KS 40-1 / 41-1/ 42-1

Universal Industrial Controller

BluePort® Front interface and BlueControl Software

Maintenance manager and error list

universal line
Three DIN sizes
Automatic/Manual key
Monitoring of heating current and input circuit
Timer and programmer
Extended limit signalling function with latch

± Universal continuous/switching APPLICATIONS Self-tuning

version, i.e. reduced stocks During start-up, the self-tuning function
± 100 ms cycle time, i.e. also Ø Furnaces and ovens determines the optimum settings for
suitable for fast control loops Ø Burners and boilers fast line-out without overshoot. With
three-point controller configuration, the
± Customer-specific linearization Ø Plastics processing „cooling“ parameters are determined
for all sensors Ø Driers separately, thus ensuring an optimum
± Freely configurable analog Ø Climatic chambers match to the process.
output, e.g. as process value
output
Ø Heat treatment plants Display and operation
± Settings can be blocked via Ø Sterilizers Clear informations are given by ten
password and internal switch for indicator LED’s in the front panel that
high security DESCRIPTION display operating mode, I/O states, and
errors. The auto/manual key switches
± Extended temperature range up
The universal temperature controller the controller into the manual mode
to 60 °C allows mounting close to
KS 4X-1 are intended for universal, directly, without lengthy operating
the process
precise, and cost-effective control tasks sequences. If required, the direct switch
± Easy 2-point or offset in all branches of industry. For this, the over can be disabled or the key can be
measurement correction unit provides simple 2-point (on/off) configured e.g. to start the internal
± Emergency operation after control, continuous PID control, or timer. This results in a level of
sensor break by means of the 3-point stepping control. The process operational safety that is usually found
„output hold“ function value signal is connected via a universal only in controllers of a higher price
± Logical combination of digital input. A supplementary analog input can category.
outputs, e.g. for general alarm be used for heating current
Front interface and Engineering Tools
measurement or as an external set-point
± Programmer with 4 segments Control parameter adjustment in
input.
and „end“ signal seconds has now also been
Every KS 4X-1 has three process outputs
± RS 422/485 Modbus RTU that can be 3 relays or 2 relays plus a implemented in the KS 40 class of
interface universal output. This universal output instruments. Via the BlueControl
± Built-in transmitter power supply can be used for operating a solid-state software incl. its simulation functions,
relay, a continuous current/voltage and especially the convenient BluePort®
± Splash-water proof front (IP 65) front panel interface, the required set-up
output or to energize a two-wire
transmitter. for a specific control task can be
determined without a detailed study of
Plug-in module the operating instructions.
KS 4X-1 controllers are built as plug-in Off cause almost all adjustments can be
modules. This enables them to be done comfortably over the instrument
replaced very quickly without tools, and front. (see page 6, BlueControl)
without disturbing the wiring.
Password protection
Table 1 Thermocouple ranges
If required, access to the various
operating levels can be protected with a Thermocouple Range Accuracy Resolution (∅)
password. Similarly, access to a L Fe-CuNi (DIN) -100...900 °C -148...1652 °F ≤2K 0,1 K
complete level can be blocked. J Fe-CuNi -100...1200 °C -148...2192 °F ≤2K 0,1 K
K NiCr-Ni -100...1350 °C -148...2462 °F ≤2K 0,2 K
N Nicrosil/Nisil -100...1300 °C -148...2372 °F ≤2K 0,2 K
TECHNICAL DATA S PtRh-Pt 10% 0...1760 °C 32...3200 °F ≤2K 0,2 K
R PtRh-Pt 13% 0...1760 °C 32...3200 °F ≤2K 0,2 K
INPUTS special -25 ...75 mV ≤ 0,1 % 0,01 %

SURVEY OF THE INPUTS Table 2 Resistance transducers

Type Sensor current Range Accuracy Resolution (∅)
Input Used for:
Pt100 -200...850 °C -328...1562 °F ≤1K 0,1 K
INP1 x (process value)
Pt1000 0,2 mA -200...850 °C -328...1562 °F ≤2K 0,1 K
INP2 Heating current, ext. set-point Resistance* 4500 Ω ≤ 0,1 % 0,01 %
di1 Operation disabled, switch-over
* The characteristic of a KTY 11-6 is preadjusted (-50...150°C)
to second set-point SP.2,
di2 (option)
external set-point SP.E, fixed
di3 (option) output signal Y2, manual Table 3 Current and voltage
operation, controller off,
disabled auto/manual key, reset Range Input resistance Accuracy Resolution (∅)
stored alarms, timer start (= Y2) 0-10 Volt ≈ 110 kΩ ≤ 0,1 % 0,6 mV
0-20 mA 49 Ω (voltage requirement ≤ 2,5 V) ≤ 0,1 % 1,5 µA
PROCESS VALUE INPUT INP1
Resolution: > 14 bits Electrical connections:
Decimal point: 0 to 3 decimals
Digital input filter: adjustable 0,000...9999 s Option
Scanning cycle: 100 ms
1
Measured value 1 L 90...250V
correction: 2-point or offset correction di2 (2)
N
3
2
3
24V AC/DC
Thermocouples (Table 1) 4
di3 5
Input impedance: ≥ 1 MΩ 4
Effect of source resistance: 1 µV/Ω
6
5 OUT1
UT 7
6 OUT2
Cold junction compensation 8
Logic
9 7
Max. additional error ± 0,5 K
10 8 U OUT3
Sensor break monitoring Modbus RTU 11 9
12
Sensor current: ≤ 1 µA RGND RXD-B
10
13
Operating sense configurable (see page 4) GND 11
HC mA INP2
14
RXD-A 12
Resistance thermometer DATA B TXD-B
15
13
di1
(16) mA 0..10 V*
Connection: 3-wire 14 INP1
17
Lead resistance: max. 30 Ω DATA A TXD-A 15
Input circuit monitor: Break and short circuit RS485 RS422
* Pay attention to the internal switch!

Resistance measuring range

The BlueControl software can be used to
match the input to the sensor KTY 11-6 Dimensions (mm):
(characteristic is stored in the controller).
min.48 (1.89’’)
) 92 +0,8 92 +0,8
4” 5”)
Physical measuring range: 0...4500 Ω (0
.
.6
10 8 (4
45 +0,6

Linearization segments 16
..1 4”

min.48 (1.89’’)

11
1. 4-0.
0
92 +0,8
-0 0
04 ..1

92 +0,8
0
.4

0.
0. 1.

Current and voltage signals KS 42-1 universal

1 2 3 OK

126
96 (3.78”)

96 (3.78”)

SP.x

Span start, end of span: anywhere within

SP.X run

125 Ada
Err
run
Ada
Err
48 (1.89”)

measuring range 45 +0,6 126

)

)
5”

5”

SP.x run

125
Scaling: selectable -1999...9999
Ada
.6

.6

Err
(4

(4
)

1 2 3 OK
”

KS 40-1 universal
8

Linearization: 16 segments, adaptable

8

KS 41-1 universal
.4

.4
11

11
(0

(0

48 (1.89”)
with BlueControl
10

10

96 (3.78”) 96 (3.78”)
Decimal point: adjustable
Input circuit monitor: 12,5% below span start KS 40-1 KS 41-1 KS 42-1
(2mA, 1V)

2 KS 40-1 / KS 41-1 / KS 42-1

SUPPLEMENTARY INPUT INP2 RELAY OUTPUTS OUT1, OUT2 OUT3 AS UNIVERSAL OUTPUT
Resolution: > 14 bit Contacts: 2 NO contacts with Galvanically isolated from the inputs.
Scanning cycle: 100 ms common connection
Freely scalable
Accuracy: better 0,1 % Max. contact rating: 500 VA, 250 VAC, 2A at
DA-converter limiting frequency T90: 50 ms
48...62 Hz, resistive load
Limiting frequency of the complete
Heating current measurement Min. contact rating: 6 V, 1 mA DC
continuous controller: > 2 Hz
via current transformer Operating life (electric): 800.000 duty cycles
Resolution: 11 bits
with max. rating
Measuring range: 0...50 mA AC
Current output
Scaling: adjustable -1999..0,000..9999 A
OUT3 USED AS RELAY OUTPUT 0/4...20 mA, configurable.
Current measurement range Signal range: 0...approx. 21,5 mA
Contacts: Potential-free
Input resistance approx. 120 Ω changeover contact Load: ≤ 500 Ω
Span: configurable within Max. contact rating: 500 VA, 250 VAC, 2A at Load effect: 0,02 % / 100 Ω
0 to 20mA 48...62 Hz, resistive Resolution: ≤ 22 µA (0,1%)
Scaling: adjustable -1999...9999 load Error: ≤ 40 µA (0,2%)
Input circuit monitor: 12,5% below span start Min. contact rating: 5 V, 10 mA AC/DC
(4..20mA → 2mA) Operating life (electric): 600.000 duty cycles
with max. rating
CONTROL INPUT DI1 Note:
Configurable as direct or invers switch or If the relays OUT1...OUT3 operate
push-button ! external contactors, these must be fitted Galvanic isolations:
Connection of a potential-free contact with RC snubber circuits to
Safety isolation
suitable for switching „dry“ circuits. manufacturer specifications to prevent
excessive switch-off voltage peaks. Functional isolation
Switched voltage: 2,5 V
Switched current: 50 µA
Mains supply Process value input INP1
Supplementary input INP2
CONTROL INPUTS DI2, DI3 (OPTION) Digital input di1
Configurable as switch or push-button ! Relay outputs OUT1,2 RS 422/485 interface
Optocoupler input for active triggering
Relay output OUT3 Digital inputs di2, 3
Nominal voltage: 24 V DC, external
Universal output OUT3
Current sink (IEC 1131 Type 1)
Logic „0": -3...5 V Transmitter supply UT
Logic „1": 15...30 V
Current requirement: approx. 5 mA Example of the linkage of the internal functions:

TRANSMITTER SUPPLY UT (OPTION) Ò

di3

di2

di1

mLoc

(Y2/SP2)
Output: 22 mA / ≥ 18 V
SP.E
run

SP.2

ÈÌ

If the universal output OUT3 is used

there may be no external galvanic
L_r

SP.2
connection between measuring and SP.E
output circuits! #
Y.2
C.off
man

8888 y1
PEnd
time

ÈÌ weff y2 OUT1
LP.AL
yPID or
OUTPUTS INP1 FAi.1
xeff xw

SURVEY OF THE OUTPUTS INP2 FAi.2 OUT2

or
Output Used for:

Control output heating/cooling

OUT1
LrES

or Open/Close, limit contacts,

OUT2
alarms, timer or programmer
(relay) Ì
End * or
HC.AL OUT3
OUT3 HCA HC.SC
as OUT1 and OUT2
(Relay or logic)

Control output, process value,

OUT3
set-point, control deviation, Πsetpoint processing with programmer and timer
(continuous)
transmitter supply 13 V / 22 mA  controller function with loop monitoring
* All logic signals can be OR-linked ! Ž limit monitoring, configurable with latch and suppression
 heating current monitoring
 output processing with logic or-combination and inverting
‘ analog inputs with logical sensor fail signal
’ digital inputs and Ò-key with lock function

KS 40-1 / KS 41-1 / KS 42-1 3

Voltage output LIMIT SIGNALLING FUNCTIONS
Timer modes 1 and 2
0/2...10V, configurable Max., Min. or Max./Min. monitoring with
Signal range: 0...11 V adjustable hysteresis.
Load: ≥ 2 kΩ
Signals which can be monitored:
2
Load effect: no Effect
Resolution: ≤ 11 mV (0,1%) • Process value 1 End
Error: ≤ 20 mV (0,2%) • Control deviation blink

• Control deviation with suppression

OUT3 used as transmitter supply during start-up or set-point changes start t.SP
Output: 22 mA / ≥ 13 V • Effective set-point
• Output signal Y Timer modes 3 and 4
OUT3 used as logic output
Functions
Load ≤ 500 Ω 0/≤ 20 mA
• Input signal monitoring 4
Load > 500 Ω 0/> 13 V
• Input signal monitoring with latch
(reset via front key or digital input) 3 End
FUNCTIONS
Several limit signals or alarms can be
Control behaviour OR-linked before being output. start t.SP
Applications: Release of a brake with
• Signaler with adjustable switching
motor actuators, general alarms, etc.
differential (ON/OFF controller) Timer mode 5
• PID controller (2-point and
continuous)
ALARMS
• Delta / Star / Off or 2-point controller
with switch over from partial to full Heating current alarm
load
• Overload and short circuit
• 2 x PID (heating/cooling, 3-point and
• Open circuit and short circuit
continuous))
Limit value adjustable 0...9999 A start t.P
• 3-point stepping controller
Self-tuning control parameters or Control loop alarm Timer mode 6
adjustable manually via front keys or Automatic detection if there is no
BlueControl software. SP.2
response of the process to a change of
Set-point functions output value.
End
• Adjustable set-point gradient Sensor break or short circuit blink
0,01...9999 °C/min Depending on selected input type, the SP SP
• Set-point control input signal is monitored for break and
• Set-point/cascade control short circuit. start t.SP
• Program controller with 4 segments
(set-point/section time) Flashing Error LED indicates active alarm
• Timer in the error list:

126
Timer
Time t.SP adjustable from 0,1 to 9999
min
SP.x run
Timer Start:
•
•
Mains on
Control input
125 Ada
Err

• Ò-key (=Y2 switch-over)

• Direct adjustment of running time Display and operation:
Behaviour with sensor break or short 3 yellow LEDs for the output states green “OK”-LED
circuit: 1 2 3 OK

• Control outputs switched off process value

• Switch-over to a safe output value second or external setpoint SP.X
126 run
programmer or timer runs
• Switch-over to a mean output value
rate of change limited 125 Ada
Err
selftuning is running
manual operation error list
automatic/manual key setpoint, actuating value, parameter

enter-key
BluePort front interface up and down keys
KS 40-1 universal

4 KS 40-1 / KS 41-1 / KS 42-1

MAINTENANCE MANAGER ENVIRONMENTAL CONDITIONS GENERAL
Display of error signals, warnings, and Protection modes Housing
latched limit messages in the error list.
Signals are latched, and can be reset Front panel: IP 65 Material: Makrolon 9415,
manually. Housing: IP 20 flame-retardant
Terminals: IP 00 Flammability class: UL 94 VO, self-extinguishing
Possible signals in the error list:
Sensor break, short circuit, reversed Permissible temperatures Plug-in module, inserted from the front
polarity Safety tests
For specified accuracy: 0...60°C
Heating current alarm
Warm-up time: < 15 minutes Complies with EN 61010-1 (VDE 0411-1):
Control loop alarm
Temperature effect: < 100ppm/K Over voltage category II
Fault during self-tuning Contamination class 2
For operation: -20...65°C
latched limit messages Working voltage range 300 VAC
For storage: -40...70°C
e.g. re-calibration warning Protection class II
(If the adjusted operating hours are exceeded a Humidity
message is displayed) Certifications
75% yearly average, no condensation
e.g. maintenance interval of actuator
Type test to DIN 3440
(If the adjusted switching cycles are exceeded a Shock and vibration
message is displayed) With certified sensors it can be used in:
Vibration test Fc (DIN 68-2-6) • Heat generating plants with outflow
Internal fault (RAM, EEPROM, ...)
Frequency: 10...150 Hz temperatures up to 120°C to DIN 4751
OPERATION AND DISPLAY Unit in operation: 1g or 0,075 mm • Hot-water plants with outflow
Unit not in operation: 2g or 0,15 mm temperatures above 110°C to DIN 4752
Display • Thermal transfer plants with organic
Shock test Ea (DIN IEC 68-2-27) transfer media to DIN 4754
KS40-1 / KS41-1 KS42-1
Process value: 10,5 mm LED 19 mm LED Shock: 15g • Oil-heated plants to DIN 4755
Lower display: 7,8 mm LED 10,5 mm LED Duration: 11ms
UL certification (applied for)
Electromagnetic compatibility
POWER SUPPLY
Complies with EN 61 326-1
Depending on version:
• Complies with the immunity
AC SUPPLY requirements for continuous, Electrical connections
unattended operation
Voltage: 90...260 VAC Depending on version:
• Complies with the emmission
Frequency: 48...62 Hz requirements class B for rural areas • Flat-pin connectors 1 x 6,3 mm or
Power consumption approx. 7 VA • Surge disturbances may increase the 2 x 2,8 mm to DIN 46 244
measurement error • Screw terminals for conductor
UNIVERSAL SUPPLY 24 V UC cross-section from 0,5 to 2,5 mm²
AC voltage: 20,4...26,4 VAC
Mounting
Frequency: 48...62 Hz
Panel mounting with two fixing clamps
DC voltage: 18...31 V DC
at top/bottom or left/right
Power consumption: approx: 7 VA (W)
Close mounting possible
BEHAVIOUR WITH POWER FAILURE Mounting position: not critical
Configuration, parameters, and adjusted Weight: 0,27 kg (9.52 oz)
set-points, control mode:
Non-volatile storage in EEPROM Accessories supplied with unit
Operating instructions
BluePort FRONT INTERFACE
® 2 fixing clamps

Connection of PC via PC adapter (see

„Accessories“). The BlueControl
software is used to configure, set
parameters, and operate the KS 40-1.

BUS INTERFACE (OPTION)

Galvanically isolated
Physical: RS 422/485
Protocol: Modbus RTU
Transmission speed:
2400, 4800, 9600, 19.200 bits/s
Address range: 00...99
Number of controllers per bus: 32
Repeaters must be used to connect more
controllers.

KS 40-1 / KS 41-1 / KS 42-1 5

ACCESSORY EQUIPMENT ORDERING INFORMATION
BlueControl (Engineering Tool)
KS 4 1 0 0 00
PC-based program for configuring,
setting parameters, and operating
KS 40-1 (1/8 DIN) 0
(commissioning) the KS 40-1 controller. KS 41-1 (1/8 DIN "landscape" ) 1
Moreover, all the settings are saved, and KS 42-1 (1/4 DIN) 2
can be printed on demand. Flat-pin connectors 0
Depending on version, a powerful data
acquisition module is available, complete
Screw terminals 1
with trend graphics. 90..250V AC, 3 relays 0
Software requirements: 24VAC / 18..30VDC, 3 relays 1
Windows 95/98/NT/2000. 90..250V AC, 2 relays + mA/logic 2
The built-in simulation serves to test the
24VAC / 18..30VDC, 2 relays +mA/logic 3
controller settings, but can also be used
for general training and observing the no option 0
interaction between controller and RS422/485 + Transmitter power supply +di2, di3 1
control loop. Standard configuration 0
Configurations that can only be Configuration to specification 9
implemented via the BlueControl no manual 0
software (not via the front-panel keys):
manual german D
• Customer-specific linearizations
manual english E
• Enable „forcing“ for inputs/outputs.
Forcing allows to write the analog and
manual french F
digital inputs and outputs via Modbus Standard (CE certified) 0
interface. UL-cerified U
• Adjustment of limits for operating DIN 3440 certified D
hours and switching cycles
German Lloyd certified (KS42-1 only) G
• Switch-over to 60 Hz mains
frequency
• Disable operator actions and ACCESSORIES
operating levels, plus password
definition Description Order no.
Current converter 50A AC 9404-407-50001
• Prevent automatic optimization of
PC adapter, for connecting BlueControl software to the BluePort® 9407-998-00001
cycle times T1, T2
Standard rail adapter 9407-998-00061
Hardware requirements: Adhesive set of physical dimension labels with 31 different dimensions
A PC adapter (see „Accessories“) is and 4 empty labels 4012-140-66041
required for connecting the controller. Operating manual German 9499-040-62718
Operating manual English 9499-040-62711
Updates and demo software can be Operating manual French 9499-040-62732
downloaded from: BlueControl Mini German/English/french www.pma-online.de
www.pma-online.de BlueControl Basic German/English/french 9407-999-11001
BlueControl Expert German/English/french 9407-999-11011

BlueControl, versions and functionality:

Functionality Mini Basic Expert
parameter and configuration setting yes yes yes
controller and control loop simulation yes yes yes
download: writes an engineering to the controller yes yes yes
online mode/ visualisation SIM only yes yes
creation of user defined linearizations SIM only yes yes
configuration of extended operating level SIM only yes yes
upload: reads an engineering from the controller SIM only yes yes
basic diagnosis function SIM only yes yes
file, save engineering data no yes yes
printer function no yes yes
online documentation, help system no yes yes
measurement correction (calibration procedure) no yes yes
program editor SIM only SIM only yes
data acquisition and trend function SIM only SIM only yes
network and multiuser licence no no yes
personal assistant function no no yes
extended simulation no no yes
extended diagnostic and service functions no no yes

6 KS 40-1 / KS 41-1 / KS 42-1

KS 40-1 / KS 41-1 / KS 42-1 7
PMA Your local representative:
Prozeß- und Maschinen- Automation GmbH
P.O. Box 31 02 29
D-34058 Kassel
Tel.: +49 - 561- 505 1307
Fax: +49 - 561- 505 1710
E-mail: mailbox@pma-online.de
Internet: http://www.pma-online.de

Printed in Germany - Edition 0207- Subject to change without notice - 9498 737 39913