residential or commercial
installations, it can interfere with other equipment under certain conditions.
In such circumstances the operator is expected to take the appropriate
measures.
Further important safety instructions can be found in the individual chapters of
these operating instructions.
2.1 Intended use
The model CS4S is a compact digital temperature controller for the display, control and
monitoring of temperature.This controller has been designed for mounting into control
panels.
The instrument has been designed and built solely for the intended use described here,
and may only be used accordingly.
The technical specications contained in these operating instructions must be observed.
Improper handling or operation of the instrument outside of its technical specications
requires the instrument to be taken out of service immediately and inspected by an
authorised WIKA service engineer.
1. General information / 2. Safety

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If the instrument is transported from a cold into a warm environment, the formation of
condensation may result in instrument malfunction. Before putting it back into operation,
wait for the instrument temperature and the room temperature to equalise.
The manufacturer shall not be liable for claims of any type based on operation contrary to
the intended use.
2.2 Personnel qualication
WARNING!
Risk of injury should qualication be insucient!
Improper handling can result in considerable injury and damage to equipment.
■
The activities described in these operating instructions may only be carried
out by skilled personnel who have the qualications described below.
■
Keep unqualied personnel away from hazardous areas.
Skilled personnel
Skilled personnel are understood to be personnel who, based on their technical training,
knowledge of measurement and control technology and on their experience and
knowledge of country-specic regulations, current standards and directives, are capable of
carrying out the work described and independently recognising potential hazards.
Special operating conditions require further appropriate knowledge, e.g. of aggressive
media.
2.3 Special hazards
WARNING!
Protection from electrostatic discharge (ESD) required.
The proper use of grounded work surfaces and personal wrist straps is
required when working with exposed circuitry (printed circuit boards),
in order to prevent static discharge from damaging sensitive electronic
components.
To ensure safe working on the instrument, the operating company must
ensure
■
that suitable rst-aid equipment is available and aid is provided whenever
required.
■
that the operating personnel are regularly instructed in all topics regarding
work safety, rst aid and environmental protection and know the operating
instructions and, in particular, the safety instructions contained therein.
2. Safety

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DANGER!
Danger of death caused by electric current
Upon contact with live parts, there is a direct danger of death.
■
The instrument may only be installed and mounted by skilled personnel.
■
Operation using a defective power supply unit (e.g. short circuit from the
mains voltage to the output voltage) can result in life-threatening voltages at
the instrument!
WARNING!
Do not use this instrument in safety or emergency stop devices. Incorrect use
of the instrument can result in injury.
2.4 Labelling, safety marking
Product label
Explanation of symbols
Before mounting and commissioning the instrument, ensure you read
the operating instructions!
CE, Communauté Européenne
Instruments bearing this mark comply with the relevant European directives.
Date of manufacture
Year.Month
Model
2. Safety

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3. Specications
Display
Actual value 7-segment LED, 4-digit, red, digit height 10.2 mm
Set point 7-segment LED, 4-digit, green, digit height 8.8 mm
Scale range -1999 ... 9999
Input
Number and type 1 multi-function input for resistance thermometers, thermocouples and
standard signals
Input conguration Selectable via terminal connections and menu-driven programming
Resistance thermometer Pt100, JPt100, 3-wire
max. permissible resistance per connecting cable: 10 Ω
Thermocouples
■
Types K, J, R, S, E, T, N, PL-II, C (W/Re5-26)
max. permissible external resistance: 100 Ω
■
Type B
max. permissible external resistance: 40 Ω
Standard signals 0 ... 20 mA, 4 ... 20 mA: Input impedance 50 Ω (external instrument shunt)
0 ... 1 V: Input impedance > 1 MΩ
0 ...5 V, 1 ... 5 V, 0 ... 10 V: Input impedance > 100 kΩ
Measuring time 250 ms
Control outputs
Control output 1 3 dierent versions are possible
Relay contact Loading: AC 250 V, 3 A (resistive load), AC 250 V, 1 A (inductive load,
cos ϕ = 0.4)
Logic level DC 0/12 V, max. 40 mA (short-circuit proof)
for the control of an electronic switch relay (solid-state relay, SSR)
{analogue current signal} 4 ... 20 mA, max. load 550 Ω
Control output 2 1) For “three-step control”
Output Contact-free relay, loading: AC 230 V, 0.3 A (resistive load)
Proportional band 0.0 to 10.0 times the proportional band of control output 1
Integral time
Identical to the integral time of control output 1 (see “Control Mode”)
Derivative time Identical to the derivative time of control output 1 (see “Control Mode”)
Cycle time 1 ... 120 s
Overlap band/deadband Resistance thermometers and thermocouples: -100.0 ... 100.0 °C
Standard signals: -1,000 ... 1,000 (with a scaling of the input with one
decimal point, this is taken over by the hysteresis).
{ } Items in curved brackets are optional extras for an additional price
1) A combination of alarm output 2 or heater burnout alarm with relay output 2 is not possible.
3. Specications

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Control mode PID, PI, PD, P, ON/OFF (congurable)
To determine the control parameters for PID control, auto tuning can
be activated.
Proportional band Thermocouples: 0 ... 1,000 °C
Resistance thermometers: 0.0 ... 999.9 °C
Standard signals: 0.0 ... 100.0 %
Integral time 0 ... 1,000 s
Derivative time 0 ... 300 s
Cycle time 1 ... 120 s (not available with analogue current signal control output)
Hysteresis Only available with ON/OFF control mode
Resistance thermometers and thermocouples: 0.1 ... 100.0 °C
Standard signals: 1 ... 1,000 (with a scaling of the input with one
decimal point, this is taken over by the hysteresis).
Alarm outputs, max. 2 (common contact terminal)
Alarm output 1 For actual-value monitoring
Alarm type, switch behaviour, hysteresis and time delay can be set
{Alarm output 2} 1) 2) Selectable as actual-value monitoring or control-loop monitoring, or as
actual-value and control-loop monitoring with combined output.
{Heater burnout alarm}
1) 2)
For single-phase heating systems (not possible with analogue current
signal control output), optionally congured up to max. 5 A, 10 A, 20 A or
50 A, the current transformer is included in the delivery
Relay contact 3) Loading: AC 250 V, 3 A (resistive load), AC 250 V, 1 A (inductive load,
cos ϕ = 0.4)
Options and performance data
{Parameter memory} 4) Memory for a 2nd set point, can be activated through the short-circuit of 2
connection terminals on the rear of the controller.
{serial interface} 4) RS-485
The transmission rate can be set (2,400 bps, 4,800 bps, 9,600 bps or
19,200 bps).
Power supply AC 100 ... 240 V, 50/60 Hz (max. permissible 85 ... 264 V) or
AC/DC 24 V, 50/60 Hz (max. permissible 20 ... 28 V)
Power consumption approx. 8 VA
Case
Material Polycarbonate
Colour black
Ingress protection Front: IP 66, Rear: IP 00 (per IEC 60529/EN 60529)
Weight approx. 200 g
Mounting Screw type mounting brackets for wall thicknesses from 1 to 15 mm
{ } Items in curved brackets are optional extras for an additional price
1) A combination of alarm output 2 or heater burnout alarm with relay output 2 is not possible.
2) When alarm output 2 and the heater burnout alarm are both available simultaneously, both alarms work o a single relay.
3) Is valid for alarm output 1 and alarm output 2 or heater burnout alarm.
4) From the options of the serial interface and the parameter memory, only one option can be selected at any one time.
3. Specications

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PV
SV
1
2
3
4
5
7
8
10
6
9
11 12 13 14
CE conformity
EMC directive: 2004/108/EG, EN 61326 emission (group 1, class A) and interference
immunity (industrial application)
For further specications see WIKA data sheet AC 85.02 and the order documentation.
4. Design and function
4.1 Description
The model CS4S temperature controller features a multi-function input, meaning the
conguration of the sensor input can be set. Thus the exibility of the controller is
considerably increased, and stock-holding is made easier. An alarm output for monitoring
the actual value is also available as standard.
The control parameters can be set across broad ranges. Auto tuning, which facilitates
nding the optimal control parameters, can be activated.
The controllers are designed for installation in a control panel.
The control output can be set either as relay (for slow control), as logic for the control of
electronic solid-state relays (for fast control and high current loads) or as a continuous
4 ... 20 mA output.
As options, there is a 2nd alarm output available for the monitoring of the actual value
and the control loop, and a heater burnout alarm for monitoring the control output, or,
alternatively, a 2nd relay output. Likewise, an RS-485 serial interface or a parameter
memory for a 2nd set point is available.The parameter memory can be selected via an
external connection terminal.
4.2 Display and controls
3. Specications / 4. Design and function

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Display Description
(1) PV Actual value display
The actual value (PV = process variable) is displayed with a red LED display.
(2) SV Set point display
The set point (SV = setting value) or the manipulated variable (MV) is displayed with a
green LED display.
(3) SV1 Set point 1
The green LED lights up when set point 1 (SV1) is activated.
(4) SV2 Set point 2
The yellow LED lights up when set point 2 (SV2) is activated.
(5) OUT1 Control output 1
The green LED lights up when control output 1 is ON.
(When the control output is analogue current signal, the LED blinks in proportion to the
output power.)
(6) OUT2 Control output 2
The yellow LED lights up when control output 2 is ON.
(7) A1 Alarm output 1 (A1)
The red LED lights up when alarm output 1 is ON.
(8) EVT Event display
The red LED lights up when the event output is ON (Option [2Ax]: Alarm output 2 and/
or option [W1x] heater burnout alarm).
(9) AT Auto tuning
The yellow LED blinks when the auto tuning or the auto reset function is activated.
(10) TX/RX TX/RX display
The yellow LED lights up when serial interface is active.
Key Description
(11) ▲ Up key
Increases a numerical value or selects a setting parameter.
(12) ▼ Down key
Reduces a numerical value or selects a setting parameter.
(13) MODE MODE key
Selects the setting mode and stores the selected setting parameter.
(14) OUT/OFF OUT/OFF key
Depending on the setting in the menu of the “Function OUT/OFF key”, using this key,
the controller is switched o or switched to manual control (see chapters 7.6 and 7.7)
When the settings for this controller must be set, rst link connection terminals
1 and 2 for the power supply, then follow the setting in accordance with
chapter 7 “Conguration”, before moving on to chapter 6 “Commissioning,
operation”.
4. Design and function

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75
45 +0.5
n x 48 -3
45
0
45 +0.5
0
+0.5
0
+0.5
0
lk
15
Ø 5,8 0,5
CTL - 6 -S
5,01
21
40
3
25 7,5
2,8
K L
10
2-Ø3,5
30
30
lk
100
40
Ø 1240 15
30 2-M3
lk
15
Ø 5,8 0,5
CTL - 6 -S
5,01
21
40
3
25 7,5
2,8
K L
10
2-Ø3,5
30
30
lk
100
40
Ø 1240 15
30 2-M3
4.3 Dimensions in mm
Sealing Screw type mounting
bracket
4.3.1 Panel cutout
4.3.2 Current transformer
CTL-6S (for 5 A, 10 A, 20 A) CTL-12-S36-10L1 (for 50 A)
Installation close alongside each other
n = number of the installed controllers
Note!
When mounting the controllers closely alongside each other,
the conditions for IP 66 protection will no longer be met.
4. Design and function

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4.4 Scope of delivery
Cross-check scope of delivery with delivery note.
5. Transport, packaging and storage
5.1 Transport
Check the temperature controller for any damage that may have been caused by transport.
Obvious damage must be reported immediately.
5.2 Packaging
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g. change in
installation site, sending for repair).
5.3 Storage
Permissible conditions at the place of storage:
■
Storage temperature: -20 ... +50 °C
■
Humidity: 35 ... 85 % relative humidity without condensation
Avoid exposure to the following factors:
■
Direct sunlight or proximity to hot objects
■
Mechanical vibration, mechanical shock (putting it down hard)
■
Soot, vapour, dust and corrosive gases
■
Potentially explosive environments, ammable atmospheres
Store the temperature controller in its original packaging in a location that fulls the
conditions listed above. If the original packaging is not available, pack and store the
instrument as described below:
1. Wrap the instrument in an antistatic plastic lm.
2. Place the instrument along with shock-absorbent material in the packaging.
3. If stored for a prolonged period of time (more than 30 days), place a bag containing a
desiccant inside the packaging.
4. Design and function / 5. Transport, packaging and storage

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6. Commissioning, operation
WARNING!
The controllers are designed for operation under the following ambient
conditions (IEC 61010-1):
Overvoltage category II, pollution degree 2
Avoid exposure to the following factors:
■
Direct sunlight or proximity to hot objects
■
Mechanical vibration, mechanical shock (putting it down hard)
■
Soot, vapour, dust and corrosive gases
■
Potentially explosive environments, ammable atmospheres
■
Ambient temperature: 0 ... 50 °C (32 ... 122 °F), without sudden changes
■
Humidity: 35 ... 85 % relative humidity without condensation
■
Not to be mounted close to electromagnetic switches or cables carrying
high currents
■
Not for direct contact with water, oil, chemicals or their vapours.
WARNING!
■
Failure to comply with this can destroy the sensor input.
■
These controllers feature neither a built-in switch nor a fuse. It is therefore
necessary to t these into the circuit outside the controller (recommended
fuse: slow-acting, rated voltage AC 250 V, rated current 2 A).
■
Carry out the PID auto tuning in a trial run.
■
Never touch any live terminals.This may cause an electric shock or
problems in operation.
■
Before working on the connection terminals or cleaning the controller,
switch o the power supply to the controller.
■
The area of the actual display can easily be damaged. Avoid any contact
with hard and sharp objects, or any excessive pressures.
6. Commissioning, operation

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6.1 Mounting
Mount the instrument individually in a vertical control panel, in order to full the
specication with respect to mounting protected from dust and sprayed-water (Ingress
protection IP 66).
Test the rigidity of the control panel and check the case for damage. If the material of the
control panel is not rigid enough or a damage is present at the case, the compliance with
ingress protection IP 66 cannot be guaranteed.
Control panel thickness for installation: 1 ... 15 mm
Max. installation height: 2,000 m
First, insert the controller into the control panel, from the front.Then attach the screw
bracket into the slots on top and bottom housing and tighten.
WARNING!
In order to avoid any damage to the plastic housing, do not tighten the screw
bracket too tightly (max. torque: 0.12 Nm).
WARNING!
If several controllers are to be mounted side-by-side, see 4.3.1 “Panel
cutouts”.
6. Commissioning, operation

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6.2 Electrical connection
WARNING!
Turn o the power to the controller before working on the terminals or checking
the connections.Touching the connection terminals with the power switched
on may cause an electric shock, which can result in serious injury or death.
WARNING!
■
The connection terminals of the CS4S controller were designed to be wired
from the left hand side.
■
Feed the connecting cables into the terminal from the left, and secure them
by tightening the terminal screws.
■
Dashed lines show the options.
■
If an option is not available, the corresponding terminal connections will
also be missing.
■
Use thermocouples and compensating cables in accordance with the input
conguration of the controller.
■
With resistance thermometers, a 3-wire version must be used.
6. Commissioning, operation
ϑ
50 Ω
Legend:
A1 Alarm output 1
EVT Output for alarm output 2 and heater burnout alarm
OUT 2 2nd control output
CT Current transformer for heater burnout alarm
SV2 Parameter memory for 2nd set point
RS-485 Serial interface RS-485
(-R/) Control output, relay
(-S/) Control output, logic level 0/12 V
(-A/) Control output, 4 ... 20 mA analogue current signal
TC Input thermocouple
RTD Input resistance thermometer
DC V Input voltage signal
DC mA Input current signal
50 Ω 50 Ω measurement shunt for DC current signals

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■
These controllers feature neither a built-in switch nor a fuse. It is therefore
necessary to t these into the circuit outside the controllers (recommended
fuse: slow-acting, rated voltage AC 250 V, rated current 2 A).
■
When using a direct current supply for a controller with a AC/DC 24 V power
supply, take care with the polarity.
■
With a controller with relay output, use an additional electromagnetic
switch, appropriately sized for the load, to protect the built-in relay contacts.
■
When wiring the input cable, in order to prevent external interference, do
not run it close to alternating current sources and load cables.
■
Under no circumstances should the power supply ever be connected to the
sensor input terminals or the connected sensor be brought into contact with
the power supply.
Solder-free cable shoes
Use solder-free cable shoes with insulated sleeving which are suitable for M3 size screws
in accordance with the following drawings.
The tightening torque for fastening the terminal screws should between 0.6 Nm and
1.0 Nm.
Option: Heater burnout alarm
(1) This alarm is not possible for measuring phase-
controlled currents.
(2) Use the current transformer (CT) supplied. Pass
one of the connecting cables of the heater current
circuit through the hole in the current transformer.
(3) Do not run the connecting cable for the current
transformer close to any alternating current
sources or high-current cables, in order to avoid
any disruptive inuences.
Ø 3.2 mm Ø 3.2 mm
5.8 mm
or less
5.8 mm
or less
11
12
CT input terminals
Heating circuit
CT
Heating
6. Commissioning, operation

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6.3 Operation
Once the controller has been installed in the control panel and wired up, it should be
commissioned as follows:
■
Switch on the power supply for the controller.
Once the power supply has been switched on, the input conguration is displayed on the
actual value display (PV display) for about 3 seconds and, on the set point display, the
assigned end value can be seen.
During this time, all outputs and control displays are switched o.
Subsequently, the actual value display will show the current measured value, the set
point display will show the selected set point (SV1 or SV2) and it will start to control.
(Should the control output be turned o, [OFF] will be shown on the actual value display.
In order to turn the control output back on again, the OUT/OFF key must be pressed for
approx. 1 second.)
■
Input of the setting parameters
To input one or more setting parameters, please follow the procedure in accordance with
chapter 7 “Conguration”.
■
Switch on the load circuit
The control loop is now in operation and the control system will try to maintain the
selected set point.
7. Conguration
For the input congurations for thermocouples and resistance thermometers, after
switching the power on, for approx. 3 seconds, the type of the selected sensor and the
temperature units are shown on the actual value display, while at the same time the set
point display shows the maximum possible temperature value with these settings. For
the input congurations for current and voltage signals, the type of the sensor set and the
scaled full scale value are displayed.
During this time, all outputs and LED displays are turned o.
Subsequently, the actual value display will show the current measured value, the set point
display will show the selected set point and it will start to control.
Should the control output be turned o, OFF will be shown on the actual value display. In
order to turn the control output back on again, the OUT/OFF key must be pressed for approx.
1 second.
6. Commissioning, operation / 7. Conguration

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Sensor input °C °F
PV display SV display PV display SV display
KE
E
C
.C
1370
400.0
E
E
F
.F
2500
750.0
JJ.C 1000 y f 1800
Rr C 1760 r f 3200
SS C 1760 s f 3200
Bb C 1820 b f 3300
EE C 800 e f 1500
TE.C 400.0 e .F 750.0
Nn C 1300 n f 2300
PL-II PL2 C 1390 PL2 F 2500
C (W/Re5-26) c C 2315 c f 4200
Pt100 PE
PE
.C
C
850.0
850
PE
PE
.F
f
999.9
1500
JPt100
JPE
JPE
.C
C
500.0
500
jpe
jpe
.F
f
900.0
900
DC 4 ...20 mA
420A
scaled end value
DC 0 ...20 mA
020A
DC 0 ... 1 V 0
18
DC 0 ... 5 V 0
58
DC 1 ... 5 V 1
58
DC 0 ... 10 V 0
108
7. Conguration

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7.1 Flow diagram for the programming levels
▲+ MODE: Press the MODE key while the ▲ key is pressed.
▼+ MODE (approx. 3s): Press the MODE key for approx. 3 seconds while the ▼ key is pressed.
▲+▼+ MODE (approx. 3s): Press the MODE key for approx. 3 seconds while the ▲ and ▼ keys are pressed.
Dashed lines show options that are only displayed if the option is actually present.
1) If, for the OUT/OFF key, the functionality “Switching automatic/manual control” is selected, the OUT/OFF key cannot switch the control output
to OFF, rather it will activate the manual control mode.
Actual value/
Set point display
Control output OFF [off] or
manual control 1)
Display of the
output power
[Set point level] [Parameter level] [Auxiliary parameter level 1]
Set point 1
(SV1) [s]
Set point 2
(SV2) [s2]
AT auto tuning/auto
reset [ae/rSee]
Control output 1 (OUT1)
Proportional band [p]
Control output 2 (OUT2)
Proportional band [P_b]
Integral time [b]
Derivative time
[d]
ARW parameter
[a]
Control output 1 (OUT1)
Cycle time [c]
Control output 2 (OUT2)
Cycle time [c_b]
Alarm value alarm 1
(A1) [a1]
Alarm value alarm 2
(A2) [a2]
MODE
MODE (approx. 3 s)
▼+ MODE (approx. 3 s)MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
MODE
▲+ MODE
OUT/OFF (approx. 1 s)
Heater burnout alarm
[a □□ . □ ]
Control loop monitor-
ing time [Lp_E]
Control loop monitor-
ing span
[Lp_a]
Locking level [Loct]
maximum set point[sa]
minimum set point [sL]
Sensor correction [so]
Communication
protocol [cASL]
Instrument address
[cAno]
Transmission rate
[cASP]
Parity [cAPr]
Stop bit [cASE]
7. Conguration