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LM3 - HG Manual (August 2005)

LM3 - HG Manual (August 2005)

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Vali Popescu
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100% found this document useful (1 vote)
697 views132 pages

LM3 - HG Manual (August 2005)

LM3 - HG Manual (August 2005)

Uploaded by

Vali Popescu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 132

Manual

Congrav® L/M 3

Subject:
Congrav® L/M 3
Category:
Feeding controller
Software:
LM 3 HG V1.83
Dokument:
7h114305.doc
Revision: 1.5
Date: 05-08-03

- Copyright as per DIN 34 –


Manual Congrav® L/M 3 HG V_._

Addresses

Germany and international:

Brabender Technologie KG Service:


Kulturstrasse 55 - 73 : ++49-(0)203-9984-299
D-47055 Duisburg FAX: ++49-(0)203-9984-166
E-mail: hotline@brabender-technologie.com
P.O.Box 350138
D-47032 Duisburg
: ++49-(0)203-9984-0 Documentation:
FAX: ++49-(0)203-9984-155
E-mail: dokumentation@brabender-technologie.com
E-mail: sales@brabender-technologie.com
Web: http://www.brabender-technologie.com

Great Britain:

Brabender Technologie Ltd Service:


3 Tanning Court : ++44-1925 244002
Howley FAX: ++44-1925 245 451
E-mail: engineering@brabender-tech.co.uk
Warrington
Cheshire WA1 2HF
: ++44-1925 244002
FAX: ++44-1925 245 451
E-mail: sales@brabender-tech.co.uk
Web: http://www.brabender-technologie.com

North America:

Brabender Technologie Inc. Service:


6500 Kestrel Road : 905-670-2933
Mississauga, Ontario FAX: 905-670-2557
Canada L5T 1Z6 E-mail: hotline@brabenderti.com
: 905-670-2933
FAX: 905-670-2557
TOLL: 888-284-4574
E-mail: sales@brabenderti.com
Web: http://www.brabenderti.com

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Manual Congrav® L/M 3 HG V_._

Guide through the document

Chapter 1 Information on the manual


- Indications on the manual, revision index

Chapter 2 Description of the device


- What is a Congrav® L/M3 ?
Chapter 3 General notes
- Information on the mains and 24VDC-supply
- Cable types to be employed
- Safety instructions for the use
Chapter 4 Hardware description
- Structure and functions of Congrav® L/M3
- The plug-in cards
Chapter 5 Commissioning of Congrav® L/M3
- Start-up and software-update
Chapter 6 Installation configuration
- Structure and functions of menu page F1xx
Chapter 7 Printer configuration, reset of memory contents
- Structure and functions of menu page F2xx
Chapter 8 Setpoints and selection
- Structure and functions of menu page F3xx
Chapter 9 Actual values of the installation and reset of throughputs
- Structure and functions of menu page F4xx
Chapter 10 Operation of an individual component
- Structure and functions of menu page Kxx1 – Kxx2
Chapter 11 Alarm reports and start conditions
- Structure and functions of menu page F5xx, Kxx5
Chapter 12 The hardware configuration
- Configuration of the digital inputs and outputs
- Configuration of the analogue inputs and outputs
- Configuration of the interfaces
Chapter 13 Calibration parameters/additional parameters
- Structure and functions of menu page F6xx
Chapter 14 Hardware test functions
- Test functions/status indications of the software
Appendix - Technical data and spare parts lists
- Listing of the mode displays
- Listing of the menu pages

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Manual Congrav® L/M 3 HG V_._

Table of contents
1 Introduction 10
1.1 The structure of the manual 10
1.2 Supplementary documentation 10
1.3 Group of users of the manual 10
1.4 Signs and warnings used in the manual 10
1.5 Terms and abbreviations employed 11
1.6 Index of revisions 11

2 Description of the device 14


2.1 The intended purpose 15
2.2 Residual danger 15

3 General notes 17
3.1 Mains supply 17
3.2 The external 24VDC-supply 17
3.3 Cable types to be employed 17
3.4 Safety notes 18
3.4.1 Safety instructions for work on the Congrav® L/M3 18
3.4.2 Safety instructions for mounting 18
3.4.3 Safety instructions for cabling 18
3.4.4 Safety instructions for the operation, the manipulation 19

4 Hardware description 21
4.1 Congrav L/M3: the types 21
4.2 Congrav® L/M3: The display and the front keyboard 21
4.2.1 The integrated front keyboard and its functions 21
4.2.2 Composition and menu structure of the display 23
4.3 Parameter modifications 24
4.3.1 The numeric input 24
4.3.2 The selection of fixed parameter sets 24
4.3.3 Parameter modifications are not taken over, if 24
4.4 The Congrav® L/M3 B 25
4.5 Overview of the slots of Congrav® L/M3 26
4.5.1 Overview: the possible connections 27
4.6 The basic execution of Congrav® L/M3 28
4.6.1 The plug-in card L/M3-MSIO 28
4.6.1.1 XS1.1: The connection of the host computer 28
4.6.1.2 XS1.1 + XS1.2: The connection of Congrav® PT03 28
4.6.1.3 XS1.3: The connection of a modem or IPC 29
4.6.2 The DS-controller 30
4.6.2.1 The I/O-modules for the DS-controller 30
4.6.2.1.1 The I/O-module-DS-LM3-R1 and ..-R2 31
4.6.2.1.2 The terminal plan of the I/O-module-DS-LM-R_ 31
4.6.3 The hardware components of the DS-controller 33

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Manual Congrav® L/M 3 HG V_._

4.6.3.1 The digital inputs and outputs 33


4.7 The optional extension of Congrav® L/M3 34
4.7.1 The plug-in card CDIO 34
4.7.2 The analogue card 35
4.7.2.1 The I/O-module I/O-module-analogue-LM3 36
4.7.3 The ProfiBus-module 37

5 Mounting and commissioning 39


5.1 Mounting 39
5.2 Connection plan of a loss-in-weight feeder 40
5.2.1 Connections of Congrav® L/M3 41
5.3 Start-up, switching on the Congrav® L/M3 42

6 F100: Installation configuration 44


6.1 F110: Installation modes 44
6.2 Analogue configuration 45
6.3 Host computer operation 45
6.4 Text switch 45
6.5 Interlocking/stop 46
6.6 Date and time 46
6.7 F150: The recipe administration 46
6.7.1 Setpoint ramp, setpoint threshold 47
6.7.2 Start-up operation 47

7 F200: Printer configuration, reset of memory contents 49


7.1 Printer functions 49
7.2 F210: How to clear memory contents 50

8 F300: Setpoint input and selection 52


8.1 Installation setpoints 52
8.2 Component setpoints 52
8.2.1 The analogue control of the setpoints 53
8.2.2 Setpoint ramp, setpoint threshold (menu page F150)Fehler! Textmarke nicht definiert.
8.3 Selection 54
8.4 F310: Delay times 54
8.5 Alarm stop 54

9 F400: Actual values of the installation,reset of throughputs 56


9.1 F430: Reset throughputs 56

10 The component operation 58


10.1 The header of the component pages 58
10.2 Kxx0: The component control 58
10.3 The operating functions 58
10.3.1 Start 58
10.3.2 Stop 58

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10.3.3 Alarm reset 59


10.3.4 Refill 59
10.3.5 Throughput reset 59
10.3.6 Start sample 59
10.3.7 Start tare 59
10.3.8 The actual value display in the right column 59
10.4 Kxx1: Product parameters 60
10.4.1 Auto-tare: 60
10.4.2 Checking max. output 61
10.4.3 Bulk density 61
10.4.4 vol. max. output 62
10.4.5 Decade switch 62
10.4.5.1 The setting of the decade switch 62
10.4.6 Mode 63
10.4.6.1 Gravimetric feeding (GF) 63
10.4.6.2 Volumetric regulation (VR) 64
10.4.6.3 Volumetric setting (VS) 64
10.4.6.4 Discharge (DI) 64
10.4.6.5 Checking max. output (CM): 65
10.4.6.6 Grav. Discharge (GD) 66
10.4.6.7 Volumetric feeding (VF) 66
10.4.6.8 Measuring (M) 66
10.5 Kxx2 The control parameters 67
10.5.1 Setting of PID controllers 67
10.5.1.1 Control adaptation 68
10.5.1.2 Grav. calc. maximum output 68
10.5.1.2.1 Memorisation of the CM-values 68

11 F500: Alarm reports and start conditions 71


11.1 Alarm reports 71
11.2 Missing start conditions 74
11.3 Error code for an operation with a serial drive controller 75
11.3.1 Serial frequency converter FC-V_ 75
11.3.2 Vibration amplitude controller DRS2 76
11.4 Kxx5: The alarm configuration 76

12 The hardware configuration 79


12.1 The hardware components of the DS-controller 79
12.1.1 The digital I/O of the DS-controller 79
12.1.1.1 Description of functioning 80
12.1.2 Configuration of the interfaces of the DS-controller 81
12.1.2.1 Supported load cell types and their configuration 81
12.1.2.2 Configuration of the drive controller 83
12.2 The configuration of the optional analogue card(s) 84
12.2.1 The digital inputs and outputs of the analogue card 84
12.2.2 The analogue inputs and outputs of the analogue card 85
12.2.2.1 Installation control and actual value of the installation 85

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Manual Congrav® L/M 3 HG V_._

12.2.2.1.1 The parameters of menu page F170 85


12.2.2.2 The analogue component functions 87
12.2.2.2.1 The definition of the signal range for the analogue I/O 88
12.3 The configuration of the LM3-CDIO 89
12.4 The modem configuration 90
12.5 Configuration of the host computer operation 91
12.5.1 The host interface on the MSIO-card 91
12.5.2 Configuration of the ProfiBus DP-operation 92
12.5.3 Configuration of the ControlNet interface 92

13 The calibration program 94


13.1 The feeder parameters 95
13.2 Explanation of the functions of the feeder parameters 96
13.2.1 CP01 - Feeder type H/G/C 96
13.2.2 CP02 – Weighing range 96
13.2.3 CP03 – Maximum output 96
13.2.4 CP04 – Underload 97
13.2.5 CP05 - Overload 97
13.2.6 CP06 – Coarse tare 97
13.2.7 CP07 - Average weight acquisition 97
13.2.8 CP08 - Throughput divisor 97
13.2.9 CP09 - Speed minimum 98
13.2.10 CP10 – Speed maximum 98
13.2.11 CP11 – Control difference 98
13.2.12 CP12 - Alarm cut-out time 98
13.2.13 CP13 - Type of interlocking 98
13.2.14 CP14 - Indication of actual value 98
13.2.15 CP15 – Lever arm factor 99
13.2.16 CP16 - Hopper contents 99
13.2.17 CP17 - Filling level minimum 99
13.2.18 CP18 – Filling level maximum 99
13.2.19 CP19 - Window/K1/Filter IDL/F, AED 99
13.2.20 CP20 – Digital speed 99
13.2.20.1 Standard motion monitoring 100
13.2.20.2 Motion monitoring for the FlexWall®plus-feeder 100
13.2.20.3 Digital speed reading 100
13.2.20.4 Recommended inputs 100
13.2.21 CP21 - Maximum refill time 100
13.2.22 CP22 - Refill optimise 101
13.2.23 CP23 - Stabilisation time 101
13.2.24 CP24 - Sampling time 101
13.2.25 CP25 - AV-cut-out time 101
13.2.26 CP26 – PID controller access time 102
13.2.27 CP27 - Controller automatic 102
13.2.27.1 The controller automatic 102
13.2.27.2 The start automatic 103
13.2.27.2.1 Non-repetitive start automatic 103

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13.2.27.2.2 General start automatic 103


13.2.28 CP28 – Filter limits 104
13.2.29 CP29 – Adaptation of actual value 105
13.2.30 CP30 - Adaptation of manipulated variable 105
13.2.31 CP31 - Adapt. of actual value VR 105
13.2.32 CP32- Alarm delay time 105
13.2.33 CP33 - Length of weighing bridge (LWB) 105
13.2.34 CP34 - Weight test value (WTV) 105
13.2.35 CP35 - Adaptation (AP) 106
13.2.36 CP36 - Auto-tare range 106
13.2.37 CP37 - No load time auto-tare 106
13.2.38 CP38 - Rated belt speed 106
13.2.39 CP39 - Belt length 107
13.2.40 CP40 - Dead-time way 107
13.3 Additional parameters 108
13.3.1 AP01 - 05 Calibration 108
13.3.2 AP11 - Usable weighing range 108
13.3.3 AP12- Drop-Out 109
13.3.4 AP13 - Tacho Mode 109
13.3.5 AP14 - Slip influence 109
13.3.6 AP15 - Slip value 109
13.3.7 AP16 - Tacho adaptation 109
13.3.8 AP17 - No load time 110
13.3.9 AP18 - AT-time 110
13.3.10 AP19 - Drive control 2 min. 110
13.3.11 AP20 - Drive control 2 max. 110
13.3.12 Notes on AP19 and AP20 110

14 Hardware test functions 112


14.1 F140: Test of I/O-periphery (installation) 112
14.2 Kxx3: Status display of I/O-periphery 113
14.3 Kxx4: Test functions and simulation 114
14.3.1 The simulation mode 114
14.3.2 Testing of the inputs/outputs (component) 114

15 Glossary 116

16 Appendix 122
16.1 Technical data 122
16.2 Electromagnetic compatibility 123
16.3 Spare parts list 123
16.4 List of the possible mode displays 124
16.5 Configuration form I/O-module-analogue-LM3 125
16.6 Listing of the menu pages 126

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Manual Congrav® L/M 3 HG V_._

TABLE OF ILLUSTRATIONS

Figure 4-1: The rear view of Congrav® L/M3 for 4 weigh-feeders with …. 26
Figure 4-2: IO-module-DS-LM3 R_ 31
Figure 4-3: Terminal plan I/O-module-DS-LM-R_ 32
Figure 4-4: I/O-module-analogue-LM3 36
Figure 4-5: Rear front L/M3 with ProfiBus-module 37
Figure 5-1: Example for the connection of a loss-in-weight feeder 40
Figure 12-1: Overview weighing systems and weight signals 82

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Manual Congrav® L/M 3 HG V_._

1 Introduction
1.1 The structure of the manual

The present manual deals with


ƒ the technical execution and
ƒ the software L/M3 HG (revision index as per cover sheet)
of Congrav L/M3. The individual chapters of the manual each describe a
closed subject according to the following order:
ƒ description of the device,
ƒ specifications for use,
ƒ hardware executions,
ƒ definition of the hardware functions,
ƒ operation,
ƒ software description,
ƒ parameter description and
ƒ configuration examples

1.2 Supplementary documentation

ƒ Appendix with wiring examples for different standard peripheral


equipment
ƒ Manual of the corresponding host computer procedure

1.3 Group of users of the manual

The operating instructions have been conceived for two groups of users.
ƒ Qualified specialist staff authorised to carry out the electrical
installation and other electrical work and duly trained. Knowledge of
and experience in the valid national and international standards, the
state of the art for work on the feeding device is required.
ƒ Operating and maintenance staff trained on the correct operation
and maintenance of the installation.

1.4 Signs and warnings used in the manual

The manual employs the following designations to point out important


notes:

These notes are very important and have to be absolutely observed.


Generally, this warning sign marks dangers for the operating staff or
possible damage to the device. Attention

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Manual Congrav® L/M 3 HG V_._

Important information on the operation of the device. Be sure to observe


this note as it permits to prevent possible sources of danger and to avoid
the dangers in advance. Important

These notes point out electrical dangers. Be sure to observe this note,
the corresponding work must only be carried out by an electrical
specialist. Electricity!

Before any work on the device, it has to be disconnected from the


electrical power supply and protected against unauthorised
reconnection.

This sign marks additional information or references to other sources of


information.

1.5 Terms and abbreviations employed

Please find a collection of the terms employed in the glossary. The


following abbreviations are employed in the manual:

DI1 = 1st digital input


The digital inputs are numbered continuously. This leads to the complete DI
designation, e.g. DI1, DI2 etc.
DO1 = 1st digital output
The digital outputs are numbered continuously. This leads to the DO
complete designation, e.g. DO1, DO2 etc.
AI1 = 1st analogue input
The analogue inputs are numbered continuously. This leads to the AI
complete designation, e.g. AI1, AI2 etc.
AO1 = 1st analogue output
The analogue outputs are numbered continuously. This leads to the AO
complete designation, e.g. AO1, AO2 etc.
Serial interface type xxx (= RS232, RS485 or RS422) RSxxx
Calibration parameter xx on menu page F600 CPxx
Additional calibration parameter xx on menu page F610 APxx
Component page y of component xx (call-up with K-keys) Kyyx
Main menu Fy00, sub-menu Fyxx (call-up with key Fy + roll-keys) Fyxx

1.6 Index of revisions

Revision 1.0
Basic version of documentation

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Manual Congrav® L/M 3 HG V_._

Revision 1.1
Adaptation of the software LM 3 HG V1.82, revised function “setpoint
threshold“ (page 53)

Revision 1.2
Change the limit values of the calibration parameters CP19, CP22 and
CP26.

Revision 1.3
Correction of the terminal plan for the customer relays “250 VAC/5A”
ƒ Page 40: Terminal declaration corrected (for componente1)
ƒ Page 32: Relay declaration corrected 250VAC/5A
ƒ Page 33: Kx- and Kx’-Declaration were interchanged

Revision 1.4
ƒ Page 105: Adaptation

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Manual Congrav® L/M 3 HG V_._

CHAPTER 2

DESCRIPTION OF THE DEVICE

Chapter 2 gives a short description of the device, including its


function, the technical data and the standard and optional
design features.

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Manual Congrav® L/M 3 HG V_._

2 Description of the device


The Congrav® L/M3 is part of the feeding controller program. The
Congrav® L/M3 is a so-called multi-feeding controller that permits to
connect a maximum of 16 weigh-feeders.

Definition weigh-feeder:
A weigh-feeder is a feeding device, its feed rate (= product quantity/time
unit) is sensed as follows:
ƒ the weighing of the hopper contents, the belt load or
ƒ the measurement of the flowrate.

The Congrav® L/M3 is based on the technique of plug-in cards and is


designed for the integration in a control cabinet, control panel or similar.
The Congrav® L/M3 and the weigh-feeders are interconnected
electrically via further electric subassemblies (e.g. drive controller). So-
called IO-modules are employed for this purpose, they are connected by
means of a pre-confectioned cable. For the manual operation the front
face of Congrav® L/M3 is equipped with an LCD display and a foil-
covered keyboard.

The software determines the functions of the individual keys and of the
display contents. The knowledge of the functions is absolutely required
for a correct operation. Important

The Congrav® L/M3 has the following main functions:


ƒ Operating the weigh-feeders.
The Congrav® L/M3 permits the parameterisation and the control of
the individual weigh-feeders. The Congrav® L/M3 receives the data
of the weigh-feeders and controls their feeding operation.
ƒ The connection of the weigh-feeders to a superset host system.
This may possibly require an optional extension card, e.g. a bus-
module for a ProfiBus DP-connection.

The present manual describes the software L/M3 HG V_._. This software permits to control
the continuous gravimetric feeding of weigh-feeders. This includes for instance:
the control of the defined feed rate,
the monitoring of the hopper filling levels/of the belt load,
the control of refilling.

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Manual Congrav® L/M 3 HG V_._

2.1 The intended purpose

The Congrav® L/M3 is not a machine in the sense of the EC-directive, it


has been conceived for the operation/control of a maximum of 16
machines, the so-called weigh-feeders. The Congrav® L/M3 functions as
operating and control unit for the weigh-feeders, if
ƒ the weigh-feeders can be connected to Congrav® L/M3 under
respect of the technical specifications,
ƒ the necessary peripheral equipment is used under respect of the
technical specifications and
ƒ the Congrav® L/M3 is correctly equipped with the necessary plug-in
cards according to the application.
The possible applications of Congrav® L/M3 are determined by
ƒ the available I/O-periphery and
ƒ the software of Congrav® L/M3.
The use of Congrav® L/M3 is only allowed under respect of the EN
60204, the valid specifications on the personal protection (e.g. BGVR),
the EMC-directive and the valid state of the art.
The user has to respect the intended purpose, as the manufacturer does
not accept liability for damage arising from the non-observance.

2.2 Residual danger

The Congrav® L/M3 is an electrical equipment that has been manu-


factured according to the state of the art. However, the following
conditions might endanger persons or cause damage to the system or the
weigh-feeder connected:
ƒ inexpert handling
ƒ incorrect cabling.
ƒ the specifications for operation are not observed and applied.
ƒ operating errors by the operator.

Operating errors are operating conditions that do not correspond to the


operating instructions of the software employed.

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Manual Congrav® L/M 3 HG V_._

CHAPTER 3

GENERAL NOTES

This chapter lists the specifications for the use of the


Congrav® L/M3. The specifications can be subdivided as
follows:
Technical specifications,
Specifications for mounting/installation
Safety notes

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Manual Congrav® L/M 3 HG V_._

3 General notes
3.1 Mains supply

On its rear side the Congrav® L/M 3 is equipped with a socket for the
power supply. Mains voltages between 85 VAC and 250 VAC are
allowed. The mains frequency may be between 47 Hz and 63 Hz.

The connection socket is equipped with two time-lag fuses of 2A.


An earthing screw (M5) for the earthing of Congrav® L/M3 is located
below the socket. The earthing screw is connected to ground potential
by means of a suitable lead, e.g. earthing strap 10x1,5mm.

Damaged fuses:
Before a change of a damaged fuse be sure to pull the coupler plug.
Damaged fuses must only be replaced by fuses of the same type and if
the device is dead. Wrong fuses or a bridge eliminate the protective Attention!
functions and are not allowed.

3.2 The external 24VDC-supply

An external 24 VDC-supply voltage is required for the functioning of the


digital inputs and outputs. The connection of the 24 VDC voltage source
to the Congrav® L/M3 is made by means of I/O-modules. A correct 24
VDC voltage source has to comply with the following points:

Voltage range 24 VDC +/- 15%, stabilised


Residual ripple < 200 mVss
Spikes < 300 mVss
Output depending on the application
per digital input: 7mA
per digital output: max. 250mA

3.3 Cable types to be employed

Area of use Cable type


Control lines, 0-10VDC
Liy(C)y 2x0.5mm²
Control lines,0(4)-20mA
RS485 Belden 9841 2x0.22mm²
RS422 Belden 9842 2x2x0.22mm²

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Manual Congrav® L/M 3 HG V_._

3.4 Safety notes

The Congrav® L/M 3 is a large-scale integrated multi-processor system.


The following safety notes have to be observed for the installation or
other jobs:

3.4.1 Safety instructions for work on the Congrav® L/M3

ƒ Only skilled staff is allowed to operate, service or maintain the


device.
ƒ When working on the plug-in cards the staff has to be sure to prevent
static discharges. Static discharges may cause the destruction of
electronic elements and thus lead to a failure of functioning of
Congrav® L/M3.
ƒ Separate Congrav® L/M3 from the mains by pulling the coupler
plug.
ƒ Never draw out or insert plug-in cards if the Congrav® L/M3 is live.
ƒ Never use force to insert or draw out the plug-in cards.
ƒ The stipulated specifications regarding the slot assignments for the
respective types of card are absolutely binding and must be complied
with to ensure correct operation.

3.4.2 Safety instructions for mounting

ƒ Never cover or block the venting slots.


ƒ The Congrav® L/M3 is designed for the integration in a control
cabinet, control panel or similar.
ƒ During the integration into a cabinet make sure that the front plate
sealing is correct and even. Otherwise the type of protection cannot
be guaranteed.
ƒ During mounting be sure to observe the weight indications of
Congrav® L/M3. It may possibly be required to reinforce the
mounting surface.
ƒ The special mounting clips have to be employed.
ƒ During mounting you have to make sure that the natural convection
of the Congrav® L/M3 remains possible.

3.4.3 Safety instructions for cabling

ƒ Be sure to provide correct earthing for the Congrav® L/M3. For the
connection to earth please use the earthing screw underneath the
mains connection. The mere earthing via the mains connection is not
sufficient.

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Manual Congrav® L/M 3 HG V_._

ƒ Cabling has to comply with the EMC-specifications. This implies a


correct screening of the signal lines.
ƒ For the cabling of Congrav® L/M3 the corresponding specifications
concerning the cable type, the allowed cable length etc. have to be
observed.
ƒ You have to employ the special I/O-modules. The I/O-modules
permit the cable connection via the terminal strips.

I/O-module DS-L/M3 R2 To be employed for the connection of


the digital inputs and outputs of the
extension card DIOP.
I/O-module-analogue- Only to be employed for the connection
L/M3 of the digital inputs and outputs of the
optional analogue card.
UBE-D/15F To be employed for the connection of
the digital inputs and outputs of the
extension card LM3-CDIO.

ƒ For the connection of the IO-modules the confectioned cables (2


lengths available 1,2m und 3m) have to be employed.

3.4.4 Safety instructions for the operation, the manipulation

Each Congrav® L/M3 must be equipped with the plug-in card L/M3-
MSIO. Otherwise the Congrav® L/M3 is not ready to function.

ƒ The operating functions of the Congrav® L/M3 are determined by


the software and its configuration. Modifications to this configuration
might change the functions of Congrav® L/M3 in a positive or
negative manner. A non-expert parameterisation may lead to severe
failures of the feeding process and may even damage the feeding
system.
ƒ Thus, modifications to the operating parameters must only be carried
through by duly qualified operating staff.
ƒ The membrane panel of the integrated front keyboard is produced in
polyester and is designed for industrial applications. No pointed or
sharp objects are to be used to operate the keyboard.
ƒ The LCD panel is produced in plexiglass and must not be scratched
by sharp objects or by dust particles as a result of rubbing, etc.

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CHAPTER 4

HARDWARE DESCRIPTION

This chapter describes the front elements, the front keyboard,


the display and the I/O-periphery of the device. In general, the
I/O-periphery is subdivided into two parts:
ƒ the basic execution and
ƒ the optional extension.

The functions and the support of the optional extension cards


are defined by the software of Congrav® L/M3.
The software assignment/support of the I/O-functions is
described in the following chapter.

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4 Hardware description
4.1 Congrav L/M3: the types

L/M 3A Congrav® L/M3 with front keyboard


L/M 3B Congrav® L/M3 without front keyboard
The operation of Congrav® L/M3B is made by means of
a Congrav® RC3 (RC = Remote Control) or an upstream
host computer system.

4.2 Congrav® L/M3: The display and the front keyboard


4.2.1 The integrated front keyboard and its functions

1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
4

3
6

(1) Tricolour status-LEDs for components 1 - 16


The LEDs and their status are assigned to the component designated by
the figure above the LED.

LEDs normal flashing


green started start delay time runs off
red start condition(s) not fulfilled aarm cut-out
orange - started and interlocked

The software manages the connected weigh-feeders as components.

(2) Function and component keys


The function keys F1 - F6 call up the main menu pages F100 - F600. The
component keys KΔ and K∇ call up the menu pages for the component
operation. If the component operation is already active, the component
keys permit to call up the next or the previous component.

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(3) The cursor-block


The cursor-block serves as general operating element for the input. It is
composed of the four cursor keys, scroll up and scroll down and the
enter-key (CR). The cursor (=inverse block) will be displayed
automatically after the first activation of a cursor-key. The cursor only
selects parameters that can be changed.

(4) The numerical keys


The numeric keys are used for numeric inputs. Beside the figures 0 - 9 this
block contains the decimal point and the clear-key (C). Pushing of the
clear-key erases the last figure of the input, provided it has not yet been
validated by means of the enter-key. Chapter 4.3 describes the numeric
input.

(5) Group-keys
This block contains (from the left to the right) the collective start-key, the
collective stop-key and the alarm reset-key. The functions start, stop and
alarm reset of these keys only refer to selected components. The selection
permits to combine the corresponding components in a group. Please
refer to chapter 8.3 for a description of the selection. The LED in the
collective start-key displays the installation status.

Status LED Meaning as a function of the selected


Start cond. red one start condition has not been fulfilled.
Troubled red flashing
an alarm cut-out has occurred.
Started green all feeders are started.
Stopped - at least one component has not been
started
Interlocked orange flashing all feeders are interlocked.

(6) The LCD-display


The LCD-display permits to visualise the parameters and the actual values
of the feeding operation.

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4.2.2 Composition and menu structure of the display

The menu pages always consist of a Page number Page interlocking


header, a parameter range and the input F100 I=off | ST ST ST ST ST ST ST ST K8
line (last line). The header is always Start cond.| ST ST ST ST ST ST ST ST K16

made up of the first two lines of a menu


page. The header contains: Installation status Component status,
mode displays

The first two figures of the page number stand for the F-key that calls up Page number:
this menu page (here: F1). The figures 3 + 4 stand for the submenus.
According to the function the submenus are called up with the scroll-
keys or with a parameter selection.
The menu pages, the page numbers of which start with a K, are
designated as component pages and are employed for the operation of
the individual component. The numbers 2+3 of the page number
indicate the component number 01 - 16.

The optional digital input key switch permits to interlock the input Page
possibility on the complete menu page, if the option I=on has been set. interlocking

The software manages the selected components (SE-C) as installation. Installation


The selection is a function switch (on/off) and can be set on menu page status
F300 (see chapter 8.3).

The header contains a mode display (2 figures) for each component. Mode displays
The first line displays the components 1-8 from the left to the right, the Status-LEDs
second line displays the components 9-16. The contents and the
representation of the mode display inform the operator about the status
of the component. The mode displays are complemented by the status-
LED of the components above the display.

The following table lists the possible formats of mode displays and the
corresponding states of the LEDs. The textual contents of the mode
displays only serve as examples.

Representation Meaning LED


normal GF component stopped off
inverted GF component started green
flashing D+ component troubled red flashing
empty the component is not available off
one start condition has not been red
normal GF
fulfilled
flashing == feeding is interlocked and started orange flashing

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4.3 Parameter modifications


4.3.1 The numeric input

According to its designation the numeric


1. Set the cursor to the actual value

input is based on a parameter that is preset K011 GF GF GF GF GF GF GF I=off


via the numeric keys, for example 100.00.
Here the input is a real number. The
meaning and the unit (kg, kg/h etc.) are
determined by the menu point selected. The
parameter output for instance can only be
entered on the corresponding menu page
and with the unit displayed.
2. Input 0 .. 9 , . 3. Validate = CR

4.3.2 The selection of fixed parameter sets

The second possibility of parameter input,


Selection of defined parameter values:
1. place cursor on actual value
the selection of a defined parameter value, Mode

indicates a choice of possible inputs for the


I/O configuration I:0 O:1

parameter selected. The cursor permits to 2. place cursor to new value

select the desired parameter value, it is then K111 GF GF GF GF GF GF GF I=off


validated by pushing of the CR-key.
| CM calc. max output
VR vol. regulation| GD grav. discharge

3. validate+return = CR

4.3.3 Parameter modifications are not taken over, if

The new parameter violates the input limitations.


In this case the report input error will be displayed in the footer. It has to
be distinguished between defined input limitations and the input limitation
that has been computed for the setpoint input. The defined input
limitations are indicated in the description of the parameter concerned.
The input limitation for the setpoint [kg/h] is computed as follows:
Setpoint < 1,1 x max. output [kg/h].

The component or not all components have been stopped.


In this case the report feeder started or feeder not stopped will be
displayed.

Most of the parameters can only be changed if their status is stopped. (


stopped ? started + interlocked!)

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The input is not possible because of an interlocking.


For both types of interlocking, i.e. interlocking of the menu page or
operating function of the weigh-feeder, the report no input possible would
be displayed.

4.4 The Congrav® L/M3 B

The Congrav® L/M3 B is neither equipped with a display nor with a front
keyboard, so that the operating, function and display elements are not
relevant for this execution. The operation and the visualisation are
provided by means of a Congrav® RC3 or a superset host system (e.g.
IPC).
The Congrav® RC3 is a separate operating unit that is connected serially
to the Congrav® L/M3. The Congrav® RC3 offers all of the functions of
Congrav® L/M3.
The host system controls the Congrav® L/M3 B via the serial host
computer interface. Please observe the following:
ƒ It has to be possible to stop the feeding operation after a failure of
the serial interface connection. Thus, it is always required to cable
the digital inputs "stop" (for the individual weigh-feeders or the
collective stop for all preselected weigh-feeders).
ƒ The function is determined by the host computer procedure
employed. The complete scope of functions of Congrav® L/M3 B
can only be achieved by means of a host computer procedure that
provides all functions.
ƒ If an interface procedure is employed without the complete scope of
functions of Congrav® L/M3 B it is necessary to employ a
Congrav® RC3 for the missing functions. This goes especially for the
determination and the adaptation of the weigh-feeder parameters.

Both executions, i.e. Congrav® L/M3 A and Congrav® L/M3 B, are


identical as far as the hardware and its extensions are concerned. As the
scope of functions of Congrav® L/M3 is determined by the software
employed, both executions have the same functions, provided they are
equipped with the same software version.
Therefore we do not distinguish between the two executions in the
following chapters. The descriptions are based on Congrav® L/M3 A, the
structure of menu pages in the display of Congrav® L/M3 A. Except for
the missing visualisation, the parameters and their functions are identical
for the Congrav® L/M3 B.

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4.5 Overview of the slots of Congrav® L/M3

Figure 4-1: The rear view of Congrav® L/M3 for 4 weigh-feeders with optional extensions

Slot XS1: (has to be available)

Reserved for the plug-in card L/M3-MSIO, that is always included.

Slot XS2: (optional extension)

Reserved for the plug-in card L/M3-CDIO. This optional extension


permits to extend the hardware of Congrav® L/M3 by means of a printer
interface (Centronics) and 6 digital inputs and outputs each.

Slot XS3: (optional extension)

Reserved for an optional bus-module. At present, cards for the ProfiBus


and the ControlNet-Bus are available.

Slot XS4: (has to be available)

Reserved for the first DS-controller. A DS-controller permits to connect 2


weigh-feeders to Congrav® L/M3.

Slot XS5 – XS11: (DS-controller)

Any further DS-controller permits to connect 2 more weigh-feeders to


Congrav® L/M3.

Slot XS5 – XS11: (optional analogue card!)

The optional analogue cards extend the hardware of Congrav® L/M3


with analogue inputs and outputs and further digital inputs and outputs.

In general, all DS-controllers are connected first, and then all analogue
cards are connected without leaving free slots in between. No empty
slots are allowed between the individual cards. Important

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4.5.1

analogue act. value output 0 - 10VDC

analogue leading 0 - 10VDC

Power supply
analogue load cell signal 0 - 10VDC

24 VDC
analogue speed 0 - 10VDC

Power supply

Analogue card
analogue manipu. variable 0 - 10VDC

IO-Modul-Analog-LM3

Brabender Technologie, 2005-08


Analogue
weight signal

Power
source
Release (opteration)

Motor line

depending
on the type
Power supply
Drive controll

Setpoint (manipul. output, serial)

24 VDC

DS-controller
Power supply
Digital speed

IO-Modul-DS-LM3 R1
serial load cell signal
Overview: the possible connections

Supply voltage load cell amplifier

Start speed monitoring Drehzahlimpulse


Speed

BT1094A

Speed signal 0 oder 24VDC

digitales Wägesignal
serial load cell signal
monitoring BT1094

ControlNet
ProfiBus DP,

Bus module
integrated in the junction box that is
mounted to the weigh-feeder

24 VDC
UBE-D/15F

Power supply

Printer

LM3-CDIO
(Centronic)
Modem

Host computer with Siemens RK512


Congrav RC3

LM3-MSIO
Manual Congrav® L/M 3 HG V_._

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4.6 The basic execution of Congrav® L/M3

In its basic execution the Congrav® L/M3 is equipped as follows:


ƒ socket for the mains connection
ƒ plug-in card L/M3-MSIO,
ƒ 1 DS-controller
and permits to control the feeding operation of a maximum of 2 weigh-
feeders.

4.6.1 The plug-in card L/M3-MSIO

The L/M3-MSIO
ƒ is the Memory-Serial-IO-card of Congrav® L/M3,
ƒ is always plugged into the first slot (XS1) and -XS1.1

ƒ is always required for an operation of Congrav® L/M3.


The L/M3-MSIO is equipped with
ƒ the program store for the operating software -XS1.2
ƒ the systems battery for buffering all SRAM-components
ƒ 3 RS485/422-interfaces with isolated potential
The three interfaces are lead out on the rear face of the L/M3-
MSIO as 9-pole DSub-sockets. -XS1.3

-XS1

4.6.1.1 XS1.1: The connection of the host computer

The first RS422-interface (XS1.1) is used for the connection of a XS1.1:


host computer. The pin functions:
1
Pin 6: RxB Pin 8: TxB
6 7 8 9
Pin 7: RxA Pin 9: TxA

This interface is not employed, if the Congrav® L/M3 is connected


to bus systems, for instance ProfiBus or ControlNet. The connection
of bus systems is always made by means of the corresponding
no bus system!
optional bus module.

4.6.1.2 XS1.1 + XS1.2: The connection of Congrav® PT03

Instead of a host computer, it is also possible to connect a Congrav®


PT03 to interfaces (XS1.1) and (XS1.2).
ƒ XS1.1 transmits the data of the weigh-feeders 1 - 8
ƒ XS1.2 transmits the data of the weigh-feeders 9 -16

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Both interfaces, XS1.1 and XS1.2, are a RS422 interface and have the
same pin functions.

Special function for XS1.2:


XS1.2 permits to carry through a software update with a notebook or a
PC.

4.6.1.3 XS1.3: The connection of a modem or IPC

The third RS422 interface XS1.3 permits to connect a modem for remote
maintenance/diagnosis.

Be sure to observe the interface type RS422.


In standard, a modem functions with the interface type RS232. For the
connection of an RS232-interface to an RS422-interface an interface
Attention!
converter is necessary.

Moreover, the interface XS1.3 is also employed for the connection of an


IPC.

The pin functions of XS1.3:


XS1.3:
Pin 6: RxB Pin 8: TxB
Pin 7: RxA Pin 9: TxA 1

The functions of the modem and their configuration can only be 6 7 8 9


provided if supported by the software employed (as per V1.80).

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4.6.2 The DS-controller

Each digital/serial controller is able to carry out open- or closed-loop


control of up to 2 weigh-feeders. In keeping with its name, this type of
controller is equipped only with digital inputs and outputs and 4 serial
RS422 interfaces.

This means that the peripherals, such as load cell and drive controller,
must be equipped with a serial RS422 or RS485 interface whose
interface protocols are implemented in the software of the Congrav®
Attention!
L/M 3.

Reading of analogue signals (e.g.: speed reading) is not possible with a


DS controller. The evaluation of the speed monitoring data (BT1094A,
etc.) is performed via digital input 1.
The cabling of the DS-controllers is made via the I/O-module-DS-LM3
Rx.

The information contained in the remainder of this manual is based on


the assumption that I/O-module DS-LM3 R1 or higher (R2, R3..) is in
use. Only this revised type of I/O-module will enable the digital read-in
Important
of speed data at up to 10 kHz, subject to appropriate software support.

4.6.2.1 The I/O-modules for the DS-controller

The weigh-feeders are cabled on the terminal strips of the I/O-modules


I/O-module-DS-LM3 Rx (at present x= 1, 2). The connection to the DS-
controller determines the assignment weigh-feeder / component number
in the software.
ƒ The I/O-module for components 1 and 2 must always be connected
to the first DS controller.
ƒ Connection to the second DS controller, for example, will
automatically assign components 3 and 4 to the terminals of the
I/O-module.

All configuration parameters of the software are affected by this


assignment. An incorrect assignment may cause considerable failures
that may lead to a deterioration of the hardware or a risk for the
Important
operating staff.

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4.6.2.1.1 The I/O-module-DS-LM3-R1 and ..-R2

DRS2
TB TA RB RA

Relay outputs 48VDC/1A


FC-V__
24VDC
Operation Alarm Refilling Power supply
- -
T/RB T/RA
Auto tare + +
RB RA TB TA

1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17 18 19

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
K4 K5 K6

Componente 2

K1 K2 K3 Componente 1
IO-Modul-DS-LM3-

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
RB RA TB TA

Operation Alarm Refilling


TB TA RB RA NC NC NC
Auto tare
Relay outputs 250VAC/5A
DO4
GND
24 V
GND 24
DI1 DI3 24
VDC Load cell RS422 R1
DI2 DI4
VDC
DO Start speed monitoring T/RB T/RA

15VDC
10VDC

GNDP
Load cell RS485

R2

Figure 4-2: IO-module-DS-LM3 R_

Terminal R1 R2 Power supply


62, 92 NC +10 VDC IDL/F, MD with RS422
63, 93 NC +15 VDC AED, ED60
64, 94 NC GNDP

The I/O-module-DS-LM3 R2 permits to supply the listed load cell types by


means of the module.

The available supply voltages are only dimensioned for the listed load
cell types.
The 24VDC on terminals (55, 85) must only be employed for the supply
Attention!
of the digital inputs.

4.6.2.1.2 The terminal plan of the I/O-module-DS-LM-R_

The following points have to be taken into consideration for the following
terminal plan:
ƒ the functions of the digital inputs and of the digital output DO4 are
determined by the software configuration.
ƒ the function for the relay K3 or K3’ "refill" as "feeder type" (= CP01)
requires a loss-in-weight feeder. With a weigh-belt feeder this relay
receives the function "auto-tare".

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Termianal strip 1 Power supply


Operation Alarm Refill
3 4 1 2 6 DRS2

Connection FU-S, FC-V accordingly

K1 K2 K3 Supply
24 VDC

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Component 2 + + - -
RB RA TB TA
16 17 18 19

Relay K1, K2, K3


for internal use Serial drive
1A, 48VDC controller

RB RA TB TA

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Component 1

K1 K2 K3

3 4 1 2 6 DRS2
Operation Alarm Refill

71 72 FU-S_ with fieldbus module 2102

B A FC-V_ with function module LecomB

Terminal strip 2
Incremental encoder DBW
bl rt ws Load cell RS485
- + Impuls

3-wire-sensor +10V-supply, max. 120 mA


IDL/F-Load cell
Operation Alarm Refill - + Impuls
Load cell RS422 +15V-supply, max. 200mA
Namur-Sensor IDL/F2-, ED60-Load cell, AED modules
+ Impuls GNDP für 10V- and 15V-supply
DE
K1’ K2’ K3’

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 Component 1
DO4 24V 24V RB RA TB TA 10V 15V GNDP
GND GND
DO Start
Relay K1’, K2’, K3’ for use IO-Modul-DS-LM3-R2
on site motion
5A, 250VAC monitoring

GND GND RB RA TB TA
DO4 24V 24V 10V 15V GNDP

65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 94 Component 2

K1’ K2’ K3’ DE


+ Impuls
Namur-Sensor
Operation Alarm Refill Load cell RS422
- + Impuls
GNDP für 10V- und 15V-supply
3-wire-sensor
+15V-supply, max. 200mA
bl rt ws IDL/F2-, ED60-Load cell, AED modules

- + Impuls
+10V-supply, max. 120 mA
IDL/F-Load cell
Incremental encoder DBW Load cell RS485

Interface cable type max. length Rev.: 1.1 power supply


24 VDC
RS422 Belden 9842 300 m Date : 01 - 09 -14

RS485 Belden 9841 300 m by: Schell

I/O-Modul-DS-LM3 R2
I/O-Modul-DS-LM3 R2

Figure 4-3: Terminal plan I/O-module-DS-LM-R_

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4.6.3 The hardware components of the DS-controller


4.6.3.1 The digital inputs and outputs

Each DS-controller is conceived for the connection of 2 components


(weigh-feeders). The software manages the available continuously
numbered components as a function of the plug-in place of the DS-
controller. The following table shows the assignment for the first 4 DS-
controllers.

Slot XS4: 1. DS Component 1 and component 2


Slot XS5 2. DS Component 3 and component 4
Slot XS6 3. DS Component 5 and component 6
Slot XS7 4. DS Component 7 and component 8

For the following indications the 1st DS-controller, i.e. components 1 and
2, stand in for all DS-controllers of Congrav® L/M3.
For each component the DS-controller offers
ƒ digital inputs and
ƒ 4 digital outputs

The I/O-module-DS-LM provides the digital outputs 1-3 as relay outputs.

DO1: DO2: DO3: DO1: DO2: DO3:


Component 1 K1’ K2’ K3’ K1 K2 K3
Component 2 K4’ K5’ K6’ K4 K5 K6
250VAC/5A 48VDC/1A

The relays on the I/O-module-DS-LM3 provide 2 relay outputs each. The


two relay outputs have different specified load capabilities. The relay
outputs K1’-K6’ are employed for the on-site treatment and the relay
outputs K1-K6 are employed for the internal cabling, for instance for
enabling the connected drive controller, because of their low loading
capacity.
Chapter 12 describes the functions of the digital inputs/outputs (chapter
12.1.1, page 79) and of the serial interfaces (chapter 12.1.2, page 81).

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4.7 The optional extension of Congrav® L/M3

Prerequisites for the use of the optional extensions:


ƒ a Congrav® L/M3 as basic unit or at least a Congrav® L/M3 with a
corresponding free slot
ƒ a Congrav® L/M3 with an operating software that supports the
functions of the extension.

4.7.1 The plug-in card CDIO

The optional extension card LM3-CDIO-card (-XS2) extends the


hardware of Congrav® L/M 3 via the addition of
ƒ a printer interface (Centronics),
ƒ digital inputs and outputs.
A printer with Centronic-interface can be connected to the printer
interface (XS2.1). The printer is configured via the printer functions of 2nd slot:
the software. The15-pole DSub-plug (XS2.2) offers 6 digital inputs
and outputs each. For their supply the CDIO-plug-in card requires
an external 24VDC-power supply.

XS2.2: optional digital-I/O -XS2.1

1 8

9 15

24 VDC DO 6
DI 6 DO 5
DI 5 DO 4
DI 4 DO 3
DI 3 DO 2 -XS2.2
DI 2 DO 1

DI 1 24V GND
Screening

The connection of the digital-I/O is provided by the interposition


module UBE-D/15F, that is connected by means of a 1:1
connection (pin1 Æ terminal 1, etc.) to XS2.2.
Please refer to chapter 12.3, page 89 for the functions of the digital
inputs and outputs.

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4.7.2 The analogue card

The analogue card is an extension of the DS controller, and cannot be


operated independently. The analogue card extends the hardware of the
DS-controller by
ƒ 8 digital inputs and 8 digital outputs.
ƒ 4 analogue inputs and 4 analogue outputs (0-10VDC).
The optional analogue card is necessary whenever peripheral equipment
is controlled in analogue mode or when additional digital inputs and/or
outputs are required.
An analogue card requires a slot. If you use more than one analogue
card the maximum number of components reduces accordingly. A
maximum of 4 analogue cards can be employed.

Exception:
An exception is a configuration of Congrav® L/M 3 with 8 DS controllers.
In this case the 3rd. slot can be used for the one single analogue card.
However, it is only possible to insert an analogue card into the 3rd slot,
ƒ if the slots 4-11 are equipped with DS-controllers and
ƒ if no bus-module is inserted into the 3rd. slot.

Further specifications for the use of an analogue card


ƒ The first analogue card is inserted in the first available slot behind the
last DS controller, and is designated -XSA1.
ƒ When extending an existing Congrav® L/M 3 configuration (e.g. 2
DS controllers and 2 analogue cards) via the addition of an
analogue card, the new analogue card (-XSA3) is inserted in the first
available slot after the last analogue card (-XSA2).
ƒ If this Congrav® L/M 3 configuration is expanded via the addition of
a DS-controller, the three analogue cards must be shifted by one slot
to the right. The new DS controller is inserted in the slot, which then
becomes available next to the last DS controller (slot 6, -XS6).
ƒ The analogue cards in a Congrav® L/M 3 are interchangeable. The
internal identity numbers of the analogue cards are determined by
the order on the Congrav® L/M 3-bus (1st analogue card, 2nd
analogue card, etc.).

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4.7.2.1 The I/O-module I/O-module-analogue-LM3

The analogue inputs and outputs are on the terminal strips of the I/O-
module I/O-module-analogue-LM3 Rx. The assignments
ƒ function Æ analogue input/output and
ƒ anlogue input/output Æ component (weigh-feeder)
are determined by the software on the corresponding configuration pages
(e.g. F170). Please refer to chapter 12, page 79 for a description of the
hardware configuration.

1 2 3 4

+ + - -
IO-Modul-Analog-LM3 Supply voltage
24VDC

1 1

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Terminal Kl1

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Terminal Kl2

Figure 4-4: I/O-module-analogue-LM3

Terminal Function Terminal Function Terminal Function Terminal Function


5 DO 1 11 DI 1 17 AI 1 + 23 AO 1 +
6 DO 2 12 DI 2 18 AI 1 - 24 AO 1 -
7 DO 3 13 DI 3 19 Screen 25 Screen
8 DO 4 14 DI 4 20 AI 2 + 26 AO 2 +
9 GND 15 24 VDC 21 AI 2 - 27 AO 2 -
10 Screen 16 Screen 22 Screen 28 Screen

Terminal Function Terminal Function Terminal Function Terminal Function


29 DO 5 35 DI 5 41 AI 3 + 47 AO 3 +
30 DO 6 36 DI 6 42 AI 3 - 48 AO 3 -
31 DO 7 37 DI 7 43 Screen 49 Screen
32 DO 8 38 DI 8 44 AI 4 + 50 AO 4 +
33 GND 39 24 VDC 45 AI 4 - 51 AO 4 -
34 Screen 40 Screen 46 Screen 52 Screen

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4.7.3 The ProfiBus-module

Figure 4-5: Rear front L/M3 with ProfiBus-module

The PROFIBUS-module is a plug-in card that is plugged into the third slot
into the L/M3-housing. A 9-pole D-sub-plug and two LEDs (green,
yellow, marked as 2) are visible on the rear panel of the PROFIBUS-
module. The LEDs signalise the status of the ProfiBus-module:

steady light = o.k. flashing = failure

The D-sub-plug permits the connection to the PROFIBUS-transmission


line. According to the EN 59170 the D-sub-plug has the following pin
functions:

Pin Meaning
1 Screen -> Screening
3 RxD/TxD-P -> Reception/transmission data Plus
5 GND serial -> Data transmission potential
8 RxD/TxD-N -> Reception/transmission data Minus

According to the ProfiBus-specification the connection is provided


by means of terminating resistances.
390Ω 220Ω 390Ω

For the connection we recommend confectioned ProfiBus-plugs 5 8 3 6

with integrated terminating resistances. Attention

As far as cabling is concerned, the specifications for an EMC


safe cabling and the specifications for the RS-485 interface have
to be observed.

The transmission rate is 1500 kbit/s provided the system has been
cabled correctly and a permissible cable type has been employed, the
line type A as per EN 50 170, a maximum line length of 200 m. Attention

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CHAPTER 5

MOUNTING AND COMMISSIONING

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5 Mounting and commissioning


5.1 Mounting

Control panel Mounting plate (Attention: please observe stability!)

Cut-out

Fixing clamps
139,00

Front

Screws for clamps

281,0 Mounting of a clamp

Cut-out dimensions for Congrav® L/M 3A Fixing of Congrav® L/M 3A

First select the position for installation. The selected position must ensure
sufficient space for the Congrav® L/M 3A after installation (ventilation,
convection, insertion of connectors, etc.). It must be guaranteed that the
maximum ambient temperature will not be exceeded after installation.
The cut-out for the Congrav® L/M 3A is sawn out at the selected
installation position. Should the stability not be sufficient for installation,
the cut-out must be reinforced accordingly. Insert the Congrav® L/M 3A
in the cut-out and secure the fixing clamps. Place the clamps against the
first fixing screw (see drawing) and fit into position by pressing gently
against the fixing screw. Then turn upwards and slot into the second fixing
screw. Use a screwdriver to tighten the screws of the clamps until the
Congrav® L/M 3A is pressed firmly against the mounting plate. The
Congrav® L/M 3A must not be fitted askew, as front protection class
IP65 will then not be attained.

Dimensions of Congrav® L/M 3B

The Congrav L/M 3B is mounted in


position using four M6 screws. As a rule,
6,29

no cut-out is required for the Congrav®


33,56
29,15

L/M 3B, as it is installed in the control


cabinet. Due consideration must be
6,29

accorded to the operating conditions,


such as ambient temperature, 59
66,28
convection, connection techniques, etc. 72,57

when installing the unit.

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5.2 Connection plan of a loss-in-weight feeder

230 VAC
L N PE
M
PTC
Nur Option
only option

L2
L N PE U V W PE T1 T2

FC-V 1-3
Funktionsmodul Lecom B
function module Lecom B

RS485
T/RA T/RB

A B 7 39 20 28
Plattformwaage MD mit BR200-B Modul
Platform scale MD with BR200-B module

RS422/485
TB TA RB RA Vcc GND Pre Pre-Return
-10K1M Befülleinrichtung
refill device
1

1 2 3 4 5 6 7 8 9

+ -

51 50 49

Congrav L/M3 - I/O-Modul-DS-LM3- R2

Baugruppe Ausführung Rev.: 1.1


L/M 3 HGC V
Drehzahl Drehzahleinlesung max. 10kHz Date : 03 - 04 - 04

Wägezelle Plattformwaage MD mit BR200-B by: Schell 0e010547

Connection of a DDW to a Congrav L/M3


(for componente 1)

Figure 5-1: Example for the connection of a loss-in-weight feeder

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5.2.1 Connections of Congrav® L/M3

Figure 5-1 gives an example for the cabling of a loss-in-weight feeder.


The execution of cabling is determined by
ƒ the type of weigh-feeder,
ƒ the employed subassemblies,
ƒ the hardware configuration of Congrav® L/M 3

and various other points.


Further examples for wiring of various standard subassemblies to the
Congrav® L/M3 are shown in a separate appendix.
Please see chapter 12 page 79 for a description of the configuration of
the hardware functions of Congrav® L/M3.

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5.3 Start-up, switching on the Congrav® L/M3

Before switching on Congrav® L/M3 the connections have to be checked


for possible faults and repaired if necessary. Connect the power supply of
Congrav® L/M3 (mains plug or external mains switch). This also starts
the initialisation of Congrav® L/M3 and switches on the display.

The welcome screen shows the Congrav®- F000


Stopped
|

type and the software version that has been BRABENDER TECHNOLOGIE
recognised. Further tests: Check
IO address: the available option cards are Software : LM 3A |
HG V1.81 | o.k.
displayed according to their IO address: 1 1 2 2 |
order of insertion. :
:
1 = DS-controller MS-Board: RC Batt. | o.k.
2 = Analogue card CD-Board: 1 |

MS-Board: Indicates whether the motherboard of Congrav® L/M3


and the battery for memory buffering are operative.
CD-Board: Indicates whether the optional extension card L/M3-CDIO
has been installed. This extension card offers for instance
a Centronic-interface for the connection of a printer.

If one or several checks are not brought to a successful end during the
initialisation, an error will be announced in the column Check and the
Congrav® L/M3 is not operative. Steps for making the system ready to
start:
ƒ switch off the mains supply,
ƒ eliminate the trouble cause and
ƒ reconnect the mains supply.

In most cases that trouble is severe, so that we recommend to contact


our after sales department.
Attention

Exception: the battery for memory buffering


If the capacity of the battery is no longer sufficient, this will also be
displayed. The Congrav® L/M3 announces that it is ready for start and
can still be operated.

Congrav® L/M3 can be operated without battery. However, the memory


will not be buffered. I.e. in case of a failure of the mains supply, all
stored data will be lost. Important

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CHAPTER 6

INSTALLATION CONFIGURATION

Chapter 6 deals with the menu pages F100 and the


corresponding submenu pages

ƒ F100: Installation configuration


ƒ F110: Installation modes
ƒ F120: Host computer parameterisation (see
chapter12.5)
ƒ F130: Text switch
ƒ F140: Test of I/O-periphery (see chapter14)
ƒ F150: The recipe administration

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6 F100: Installation configuration


The menu page F100 - installation configuration - manages parameters
that are required for running the installation and for the general
configuration. Please find below an explanation of the individual
parameters according to the order of the cursor positions.

6.1 F110: Installation modes

We distinguish two types of modes, namely the superset installation


modes and the component modes of the individual components. The
menu point mode on menu page F100 configures the installation mode.

The individual components feed independently of each other as a Single


function of the setpoint. A linkage of the individual components is only
provided by the selection for the calculation of the total values (total
setpoint, total actual value, total throughput) and for the alarm stop-
function.

A group consists of several components, which are activated by the Group


selection. The group size is determined by the group setpoint. The
setpoints of the individual selected components are entered in percent of
the total setpoint of the group.

Corresponds to the group mode. In addition, there is a 100%- 100% group


monitoring of the sum of the preselected component setpoints. If the
sum is not equal to 100%, the report group setpoint <> 100% will be
emitted and the group cannot be started.

With master/slave operation a basic product can be mixed with several Master/Slave
other products (e.g. additives). The setpoints of the individual slave
feeders are determined in relation to a master setpoint in %. The master
feeder is characterised by a setpoint input of 100%. In case of no master
feeder or several master feeders there is an alarm report.

This point is corresponding to the master/slave operation. However, the MS-actual


setpoints of the individual slave feeders are determined in relation to the value
actual value of the master in %. As there is no actual value for the
master during the start period, the system will first take the setpoint of
the master component. After 15s the system will automatically switch
over to the actual value of the master. With the master feeder the
function "alarm stop" has to be selected, furthermore it has to be in GF
mode. The slave feeders have to be in modes GF, VR, VS, GD or VF.

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6.2 Analogue configuration

On menu page F100 the parameter "analogue configuration" has the


following functions:
ƒ With the modes group, 100%-group and master/slave it is possible
to control the group or master setpoint by means of an external
signal.
ƒ The total actual value (= sum of the actual values of all selected
components) can be emitted as analogue actual value signal.

The following features apply to the analogue control (AC):


AC-signal = 0(2) VDC act. SP = 0 kg/h AC features
AC-signal = 10 VDC act. SP = group/master setpoint (F300)

The following features apply to the actual value signal (AV):


AV-signal = 0(2) VDC act. Value = 0 kg/h AV features
AV-signal = 10 VDC act. value = total output (F170)

Signal range = 0-10VDC Signal range = 2-10VDC Example:


Group setpoint = 100 kg Group setpoint = 100 kg
AC-signal = 4 VDC == 40% AC-signal = 6 VDC == 50%
act. SP = 40%*100 = 40 kg/h act. SP = 50%*100 = 50 kg/h

Specifications for the analogue installation configuration:


ƒ The analogue installation configuration and the total analogue
actual value only take into consideration selected components.
ƒ The analogue inputs are only available with an optional analogue
card. Please refer to the description of menu page F170 (chapter
12.2.2.1, page 85) for the configuration of the analogue inputs for
both functions.

6.3 Host computer operation

The parameter host computer operation permits to activate the host


computer operation. Please refer to chapter 12.5, page 91 for a
description of the host computer configuration.

6.4 Text switch

For the display texts you can switch between the languages included
(F130). If the language English lb has been selected, the units will change
at the same time from lb/h (pounds per hour) to lbs (pounds). The
following parameters are concerned:

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lb/h: Setpoint, actual value, sampling quantity, output, max. output,


total output
lb: Throughput, weight, auto-tare
PCF: Bulk density (input range 10 - 250)
cuft: Hopper contents (input range 0.01 - 350)

6.5 Interlocking/stop

off If one weigh-feeder is interlocked, the weigh-feeder remains


started. Feeding can be continued after the elimination of
interlocking.
on If one weigh-feeder is interlocked, the weigh-feeder is stopped.
To continue the feeding operation the interlocking has to be
eliminated and then the weigh-feeder has to be started.

6.6 Date and time


The menu page F100 permits to select date and time by means of the
cursor and to enter them in the format (DD.MM.YY) or (hh.mm).

6.7 F150: The recipe administration

To call up menu page F150 you push the -key twice or the -key
once if you are on menu page F100 (F1-key).
The Congrav® L/M3 will store the actual configuration of Congrav®
L/M3 (= ale parameter settings) in a separate memory range as recipe.

How to store a recipe


Place the cursor to the menu item "store recipe" and enter a recipe
number (01 - 14). The CR-key permits to store the actual configuration
with the recipe number that has been entered, it can be loaded again by
means of the function "load recipe".

It will not be checked whether parameters have already been stored


under the recipe number indicated. By pushing the CR-key, the memory
area defined by the recipe number is overwritten by the actual
parameters. The old memory content can only be recovered by the
Attention
corresponding configuration of Congrav L/M 3 and the subsequent
memorisation.

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Load recipe
Place the cursor on the menu point load recipe and enter a recipe
number (01 - 14). The CR-key permits to load the parameters stored with
the recipe number entered in the working memory of Congrav L/M 3.

Pushing of the CR-key overwrites the actual parameter settings with the
memorised settings. Restoring the old adjustment is only possible if it
had been memorised with another recipe number. Attention

In case of a download of a new software version to Congrav® L/M3 all


available recipes are reset, if the old and the new version number of the
software differ from one another. Attention

6.7.1 Setpoint ramp, setpoint threshold

Please see chapter 8.2.1, page 53, setpoint types, for a description of the
functions of the parameters setpoint ramp and setpoint threshold.

6.7.2 Start-up operation

Start-up operation means that the alarms control difference positive,


control difference negative, speed min., speed max. and anti-vibration are
suppressed for a period of time that has been entered. If the alarms occur
after rundown of the period adjusted, there will be an alarm report with
or without cut-out according to the alarm configuration (Kxx5). The
alarms overload, underload and refill fault are processed according to the
alarm configuration without taking into account the period that has been
entered.

0 Start-up operation deactivated.


>0 Start-up operation activated. The maximum value is 3600 s.

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CHAPTER 7

PRINTER CONFIGURATION, RESET OF


MEMORY CONTENTS

Chapter 7 deals with the menu page F200 and the


corresponding submenu pages

ƒ F200: Printer configuration


ƒ F210: Reset memory contents

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7 F200: Printer configuration, reset of memory contents


7.1 Printer functions

The optional extension card L/M3-CDIO permits to connect a printer with


a Centronics interface. If the corresponding hardware extension of the
Congrav® RC4 is available and if a suitable printer is connected the
software assists the following printer functions:

With an interval print the menu page selected will be printed Interval print:
automatically according to the interval (print time) defined. The
menu page for interval print will be determined by input of the
menu page number (numerical input + "F" or "K") for the menu
point menu page. The menu page number will be displayed in the
upper left corner of any menu page. To select the "F"- or "K"-page
you place the cursor on "F" (or "K") and then push the enter-key.

The function alarm printout activates an alarm recording for Alarm recording:
troubles during the operation. These troubles optionally lead to an
alarm cut-out or only to an alarm report, they are displayed by the
following printer record:

28.05.97 23:45
K 01 Speed minimum

or if the alarm is deleted:

28.05.97 23:46
K 01 Speed minimum reset

The input of the component number 1..16 leads to a printout of Printout of


the actual calibration parameters of the corresponding calibration data:
component. After the printout the component number entered will
automatically be reset to 0.

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7.2 F210: How to clear memory contents

On menu page F210 you will find three functions that permit to clear defined memory
contents.

There is generally no security check before deletion of the data. As a


safeguard against undeliberate data deletion this menu page is
interlocked by a code. The delete job can only be called up if the code
Attention
0884 has been entered directly after call-up of the menu page.

RAM:
Deletes all data in the RAMs of the DS-controllers and loads the booted
data of the master controller. In case of a changed configuration of the
modem interface (see chapter 12.3, page 89) the memorised
configuration data remain the same.

All data delete:


Deletes all data, also the configuration data of the modem interface, in
all memory chips and replaces them by standard values.

Recipe init:
Initialises all recipes by the actual configuration.

After execution of the corresponding delete function the report "data


deleted" is displayed, this report has to be acknowledged.

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CHAPTER 8

SETPOINTS AND SELECTION

Chapter 7 deals with the menu page F300 and the


corresponding submenu pages

ƒ F300: Setpoint input, selection


ƒ F310: The start/stop-delay times, alarm stop

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8 F300: Setpoint input and selection


This page permits to enter the setpoints and the selection. For an easy
operation the cursor-keys left and right are active. Depending on the
number of DS-controllers employed, the components are displayed. If the
number of DS-controllers employed is higher than 4, the menu page
F301 will be displayed for the components 9-16, it has the same structure
as menu page F300.

With the setpoints displayed, we have to distinguish between two types:


namely the computed and the entered setpoints. Whether the setpoint is
to be entered in kg/h or % is determined by the selected installation or
component mode.
All setpoints can also be modified if the feeding operation has started.
Attention
However, the setpoint modification is only accepted, if the setpoint input
or the setpoint computation comply with the setpoint limitation setpoint
< 1.1 * max. output.

8.1 Installation setpoints

Single The total setpoint is calculated from the sum of the


setpoints of all selected components.
Group The group setpoint is entered in kg/h.
Master/Slave The master setpoint is entered in kg/h.
Analogue control The group and the master setpoint are controlled in
analogue manner. The value entered in kg/h is
corresponding to a control signal of 10 V.

8.2 Component setpoints

Mode Setpoint in % Setpoint in kg/h *only valid for


SP [ kg / h ] * selected components
Single 100% ⋅
Total _ SP [ kg / h ]
Input
*
Group Input SP% ⋅ group _ SP [ kg / h ] without selection:
* max. output (CP03)
Master/Slave Input SP% ⋅ master _ SP [ kg / h ]
instead of
The input refers to 10V DC The kg/h-setpoint will not
total_SP¬group_SP¬
and determines the constant be calculated. master_SP
Discharge manipulated variable. The The available values are
setpoint entered will not be based on the setpoint
taken into consideration by a input for the feeding
100%-monitoring. mode (e.g. GF)

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8.2.1 The analogue control of the setpoints

There are two different manners to adjust the setpoints by an analogue


control signal.
ƒ The installation control permits to control the group or master
setpoint. Please refer to chapter 12.2.2.1, page 85 for a description
of the installation control. The installation control can only be
employed for the installation modes group and master/slave.
ƒ The single control permits to control the setpoint of the component.
Please refer to chapter 12.2.2.2, page 87 for a description of the
single control. The single control of the component setpoints can
only be used with the installation mode single.

8.2.2 Setpoint ramp, setpoint threshold (menu page F150)

The setpoint threshold is the threshold value for the reaction of


the software to a setpoint modification. It can be determined in
a range of 0 – 500% .
ƒ Setpoint modification< 5% * actual setpoint
The modification is controlled by the control system. The
internal memories will not be reset.
ƒ Setpoint modification< setpoint threshold* act. setpoint
There will be a setpoint jump. The value “manipulated
variable, old“ is the average value of the last 32 values
before the setpoint modification. A volumetric period that
is corresponding to the “start delay time“ that has been
entered will run down.
setpoint, new
Setpoint jump= manip.variable, old ⋅
setpoint, old

ƒ Setpoint modification> setpoint threshold* act. setpoint


There will be a setpoint jump that is a function of the
CMO. All internal memories will be reset and a volumetric
period that is corresponding to the “start delay time“ that
has been entered will run down after the jump of the
manipulated variable.
setpoint, new
Setpoint jump= 90% ⋅
act. output

If the “gravimetric checking of max. output“ has been


deactivated, the setpoint modifications will be carried out as a
function of the CMO. Ramp = 0
The setpoint jump will reduce the control time of the new
0s
setpoint considerably. The setpoint ramp defines the steepness p=1
Ram
of the jump of the manipulated variable (see graph). 0 10

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8.3 Selection

The selection of a component has the following effects:


ƒ The component selected can be addressed by the keys start, stop and
alarm reset.
ƒ The calculation of the total setpoint, total actual value and total
throughput are exclusively carried through under respect of the
components selected.
ƒ The option alarm stop (see chapter 8.5) only takes into consideration
the selected components.
ƒ The modes group and master/slave only takes into consideration the
selected components.
ƒ The 100%-monitoring for the mode 100% group only takes into
consideration the selected components.
The selection can only be switched on/off if the feeder is stopped.

8.4 F310: Delay times

Between the activation and the carrying-out of the start or stop order of a
component you can fix a delay time (in seconds).

After the start order of the component the run-off of the start delay time Start DT
will be indicated by a green and flashing status-LED and a "DT"-mode
display in the status line. Parameter modifications during the start delay
are refused, exception: setpoints and controller parameters.

After the stop order of the component the run-off of the stop delay time Stop DT
will be indicated by a green and flashing status-LED and a "DT"-mode
display in the status line. During the stop delay time the actual feeding
operation will be continued according to the parameterisation.
Parameter modifications during the stop delay time are refused,
exception: setpoints and controller parameters.

8.5 Alarm stop

In case of an alarm cut-out (= stop of the component due to a failure) a


selected component with the activated option alarm stop, will stop all
other components selected on page F300.

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CHAPTER 9

ACTUAL VALUES OF THE INSTALLATION,


RESET OF THROUGHPUTS

This chapter deals with the menu page F400 and the
corresponding submenu pages
ƒ F400: The actual values of the installation
ƒ F410: The actual values: setpoint, actual value,
throughput
ƒ F420: The actual values: weight, control
difference, speed
ƒ F430: Reset of throughputs

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9 F400: Actual values of the installation,


reset of throughputs
The menu pages F400, 410 (411) and 420 (421) only serve for the
display of the actual feeding values, thus there is no input possibility. After
pushing of the F4-key (= menu page F400) the menu pages are called
up with the scroll up key in rising order F410 (F411) F420 (F421) F430
F400 etc. The scroll down key calls up the pages in falling order.
The menu page F400 displays the total values of the installation. These
totals are calculated from the sum of the component values of the
selected components.

Components that have not been selected will not be taken into
consideration for the calculation of the corresponding totals.

The menu page F410 (F411) shows a table of the actual values of the
feeding operation
ƒ Setpoint: Quantity to be fed in kg or lb,
ƒ Actual value: Actual feed rate in kg/h or lb/h
ƒ Total: The actual throughput is the addition of the product
quantity that has been fed.

The menu page F420 (F421) shows a table of the actual values of the
feeding operation
ƒ Weight: With a tared weighing system the weight value is
corresponding to the product weight in the hopper of
the feeding device.
ƒ Difference: Actual control difference (setpoint – actual value).
ƒ Speed: The actual operating range of the feed drive. With
speed monitoring the speed will be displayed as
manipulated variable that has been emitted.

9.1 F430: Reset throughputs

The menu page F430 lists all throughputs of the installation and of the
individual components. The throughput of a component is the addition of
the product quantity that has been fed. The throughput of the installation
is the addition of the individual throughputs of the selected components.
The throughputs are calculated and displayed as a multiple of the defined
throughput divisor (CP08) or F100: The throughputs are reset manually
by placing the cursor on the corresponding line of the L-field and then
pushing the enter-key.
After reaching of the maximum value the throughput counter will start
again at 0 taking into account the carry.

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CHAPTER 10

THE COMPONENT OPERATION

Chapter 10 deals with the K-menu pages.


These menu pages form the level of the
- Component operation -
as they permit to control, configure and analyse each
individual component.
This chapter describes the menu pages Kxx0, Kxx1 and Kxx2.
The further menu pages contain parameters for the
configuration and the testing of the Congrav®-hardware.
Please refer to the corresponding chapters for a description of
these pages.

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10 The component operation


The component pages permit to address all 16 components (weigh-
feeders) individually. The page number Kxxy indicates the
ƒ identnumber of the component by means of the figures "xx" and
ƒ the actual menu page means of the figure "y".
The individual menu pages Kxx0 - Kxx8 show the same structure (K010
== K160, etc.) for all 16 components.

10.1 The header of the component pages

Type of feeder: H = Loss-in-weight feeder (DDW)


C = CP-FlowMeter, Coriolis Mass Flow Scale (CDW)
G = Weigh-belt feeder (DBW)
Component xx: The component, the parameter values of which are
displayed and that is responded by the operating
functions.
Alarms: Alarm reports of current alarms or missing start
conditions.

10.2 Kxx0: The component control

Menu page K010 – K160 manages all K010 I=off | ST GF GF GF GF GF GF GF


Start cond. | GF GF GF GF GF GF GF GF
operating functions (left column) and
Component operation
displays the actual values (right column) for H-type Feeder 01 Output=0
the feeding operation.
Start | Setpoint 100.000 kg/h
This menu page permits to operate each Stop | Actual value 0.000 kg/h
component individually and independently Alarm reset
Refill
|
|
Control diff.
Weight
0.000 %
0.000 kg
of the selection. The desired function is | Speed 0.000 %
selected by cursor and validated by the CR- Thr. reset | Throughput 0.000 kg
key. Start sample| Sample 0.000 kg/h
Start tare | Tare 0.000 kg

10.3 The operating functions

10.3.1 Start
The component is started under consideration of the determined start
delay time if all required start conditions have been fulfilled.

10.3.2 Stop
The component is stopped under consideration of the fixed stop delay
time.

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10.3.3 Alarm reset


The present alarm is reset so that an operation of the component is again
possible.

10.3.4 Refill
This parameter is not available for DBW, CDW or CP.
Manual refill can be switched on and off.

10.3.5 Throughput reset


The throughput of the component is reset to 0.

10.3.6 Start sample


This parameter is not available for DBW, CDW or CP.
Start of the function "sample". In the right column the product quantity in
kg (lb) that has been fed during the sampling time is added. After run-off
of the sampling time the sample value that has been calculated in kg/h
(lb/h) will be displayed. The sampling value is an indication for the
feeding accuracy, provided that the weighing system has been calibrated
correctly.
Sampling is interrupted, if
ƒ an alarm appears during the sampling phase
ƒ the component is stopped or interlocked
ƒ anti-vibration is activated
ƒ manual filling or automatic filling are activated

10.3.7 Start tare


Start of the auto-tare function (DDW, CP) or of the auto-tare operation
(DBW, CDW) (see 0).

10.3.8 The actual value display in the right column


Setpoint: The component setpoint in kg/h
Actual value: The actual feeding value
Difference: The computed control difference
Weight: Weight value of a DDW
The belt load of a weigh-belt feeder
Loading of the CDW/CP-FlowMeter
With the mode vol. regulation VR: display of the flowrate.
Speed: The speed that has been red.
With speed monitoring the speed will be displayed as
manipulated variable that has been emitted.
With a Coriolis Mass Flow Scale the speed of the feeding
unit (e.g. rotary valve) will be displayed - not the speed
of the Coriolis motor. Attention
Throughput: The throughput, the summation of the product quantity
that has been fed.

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Sample: During the measuring of a sample the product quantity


that has been fed out in total will be displayed. At the
end of sampling the product quantity that has been fed
out and measured will be converted to the corresponding
feed rate (kg/h) and displayed. The display is reset to
zero, if sampling could not be concluded (e.g. by
refilling).
Tare: Display of the stored auto-tare value

10.4 Kxx1: Product parameters


K011 I=off | ST GF GF GF GF GF GF GF
10.4.1 Auto-tare: Start cond. | GF GF GF GF GF GF GF GF

Product parameter
Taring of a DDW or CP: H-type Feeder 01 Output=0

ƒ Place the cursor on auto-tare.


ƒ Push the Enter-key. Auto-tare
Check max. output
0.000
0.000
kg
kg/h
Bulk density 0.500 kg/l
The actual weight value is tared under the vol. max. output 0.000 l/h
condition (weight < 5% of the weighing Decade switch 0.000
Mode GF
range) (= 0 set). If the actual weight exceeds
the max. allowed auto-tare value, the weight
displayed will first be reduced by means of
the parameter coarse tare (CP06).

Taring of a DBW:
With a weigh-belt feeder, the auto-tare operation will be selected in this
case and with a following start order it can be started with a constant
manipulated variable of 50%. The AT-procedure ends automatically after
elapse of the no-load time and one further revolution of the belt. The AT-
procedure ends with an alarm report, if the tare value is ≤ 0 or if it is
bigger than the AT-range.

Taring of a CDW:
With a CDW auto-tare operation is selected and started with the start
command. The auto-tare operation ends automatically after run-off of the
no load time and the auto-tare time. During auto-taring the weight values
that have been read in are averaged and the average value is
memorised.

With a Coriolis Mass Flow Scale the operating contact (digital output 1)
will not be set during auto-taring.

The input of the auto-tare value

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ƒ Place the cursor on the menu point auto-tare.


ƒ Place the cursor on the value auto-tare (1 x cursor to the right)
ƒ Enter the auto-tare value in kg or lb.

10.4.2 Checking max. output


This parameter is not available for DBW, CDW or CP.

This menu item has 4 functions:


ƒ Display of the output computed for a speed of 90% (see chapter
10.4.6.5, page 65).
ƒ Display of the actual output computed gravimetrically.
ƒ Display of the flowrate computed on the basis of the input of the
volumetric output (see chapter 10.4.4, page 62)
ƒ Manual input of the output. With the manual input of the output all
internal values are reset to zero. The input is related to a speed of
90%.
The output value is required for the start of feeding and for a setpoint
modification. The output value permits to compute the jump of the
setpoint during the start, so that the control needs a shorter transient
phase. A wrong output value extends the transient phase and may lead to
an alarm cut-out in extreme cases due to a control violation that is much
too high or due to a filter violation.

The values entered for the output in [kg/h] and the volumetric output in
[l/h] influence one another, as one value is calculated from the other.
Attention

10.4.3 Bulk density


This parameter is not available for DBW, CDW or CP.

The bulk density of the product is required for the computation of the
filling level. The input of the bulk density is limited to the range 0.01-10
kg/l (0.01-200 PCF). A modification of the bulk density has no influence
on the manipulated variable of the start (bulk density_old is not taken into
consideration).

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10.4.4 vol. max. output


This parameter is not available for DBW, CDW or CP.

If it is not possible to compute the actual output, the output value can be
computed from the input of the volumetric output CM [l/h] (theoretic
output volume of the screw feeder) and the bulk density (BD) of the
product.

CM [kg/h] = CM [l/h] * BD [kg/l]

Of course, the actual output also is a function of the actual product


characteristics, so that differences might come up between the theoretic
and the actual output.

Having checked the output by the controller is always better than a


manual input of the volumetric output.
Attention

10.4.5 Decade switch


This parameter is not available for DBW, CDW or CP.

The parameter is employed for the setting of the performance range of


the vibration amplitude controller DRS2 (feeding device = tray!). It is only
activated, if a "2" has been entered for the parameter drive control on
page Kxx8 (see chapter 12.1.2.2, page 83).

A modification of the decade switch also changes the feed rate range of
the weigh-feeder and always requires a check of the output. With a
wrong setting of the output as far as the setting of the decade switch is
concerned might lead to an incorrect functioning of downstream Attention
processes.

10.4.5.1 The setting of the decade switch

Input 1 10 Deactivates the DIP-switch on the device and transmits 1 = decade 0


the setting of the decade switch via the serial interface 2 = decade 1
(Standard) of the device to the DRS2. Input 1 ... 10 is assigned to .....
the decade switch setting 0 ... 9. 10 = decade 9
Input = 0: In combination with the selection of DRS2 on page
Kxx8 this input has the effect that no decade switch
setting is transmitted via the interface and that the
DRS2 functions with the last setting.

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This means also that the hardware setting (DIP-switch) is validated after a
mains reset, because the software does not transmit any decade switch
setting. The hardware setting is not inquired by the software. Attention

For this reason the input 1 – 10 is always prescribed for a DRS2


operation, as only these inputs permit a clear operating state of the
DRS2.
<Input 1..10>

10.4.6 Mode
10.4.6.1 Gravimetric feeding (GF)

The object of gravimetric feeding is the continuous feeding operation of


the weigh-feeder within the adjusted feed rate (= setpoint). In this range
the actual value is read into the load cell and generated from the weight
decrease per time unit (= actual value). The actual value is used for the
calculation of the control difference (setpoint - actual value) for the PID-
control algorithm. With gravimetric feeding we distinguish several
operating phases:
ƒ the undisturbed gravimetric phase (GF), during which the feed rate is
controlled as described above by means of the PID-controller. If the
control difference lies within the limits of the allowed control
difference (CP11), this is displayed by the mode display "GF". A
violation of the maximum allowed control difference is indicated by
the mode displays "D+" (too much) and "D-" (too little).
ƒ the refill phase (RF), during which the weigh-feeder is refilled. On
reaching of filling level min., refill (RF) is initiated. The control is
deactivated with the start of refilling and during the complete refill
phase the average of the manipulated variable is put out constantly
(if the refill automatic is switched off). During this feeding phase a
setpoint modification is processed proportionally. After elapse of the
stabilisation period (ST) the refill phase will be finished and the
gravimetric feeding (GF) is again active.
ƒ the troubled gravimetric phase, where the anti-vibration filter (CP28)
is activated due to a violation of the filter limits. The AV-filter
violations are caused by external disturbances (vibrations). During
this phase the influence of the PID-controller is deactivated and only
a constant manipulated variable is emitted. The AV-filter violations
are displayed by the mode display "AV".

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10.4.6.2 Volumetric regulation (VR)

Volumetric regulation functions according to the principle of the


throughput control. The actual value matches the flowrate of the product
and is measured by means of suitable measuring instrument (micro
motion or impact plates) and processed for the PID-control. The 0-
10VDC signal of the measuring instrument is read in via the analogue
load cell input of the Congrav®. This requires an ISC-CM-A. This free
analogue input is configured as load cell input for the corresponding
component. The transport device (e.g. pump) is controlled via the
manipulated variable output of the Congrav® L/M3. A parameterisation
takes into account the following parameters:

Weighing range (CP02) = maximum flowrate in [l/min]


Weight display = actual flowrate in [l/min]
Output (Kx10) = maximum output in [l/h]
Act. val. adaptation = average val. for computation of act. value
(CP29)
Lever factor (CP15) =1
Adapt. actual value VR = see below
(CP31)

With measuring instruments that cannot be calibrated and do not provide


a standard signal, the adaptation between setpoint and actual value has
to be carried out by means of the parameter adaptation of actual value
VR (CP31) (does not replace (CP29)).
The mode VR starts with the manipulated variable ycon. As long
as the alarm delay time runs off all disturbances are ycon = 100% ×
setpo int
suppressed to stabilise the feeding operation. The control starts output
after half of the alarm delay time.

10.4.6.3 Volumetric setting (VS)

With this mode the speed of the feeding device is used as


actual value. The speed is measured by means of appropriate
methods and is then made available to the Congrav® L/M3.
setpo int
The feed rate of the feeding device and the flowrate have to ycon = 75% ×
output
be adjusted to each other so that the setpoint in kg/h and the
actual feeding capacity are matching. The product flow will
not be measured.

10.4.6.4 Discharge (DI)

With this mode the program uses a constant manipulated variable. It is


possible to change the manipulated variable by entering a desired

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setpoint in % (Attention: the system sets 0% equal to 75%). The


computation of the actual value/throughput functions according to the
weigh-feeder selected and all limit values that are a function of the weight
have no function. Alarm monitoring only functions for the speed
monitoring.

10.4.6.5 Checking max. output (CM):

With this mode it is possible to determine the max. output of the loss-in-
weight feeder as a function of the product. The max. output value is a
reference value for the jump of the manipulated variable during the start
of GF or VF feeding that is resulting from a setpoint input. This is why a
CM-mode should be carried through, if possible, before the start of the
feeding operation.
The computation of the max. output is carried out with a constant speed.
The constant speed of 10% and 90%. The constant speed can be
changed for the upper range and is entered as setpoint in [%] (discharge
setpoint) on menu page F300 with the corresponding component. The
discharge setpoint will generally be validated. The duration for the
checking of the max. output will be determined by means of the
calibration point sampling time (CP24). The time entered will be divided
into 2/3 for the lower and 1/3 for the upper speed range.

The input has to be done before the start of the checking of the output.
Inputs during the check are not allowed.

The output values that have been computed are entered on menu page
F610 (please see chap.10.5.1.2, page 68) for the corresponding ranges.
Menu page Kxx1 permits to enter the parameter check. max. output and
the last actual value that has been computed.

Further specifications:
ƒ Before the start of the checking of the max. output the discharge
device is refilled with product by a short-term DI-operation.
ƒ The allowed filling level range for checking the max. output is the
range between overload and underload. In the overload range and
in the underload range there is always an alarm cut-out.
ƒ This mode can be interrupted at any time by pressing the stop-key
and started again with any new start.
ƒ Alarms that occur during the checking of the output are displayed as
"CM ERROR" after the program has run down.
ƒ In case of an interruption or in case of a stop or a disturbance, no
values will be stored, so that "Check. max. output = 0" will be
displayed.

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10.4.6.6 Grav. Discharge (GD)

This mode is no independent mode but a special function of the mode


gravimetric feeding. It is possible to switch over between GF Ù GD with
feeding being started or stopped. With GD-mode there will be no refill
upon reaching filling level min., instead the gravimetric feeding operation
will be continued until reaching the filling level underload. If the filling
level underload has been reached, the alarm report underload
with/without cut-out will be displayed and there will be a switchover from
GD to GF. During GD-operation no further status indications will be
displayed in the mode display – except for "GD".

If there is no alarm cut-out in case of underload, mechanical damage


risks to be caused as the screw is not filled with product while the speed
is constantly rising (controller!). This goes also for underload values that
Attention
are too small. (Screws are not turning true).

10.4.6.7 Volumetric feeding (VF)

With this mode the manipulated variable stays constant (ycon),


there is no control. Otherwise this mode is corresponding to ycon = 100% ×
setpo int
gravimetric feeding mode (monitoring of filling level, filling, output
computation of actual value etc).

10.4.6.8 Measuring (M)

This mode that can only be selected for the Coriolis Mass Flow Scale and
the CP-FlowMeter permits the computation of the actual value of the
flowrate without control.

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10.5 Kxx2 The control parameters

For the gravimetric control of a weigh- K012 I=off | ST GF GF GF GF GF GF GF


Start cond. | GF GF GF GF GF GF GF GF
feeder a PID-controller with a variable cycle
Control parameter
is employed. HS-type Feeder 01 Output=0

10.5.1 Setting of PID controllers


The PID controller is based on the following 01
02
Control 1 P-term
Control 1 I-term
10.000
1.000s
differential calculus: 03 Control 1 D-term 0.000s
04 Control adaptation 1.000
05 Grav.calc.maximum output 0.000
( ∑ ( xd ) + T )
TS TV 1
yi = K p1 ⋅ xdi + i ( xdi −1 − xdi )
TN 1 s

yi: Change of manipulated variable xdi: Control difference


Ts: Scanning time Kp1: P TN1: I Tv1: D

The controller has the function to control the difference (setpoint - actual
value) that has been built up during feeding. For this purpose the
Congrav® L/M 3 takes an actual value from the continuous course of the
weight value in defined intervals, it will then compute the control
difference from this value and from the setpoint that has been entered.
The control difference thus computed will be processed by the control
algorithm.
The feed drive will be controlled by Congrav® L/M 3 via a drive
regulator with the manipulated variable. The control algorithm will
change the manipulated variable as a function of the control difference
that has been calculated, and the drive regulator will change the speed
or the vibration amplitude of the feed drive accordingly. As a function of
the controller access time the controller will influence the course of the
manipulated variable. The calibration parameter CP26 permits to adjust
the controller access time to the special demands of the feeding
operation.
The sensitivity of reaction of the control circuit towards a control
difference that has appeared is determined by the control parameters P, I
and D. These control parameters are listed on this menu page, so that
the control circuit can be adjusted to the special demands of the feeding
operation. To simplify this adjustment the calibration parameter 27
permits to select the controller automatic.

With an activated controller automatic the PID-parameters will be set


automatically. A manual input is not possible. A possible adjustment can
only be made by means of the parameter controller adjustment. Attention

The controller automatic will set the controller parameters automatically


with empirical values according to the following table:

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Output in kg/h P1 I1 D1
0 - 0.2 50 0,1 2
>0.2 - 0.5 50 0,1 1
>0.5 - 1 40 0.2 0
>1 - 10 30 0,2 0
>10 - 50 30 0,3 0
>50 - 150 30 0,5 0
>150 - 250 25 0,5 0
>250 - 500 20 0,5 0
>500 - 1000 15 1 0
>1000 10 1 0

10.5.1.1 Control adaptation

The parameter control adaptation permits to adjust the values from the
table, if necessary. You have to enter a factor, i.e.:

Input < 1 the control gets weaker


Input > 1 the control gets stronger
Input = 1 the control corresponds to the values from the table

A change of the controller parameters will change the general feeding


behaviour. Therefore, a change has to be carried through carefully.
The respect of the allowed speed range is a precondition for an
optimum feeding. The controller automatic and the entire control
process are dimensioned for a speed range of 7,5 - 75% (standard). Attention
With an increase of this speed range possible additional adjustments are
required.

10.5.1.2 Grav. calc. maximum output

Input = 0 the function is not active


Input = 1 the function is active
The gravimetric computation of the output is a measure to get a
continuous output value throughout gravimetric feeding, if the filling level
value lies within the limits "overload" and "filling level min.". After the start
of gravimetric feeding the feed rate is measured and memorised for a
period of 20s. Then the computation will continue with an refresh time of
app. 9s.

10.5.1.2.1 Memorisation of the CM-values

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The complete speed range of the feeding operation (0-100%) is


subdivided into 5 CM-range.

Range Speed: F610-parameter


Range 1: Speed 0% – 20% Calibration 20%
Range 2: Speed 20% -40% Calibration 40%
Range 3: Speed 40% -60% Calibration 60%
Range 4: Speed 60% -80% Calibration 80%
Range 5: Speed 80% -100% Calibration 100%

The corresponding CM-value is computed according to the speed range,


then it is converted to the limit value of the range, i.e. 20%, 40%, 60%,
80% or 100% and then it is stored on menu page F610.

The CM-memory parameters


ƒ only display values that have been computed for the corresponding
ranges. Otherwise they are equal to zero.
ƒ in case of a manual input of the max. output (see chap. 10.4.2,
page 61) they are reset to zero.
ƒ after the gravimetric computation they are memorised but not taken
over for the control during a started feeding operation. It is only
taken over with a new start.
ƒ are computed linearly with a start of feeding, if the memory
parameter is equal to zero for the corresponding speed range. The
linear computation takes into consideration the neighbouring lower
and higher range the value or which is not equal to zero. The linearly
computed values will not be displayed.
ƒ are required for the computation of the jump of the manipulated
variable with a setpoint modification.

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CHAPTER 11

ALARM REPORTS/START CONDITIONS

Chapter 11 describes
ƒ the menu page F500 and
ƒ the menu page Kxx5.

Menu page F500 has the function to indicate an alarm or a


missing start condition.
Thus, the operator is informed about the status of the
individual components in case of a missing start condition of
Congrav® L/M3 (red LEDs light up).
The menu page permits to configure the reaction of the system
to some alarms. The following possibilities are available:
"alarm report with cut-out" and "alarm report without cut-out".

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11 F500: Alarm reports and start conditions


11.1 Alarm reports
The alarm reports of Congrav® L/M3 fall into two categories. The first
category [A] can be configured via the menu page "alarm configuration"
(see 11.4) and generally leads to an alarm cut-out, the second category
[M] is configured via the menu page "alarm configuration".

[A] Load cell ? valid for all types

The serial load cell data are missing, because either


ƒ the serial connection has been interrupted,
ƒ the serial connection is troubled by an external source or
ƒ the load cell or the serial interface are damaged.

[A] AT- fault valid for DBW

the AT-operation of the weigh-belt feeder was troubled, because


ƒ the belt load violates the allowed auto-tare range or
ƒ the belt load is ≤ 0 and cannot be tared.

[A] FC- fault (see chapter 11.3, page 75)

The communication with the serial drive regulator that has been selected
is disturbed. You have to find and eliminate the cause for this trouble.
Malfunctions of the communication with the drive regulator have a
negative impact on the control behaviour of the Congrav®.

[A] Softstart fault valid for DDW

The softstart has computed an unallowed output value, because


ƒ the speed for the softstart has been selected too low or
ƒ the computation has been disturbed by external alarms

[A] CO- fault valid for all types

This alarm report appears if the bus communication is troubled during a


started feeding operation.

[A] EE-, MM-error valid for all types

Memory module fault, to find the cause for these faults it is required to
contact the BRABENDER service department.

[A] Data reset valid for all types

This report will be displayed after each data reset (F210) or after the
function "recipe init" has been carried out.

[M] Speed min. valid for DDW, DBW

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The minimum speed has been fallen short of, because either
ƒ the value determined for minimum speed is too high,
ƒ the parameter digital speed (CP20) has been adjusted incorrectly,
ƒ the speed reading of the Congrav® is defective,
ƒ the setpoint is to small for the dimensioning of the feeder or
ƒ the PID-controllers have been adjusted incorrectly.

[M] Speed max. valid for DDW, DBW

The maximum speed has been exceeded, because either


ƒ the value determined for maximum speed is too small,
ƒ the setpoint is too big for the dimensioning of the feeder or
ƒ the PID-controllers have been adjusted incorrectly.

[M] Underload valid for DDW

The hopper filling level has fallen short of the min. quantity, because
ƒ the hopper has not been refilled,
ƒ the limit values underload and filling level min are to close to one
another,
ƒ the overload protections have been adjusted incorrectly or
ƒ the mode gravimetric discharge has been selected.

[M] Underload valid for DBW

The minimum belt load has been fallen short of, because
ƒ no product or too little product on the belt
ƒ the feeding belt stands still (e.g. slippage on the drive roller),
ƒ the slide valve on the inlet has been adjusted incorrectly or
ƒ the parameterisation is not adjusted to the operating conditions.

[M] Overload valid for DDW

The hopper filling level has exceeded the max. quantity, because
ƒ the limit values overload and filling level max are too close to one
another for the refill operation or
ƒ too much product been refilled into the hopper,
ƒ the DDW has been overloaded by an external charge.

[M] Overload valid for DBW

The maximum belt speed has been exceeded, because either


ƒ the slide valve on the inlet has been adjusted too high or
ƒ the parameterisation is not adjusted to the operating conditions.

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[M] Refill fault valid for DDW

The min. filling level has not been exceeded within the determined refill
time, because
ƒ the feeder has not been refilled (failure in the upstream filling
device),
ƒ the digital output refill is defectuous or
ƒ the refill quantity is too small compared to the setpoint.

[M] Control difference pos. / neg. valid for DDW

The control difference took longer than the alarm cut-out time, because
either
ƒ the PID controllers have been adjusted incorrectly,
ƒ the PID controllers build up due to external perturbations,
ƒ the filter limits are constantly violated and thus the control is too
much attenuated,
ƒ the screw is not filled with product (e.g. bridging) or
ƒ product pours out of the upstream filling station

[M] Control difference pos. / neg. valid for DBW

the control difference took longer than the alarm cut-out time, because
either
ƒ the PID controllers have been adjusted incorrectly,
ƒ the PID controllers build up due to an inhomogeneous product layer
on the belt or
ƒ the belt slides over the drive roller (slippage!)

[M] AV-fault valid for DDW

The violation of the filter limits took longer than the AV-cut-out time,
because either
ƒ the filter limits that have been entered are too small,
ƒ due to external perturbations the filter limits have been continuously
violated or
ƒ the PID controllers have been adjusted incorrectly.

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11.2 Missing start conditions

With single operation the feeding operation can only be started, if all start
conditions of the corresponding component have been complied with.
With group operation or master/slave operation the feeding operation
can only be started, if the start conditions of the selected components
have been complied with.

Exception for a DDW:


Exception: the start condition weight < min. In this case, a start order
immediately activates refilling.

However, you have to make sure that the weight value in the hopper has
to be higher than the underload mark, otherwise there is an immediate
alarm cut-out of the component after the start. Caution:

Start condition Meaning and causes


x = 01..16
Bulk density ? Missing input of bulk density for the DDW (Kxx1).
Output =0 Missing input of output value for the DDW (Kxx1). The output value
can be defined by an input or by carrying out the mode check. max.
output.
Min<underload The filling level limits have to correspond to the following order:
Min > Max Underload < fill. level min < fill. level max < overload
Max>overload
Weight < Min. The product quantity in the hopper of DDW is inferior to the
minimum filling level.
It is possible to start the feeder with this start condition. The start
automatically activates the refilling.
Tare weight=0 Missing input of output value for the DBW (Kxx1). The auto-tare
value can be defined by an input or by carrying out the mode auto-
tare.
SP > max. output The setpoint violates the setpoint limitation. This start condition will
only be displayed with group or master/slave operation, if a
component has been selected after the input of the master or group
setpoint.
Calibration? With a CP-FlowMeter all calibration factors are = 0. For a start at
least one calibration factor has to be > 0.
FU Start. Missing The serial drive controller has not been recognised.
Weight signal ? The serial load cell is not recognised.
Speed Coriolis Is only displayed for a Coriolis Mass Flow Scale with digital speed
reading (tacho mode=1). The speed that has been read in is
inferior to or equal to 50% (nominal speed of a Coriolis Mass Flow
Scale =100% !).

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11.3 Error code for an operation with a serial drive controller


11.3.1 Serial frequency converter FC-V_

Alarm report Error Cause Remedy


FU-Error 11 Short circuit Short circuit ƒ Check whether motor lines
on the drive have a short circuit
side, e.g. ƒ Check the motor
caused by ƒ Substitute the damaged motor

ƒ Damaged motor line


ƒ Turn-to-turn fault in the motor
FU-Error 12 Shorts to earth ƒ Shorts to earth or line capacity ƒ Check whether motor lines
too big (reactive power) have a short to earth
ƒ Decrease the line capacity
FU-Error 13 Overload during ƒ Run-up time (C012) has been ƒ Increase the run-up time
run-up or short- set too short ƒ Check the wiring
circuit ƒ Damaged motor line ƒ Check the dimensioning of the
ƒ Turn-to-turn fault in the motor motor
ƒ Substitute the damaged motor
FU-Error 14 Overload during ƒ Operating time (C013) has ƒ Increase the operating time
run-up been set too short
FU-Error 15 Overload ƒ Accelerations with overload ƒ Check the setting of the device
occur frequently or are too long ƒ Check the dimensioning of the
ƒ Too high load with constant motor
speed
FU-Error 16 Motor overload ƒ Continuous current too high ƒ Check the setting of the device
ƒ Accelerations with overload ƒ Check parameter C120
occur frequently or are too long
FC-Error 22 Overvoltage error ƒ Overvoltage of the mains takes ƒ Check the mains voltage
longer than 5 seconds ƒ Frequency converter has to be
operated with permissible
mains voltage
FC-Error 50 Excess temperature ƒ Ambient temperature > 40°C ƒ Cool down the device
dissipator ƒ Incorrect fitting position ƒ Provide a better aeration of
ƒ Dissipator extremely dirty the device
ƒ Vertical mounting!
ƒ Clean the dissipator
FC-Error 76 Error during ƒ More than 8 error indications ƒ Eliminate the causes for the
automatical error during a period of 10 min. errors that have occurred.
reset
FC-Error 91 External error ƒ Signal via the external input "Trip ƒ Check external encoder
set" ƒ Substitute the damaged
encoder

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11.3.2 Vibration amplitude controller DRS2

FC-Error 1 Overload ƒ Load in the feeding tray too ƒ Reduce the product layer in
heavy the feeding tray.
FC-Error 2 Calibration error ƒ Reverse poling of the tacho ƒ Check the wiring
connection ƒ Change the poles of the tacho
ƒ Damaged tacho connection connection
ƒ Damaged tacho ƒ Substitute the damaged tacho

11.4 Kxx5: The alarm configuration

K015 I=off | GF GF GF GF GF GF GF GF
| GF GF GF GF GF GF GF GF

Alarm configuration The configuration status of the alarme:


HS-type feeder 01 Position the cursor on the corresponding line
(e.g. overload) and commute the
S+ Speed minimum cut-out configuration status by means of the CR-key.
S+ Speed maximum cut-out
D- Control diff. negative cut-out
D+ Control diff. positive cut-out
OL Overload report only
UN Underload cut-out
RF Refill cut-out
AV Anti-vibration cut-out

An alarm report with alarm cut-out has the function to protect the
weigh-feeder from damage that might possibly be caused by the alarm
(e.g. overload). Thus, a modification of the alarm configuration always
Attention
has a negative impact on the protection of the weigh-feeder.

Alarm cut-out (= switch-off)


With an alarm cut-out the feeding operation of the component will be
stopped immediately after the alarm has occurred. The alarm of this
component stops all selected components, if the option alarm stop has
also been selected. A start of the component or a collective start of all
selected components is only possible after the reset of the alarm. An
alarm cut-out is displayed as follows
ƒ red flashing LED (component)
ƒ red flashing start-LED (of a selected component)
ƒ flashing mode display
ƒ the digital output "alarm" is set
ƒ the digital output "alarm of a selected component" (CDIO, optional)
is set (for a selected component).

Alarm report (= report only)

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In case of an alarm report without alarm cut-out, the feeding operation of


the component and the feeding operations of the other selected
components will not be stopped. The frozen mode display is only
refreshed after the reset of the alarm report. The stop of the feeding
operation cancels the alarm report and resets the digital output alarm
report that has possibly been set. An alarm cut-out is displayed as follows:
ƒ frozen mode display
ƒ dig. output alarm report set.

Overload report only during gravimetric feeding


If the hopper filling level exceeds the overload value that has been
determined there is only an alarm report, accompanied by an automatic
switch-over to volumetric feeding. The volumetric feeding operation
continues until the hopper filling level has fallen short of the overload
value. As soon as the hopper filling level has left the overload range, the
gravimetric feeding operation starts and the alarm report will be reset.

Refill fault report only during gravimetric feeding


The hopper filling level does not exceed filling level minimum (CP17)
during the max. refill time (CP21), there will be a report about the refill
fault and the feeding switches back to gravimetric feeding operation. The
gravimetric feeding operation will run on until the hopper filling level has
reached the limit value underload which will lead to a cut-out or a report,
depending on the configuration.

If there is no alarm cut-out in case of underload, mechanical damage


risks to be caused as the screw is not filled with product while the speed
is constantly rising (controller!). Attention

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CHAPTER 12

HARDWARE CONFIGURATION AND


HARDWARE FUNCTIONS

This chapter deals with the following aspects of the hardware


configuration
ƒ Assignment of the functions and
ƒ Software support

Both points, i.e. the assignment of the functions and the


software support are a function of the software employed. The
following chapter only takes into consideration the software
version that is indicated on the cover of this manual and that is
described in this manual.

The configuration of the hardware is provided on several menu


pages of the software of Congrav® L/M3. This chapter only
indicates the corresponding menu pages and describes the
corresponding parameters and their setting. For cross-
references to other menu pages the page numbers of the
menu pages are indicated, e.g. (F110). Also, the parameter
description is accompanied by the menu page, where this
parameter is listed.
(e.g. F160: baud rate).

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12 The hardware configuration


12.1 The hardware components of the DS-controller

Menu page Kxx8 (xx = 01 – 16) permits to configure K018=off


Stopped
|

I/O-configuration
ƒ the digital input 1 of the DS-controller **-type feeder 01
Dig. input 1 0 3=F 4=S
ƒ the digital input 4 of the DS-controller Dig. input 4 0
ƒ the digital input 4 of the DS-controller Dig. output 4
Load cell type
0
1 1=IDL 2=AED 3=A
ƒ the serial interfaces of the DS-controller LC RS422/485
Drive control
1
1
1=422 2=485
1=FC 2=VC 3=A
ƒ the signal form of the analogue input/output St RS422/485 2 1=422 2=485
Analogue control 0 1=0-10V
(explanation: (see chapter 12.2.2.2.1, page 88) Act. value output 0 1=0-20mA 2=4-20mA

for the corresponding selected component.

12.1.1 The digital I/O of the DS-controller

The first three parameters on menu page Kxx8 permit to configure the
functions of the digital inputs and outputs of the DS-controller, that have
no defined function.

DI 1 Parameter Kxx8 Input Function


Digital input 1 0 Interlocking
1 Refilling
2 Grav. discharge/bypass
3 Digital speed
4 Speed monitoring
DI 2 Start
DI 3 Stop
DI 4 Parameter Kxx8 Input Function
Digital input 4 0 Interlocking
1 Refilling
2 Grav. discharge/bypass
3 Alarm reset
4 Interlocking

DO 1 Operation
DO 2 Alarm
DO 3 Refill (DDW), auto-tare (DBW), bypass (CDW)
DO 4 Parameter Kxx8 Input Function
Digital output 4 0 Control difference
1 Throughput
2 Overload
3 Underload
4 Alarm report

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12.1.1.1 Description of functioning

The digital inputs always have to be operated with a positive logic. I.e.
the functions are carried out, if a 24VDC-pulse (pulse duration 0.5s – 2s)
lies on the corresponding digital input. The only exception is the function
"interlocking". This function operates with a permanent signal and with the
logic specified for "interlocking type" in the calibration parameter (CP13,
chapter 13.2.13, page 98).

Interlocking The feeding operation will not be started as long as


the interlocking input is set.
Start The feeding operation is started under respect of the
start delay time (F310), if the system is not
interlocked or if there are no alarms.
Stop The feeding operation is stopped under respect of
the stop delay time(F310).
Al. reset Reset of alarm reports that are displayed.
Refill The refilling of the weigh-feeder is started. With a
weigh-belt feeder auto-tare operation will be started.
GD Discharge The mode "gravimetric discharge" is selected.
Immediate stop The feeding operation is stopped under respect of
the stop delay time.
Digital Speed: Speed as frequency signal (max. 10kHz).
The frequency reading is configured by means of the
calibration parameter "digital speed" (CP20).
Speed monitoring Permanent signal 24 VDC on the digital input,
the manipulated variable is displayed as speed.

For the duration of the corresponding function the digital outputs supply a
24VDC-signal. The only exception is the function "throughput".

Operation The feeding operation is started.


Alarm The feeding operation has been stopped due to an
alarm.
Refill Weigh-feeder: Refilling is active
Belt feeder: Auto-tare operation is started
Alarm report An alarm report has occurred (no alarm cut-out!).
Underload The limit value "underload" has been fallen short of.
Control diff.+- A positive/negative control difference is on.
Overload The limit value "overload" has been exceeded.
Throughput A 0,5s pulse will be emitted as a function of the
setting of the throughput divisor, if the throughput
divisor has been increased by the value of the
throughput divisor.

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12.1.2 Configuration of the interfaces of the DS-controller

The DS-controller offers two serial RS485 or RS422 interfaces for each
component. These interfaces permit to respond the serial load cells and
the drive controller. It only supports load cells and drive controllers the
serial protocols of which are integrated in Congrav® L/M3.

12.1.2.1 Supported load cell types and their configuration

IDL/F Digital one-wire-load cell. With an Eexi-design the


RS422 connection of the load cell is provided via the connection
card BT1094 or BT1096.
IDL/F 2 Digital one-wire-load cell with digital filter technique.
RS422 Supplies a serial weight signal.
ED60 Digital two-wire-load cell. The connection of the load cell
RS422 is made via the connection module BR201.
MD_ Digital two-wire-load cell. The connection of the load cell
RS422 is made via the connection module BR200-B.
AED Serial connection module for an EMS-load cell. The mV
RS422 load cell signal is processed by a digital filter technique
and converted into a serial signal.

EMS Analogue mV-load cell with the communication module


0 - 10VDC BT0296 for a signal range 0-10VDC.
Throughput Analogue throughput measuring instrument (e.g. Micro
0 - 10VDC Motion) that supplies a 0-10VDC standard signal. These
measuring instruments are employed for the mode
"volumetric regulation" (see chapter 10.4.6.2, page 64)

Precondition for the analogue weight reading:


An analogue input that is configured accordingly is available.

Kxx8: Load cell type:


The indication of the load cell type activates the corresponding weight
reading on the Congrav® L/M3.
1: IDL/F-, ED60- or MD-load cell (serial weight signal)
2: AED-module (serial weight signal)
3: analogue weight signal, 0-10VDC or 2-10VDC.

Kxx8: WZ RS422/RS485
Signal form of the serial weight signal for the load cell types 1 and 2. The
possible inputs are displayed to the right of the input field.

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Figure 12-1 shows an overview of the standard weighing systems and the
possible signal forms. The communication modules are external sub-
assemblies for
ƒ the electrical supply and
ƒ the electrical connection of the load cells to the Congrav® and
ƒ are mounted to the feeding device (junction box) or in the control
cabinet of the Congrav®.
A standard connection plan describes the connection to the Congrav®.
The standard connection plans are not included in this manual, please
find them enclosed in the documentation folder.

Feeders Hopper scale


Weighing syst.

Platform Belt Hybrid Platform Platform Platform Hopper Micro-


scales feeders systems scales scales scales scales Batch
DDW-H3_
PW1 .... DBW .... DDW-H2_ P1 .... P8 B4.2 - B9 MD
DDW-H1_
Load cells

DMS IDL/F IDL/F2 ED60 ED60(MD) ED60 DMS


analogue, digital, digital, digital, digital, digital, Analogue,
6 Wires 1 Wire, 1 Wire, 2 Wires, 2 Wires, 2 Wires, 6 Wires,
mV TTL RS422 Frequ. Frequ. Frequ. mV
Interposition modules

BT0296 AED BT1094 BR201 BR200-B BR201 AED

In: 0-20mV In: 0-10mV In: TTL In: Frequ. In: Frequ. In: Frequ. In: 0-10mV
Out: 0-10VDC Out: RS422 Out: RS422 Out: RS422 Out: RS422 Out: RS422 Out: RS422

mV 0-10VDC RS422 RS422 mV


EX-proof area

DMS IDL/F ED60 ED60(MD) ED60 DMS


analogue, digital, digital, digital, digital, Analogue,
6 Wires, 1 Wire, 2 Wires, 2 Wires, 2 Wires, 6 Wires,
mV TTL Frequ. Frequ. Frequ. mV

KFD2-WAV-Ex1 Ex-proof buffer Ex-proof buffer Ex-proof KFD2-WAV-Ex1


amplifier amplifier buffer ampl.

BT1096R1 BR201 BR201


mit BR200
EX-free area

0-10VDC RS422 RS422 0-10VDC

Figure 12-1: Overview weighing systems and weight signals

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12.1.2.2 Configuration of the drive controller

At present, the following drive controllers are supported:

FC-V_._ Frequency converter for a threephase drive. The field bus


RS485 module is required for the serial connection.
FC-S_ Frequency converter for a threephase drive. The field bus
RS485 module is required for the serial connection. The FU-S_-
series has been replaced by the FC-V_-series.
DRS2 Vibration amplitude controller with vibration amplitude
RS422 o. RS485 feedback for a vibrating conveyor as feed drive.

Other foreign devices can only be connected in analogue manner to the


Congrav® L/M3. I.e. the Congrav® L/M3 has to be equipped with one
optional analogue card at least, so that sufficient free analogue
inputs/outputs are available. Examples for devices with an analogue
connection:

806273E Drive controller for a d.c. drive.


0 - 10VDC
RMS2 Vibration amplitude controller with vibration amplitude
0 - 10VDC feedback for a vibrating conveyor as feed drive.

Kxx8: Drive control


Selection of the drive controller that is connected to the Congrav® L/M3.
The possible inputs are displayed to the right of the input field.
FC: The drive controller FC-V_ permits to drive a threephase
current drive.
DRS2 The drive controller DRS2 permits to drive a vibrating
conveyor.
A: The drive controller is driven in analogue manner. For this
purpose, an optional analogue card with the corresponding
configuration on menu page Kxx6 is required (chap.12.2,
84ff).

Kxx8: WZ RS422/RS485
Selection of the interface type of the drive controller. The possible inputs
are displayed to the right of the input field.
Standard solution for an FC-V: RS485

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12.2 The configuration of the optional analogue card(s)

Each analogue cards offers the following extensions for the hardware of
Congrav® L/M3
ƒ 8 digital inputs and outputs
ƒ 4 analogue inputs and outputs

12.2.1 The digital inputs and outputs of the analogue card

The menu page Kxx7 (xx = 01 – 16) lists the K017 I=off |
Stopped
available functions for the digital inputs and Digital configuration
**-type feeder 01
outputs and permits the assignment of their DI Interlocking 00 DO Operation 00
DI Start 00 DO Alarm 00
components and functions. DI Stop 00 DO Refill 00
The digital inputs and outputs of the available DI Al. reset 00 DO Alarm report 00

analogue cards in a Congrav® L/M3 are DI


DI
Refill
G-discharge
00
00
DO
DO
Underload 00
Control diff+- 00
numbered continuously. I.e., DI Immediate stop00 DO Reserve 00
DI Reserve 00 DO Overload 00

1. Analogue card DI 01 – DI 08 and DO 01 – DO 08


2. Analogue card DI 09 – DI 16 and DO 09 – DO 16
3. Analogue card DI 17 – DI 24 and DO 17 – DO 24
4. Analogue card DI 25 – DI 32 and DO 25 – DO 32

The assignment function – digital input or function – digital output is


provided by the input of the continuous number of the digital input or
output. An example may serve to make this clear:

DI Start 12 the 12th digital input = DI 04 of the 2nd analogue


card

The assignment component (weigh-feeder) – configuration DI/DO is


made by means of the numbering of menu page K017 – K167. The
menu page illustrated above has the menu page number K017, i.e. the
inputs are valid for the component 01.

After having modified the assignment of functions, a correction of the


wiring is always required. Otherwise considerable functional failures
might be caused, e.g. by responding a wrong periphery. Attention!

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12.2.2 The analogue inputs and outputs of the analogue card

As far as the analogue inputs and outputs of the optional analogue card
are concerned, two types of functions are distinguished:
ƒ Installation functions for the selected components. With the
configuration of these functions no component is assigned to the
function, therefore it is carried through on an F-menu page.
ƒ Component functions are only assigned to the corresponding
component. These functions are always configured with a K-menu
page, as the menu page permits the assignment to the
corresponding component.

12.2.2.1 Installation control and actual value of the installation

analogue installation control:


With the modes group, 100%-group and master/slave it is possible to
control the group or master setpoint by means of an analogue signal.
The following features apply to the analogue control (AC):
AC-signal = 0(2) VDC act. SP = 0 kg/h AC features
AC-signal = 10 VDC act. SP = group/master setpoint (F300)

Signal range = 0-10VDC Signal range = 2-10VDC Example:


Group setpoint = 100 kg Group setpoint = 100 kg
AC-signal = 4 VDC == 40% AC-signal = 6 VDC == 50%
act. SP = 40%*100 = 40 kg/h act. SP = 50%*100 = 50 kg/h

analogue actual value of the installation:


The total actual value (= sum of the actual values of all selected
components) can be emitted as analogue actual value signal.
The following features apply to the actual value signal (AV):
AV-signal = 0(2) VDC act. Value = 0 kg/h AV features
AV-signal = 10 VDC act. value = total output (F170)

The menu page F170 permits the configuration for the installation control
and the actual value of the installation, it has to be called up by means of
the parameter "analogue configuration" on menu page F100.

12.2.2.1.1 The parameters of menu page F170

The activation/deactivation of the installation control


ƒ Place the cursor on the menu point "analogue control".
ƒ Push the CR-key.

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ƒ The status of the analogue control will change (off Ù on)

Determine the signal range of the installation control


ƒ Place the cursor on the menu point "analogue control".
ƒ Push the cursor-key right once and thus place the cursor to the signal
range.
ƒ Push the CR-key.
ƒ The signal range will change (0-10V Ù 2-10V)

Display of the analogue control signal


The third parameter in the line "analogue control" displays the actual
control signal in [%].

Analogue input
The parameter "analogue input" permits to define the analogue input by
the input of the continuous number of the analogue input.

1. Analogue card AI 01 – AI 04 and AO 01 – AO 04


2. Analogue card AI 05 – AI 08 and AO 05 – AO 08
3. Analogue card AI 09 – AI 12 and AO 09 – AO 12
4. Analogue card AI 13 – AI 16 and AO 13 – AO 16

Analogue actual value of the installation


The analogue actual value is configured as a function of the analogue
control.

Total output
With an analogue actual value output the value entered is assigned to a
10VDC-signal.

Throughput divisor installation


The input in kg or lb determines the value for the throughput counter of
the total throughput. The throughput divisor can be defined in a range
between 0.001 to 999999 [kg] or [lb]. The input should be selected so
that the internal counter has at least 0.1% of the max. output of the
selected components.
The max. value of the throughput display depends on the throughput
divisor:
ƒ Divisor < 60g max. value = 16,7772 106 x divisor
ƒ Divisor = 1kg: max. value = 999,999kg
ƒ Divisor = 10kg: max. value = 999,990kg
ƒ Divisor = 1,000kg: max. value = 999,000kg etc.

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The throughput counter is reset taking into account the carry after having
reached the maximum value. For the connection of an external counter
you require the optional extension card L/M3-CDIO.
The digital output total throughput is available on the optional extension
card L/M3-CDIO. The digital output can emit a maximum of 3600
pulses/h. This has to be taken into account for the definition of the
throughput divisor.

ΣRated outputs of the selected components = 1000 kg/h Example:


max number of pulses = 3600/h
max. allowed divisor = 1000/3600 = 0,27777
recommended input = 0.280 kg or higher

12.2.2.2 The analogue component functions

The analogue inputs and outputs for the K016 I=off |


Stopped |
individual components are configured on the Analogue configuration
**-type feeder 01
menu page Kxx6 (xx = 01 – 16). This menu
AI Load cell 00
page displays the supported functions of the AI Speed 00
analogue inputs (AI) and the analogue outputs AI Control 00

(AO). The menu page permits to assign the AO Manip. var. 00


AO Act. value 00
components.

In the illustration:
"K016" means that the definitions are valid for component 01.
At present, the following functions are supported
ƒ Load cell, analogue input for the analogue weight reading,
ƒ Speed, analogue input for the analogue speed reading,
ƒ Control, analogue input for the analogue single control,
ƒ Manipulated variable, analogue output for the analogue speed
signal to the drive controller,
ƒ Actual value, analogue output for the actual value of the component,
supported.

It is recommended to note the configuration of the analogue card(s) for


later activities. Please find the corresponding form in the appendix
(chap. 16.5, page 125).

In case of a modification of the software configuration without the Attention!


corresponding modification of the wiring, functional failures might occur
that endanger the operating staff or cause damage to the hardware.

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12.2.2.2.1 The definition of the signal range for the analogue I/O

The definition of the signal range for the analogue inputs/outputs on


menu page Kxx8 (x= 01 ... 16) is carried through with the following
parameters.

Kxx8: analogue control


Permits to configure the signal range for the analogue control of the
corresponding component (single control). The assignment of the
analogue input is made on the menu page Kxx6.
0: function deactivated
1: 0 - 10VDC

The following features apply to the analogue single control (AC):


AC-signal = 0(2) VDC act. SP = 0 kg/h AC features
AC-signal = 10 VDC act. SP = max. output (CP02)

Kxx8: Actual value output


Permits to configure the signal range for the analogue control of the
corresponding component (actual value of the component). The
assignment of the analogue input is made on the menu page Kxx6.
0: Function deactivated
1: 0 - 10VDC
2: 2 - 10VDC

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12.3 The configuration of the LM3-CDIO

The digital inputs and outputs of the LM3-CDIO-extension card are


assigned to determined functions that cannot be configured by the
software. Opposite to the digital inputs/outputs of the DS-controller and
the analogue card that are assigned to a component, the digital I/O of
the LM3-CDIO function for the complete installation. These functions
address all components or all selected components (SE-C).
The digital inputs always have to be operated with a positive logic. I.e.
the functions are carried out, if a 24VDC-pulse (pulse duration 0.5s – 2s)
lies on the corresponding digital input. The only exception are the
functions "interlocking" and "key switch". These functions are operated
with a 24VDC permanent signal.

Digital inputs
DI Function
DI1: Installation interlocking, all weigh-feeders are interlocked
DI2: Collective start, all selected components are started
DI3: Collective stop, all selected components are stopped
DI4: Collective reset, all alarms of the selected components are reset.
DI5: Key switch, the inputs on the menu pages with the option I=on
are interlocked
DI6: Immediate stop without stop delay times

For the duration of the corresponding function the digital outputs supply a
24VDC-signal. The only exception is the function "pulse throughput".
Each time the total throughput will reach an integer multiple of the divisor
that has been adjusted, a 0,5s-pulse will be emitted.

Digital outputs
DI Function
DO1: All selected components have started
DO2: Alarm of one selected component
DO3: Total throughput pulse output (max. 3600 pulses/h)
DO4: Start condition of one selected component is missing
DO5: Communication error
DO6: Reserve

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12.4 The modem configuration

The serial interface XS1.3 (attention: RS422!) F160 I=off |


Stopped
of the MSIO-card permits to connect a Modem

modem for remote maintenance purposes. Status


Baud rate 9600
The parameters for the configuration and
operation of the modem are available on Phone number 0049,203,9984133

menu page F160. Dial


Interrupt
Maximum timeout 060 s

F160: Status:
Indicates whether the system is connected to
the telephone network (online or offline).
F160: Baud rate:
Determination of the baud rate for the transmission. The menu page
F171 supports the settings 9600, 19200 and 38400.

F160: Phone number:


Input of the phone number via the numeric keys:
ƒ maximum length of 18 characters,
ƒ all numbers,
ƒ a possible code selector and
ƒ all interval signals (decimal point in the numeric key bloc)

F160: Dial

Start dialling
F160: Interrupt

Stop the modem operation.


F160: Max. timeout
Timeout for a connection without data transfer. Values between 0 and
900s are possible.

The Congrav® L/M3 supports modems that employ the extended


HayesTM AT command set. For other modem types it is necessary to
change the initialisation strings of Congrav® L/M3. This modification is
only possible via the host computer interface Siemens RK512 or with the
PC software Smart Service. The telegram has a length of 28H and Attention
includes 4 strings with 20 characters each. The strings are transmitted
according to the fixed order Init 1/Phone string/Init 2/Phone number.

Standard setting: AT&F/ATS0=1&D0&C1/ATX3DT/0049,203,9984133

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12.5 Configuration of the host computer operation


12.5.1 The host interface on the MSIO-card

The parameter host computer on menu page F100 permits to select the
menu page F120 for the configuration of the host computer operation. If
it has been configured, you quit the menu page by means of the menu
item return. The menu items bus address and bus mode configure an
optional bus module (e.g. ProfiBus), please see chapter 12.5.2.

F120: Procedure
The parameter procedure permits to call up the menu page F121 with the
available host computer procedures. The selection of a procedure
activates the host computer operation.

F121: Brabender PT03


For the connection of a Congrav® PT03 to the interfaces XS1.1 and
XS1.2 of the LM3-MSIO-card.

F121: Siemens RK512


The telegram structure is corresponding to the specifications for the
Siemens RK512 with 3964R. Please find a description of all functions of
the procedure in the corresponding manual.

F121: Siemens RK512-L


The Siemens RK512 interface protocol is based on the Congrav® L. The
interface protocol is selected for the connection of a Congrav® L or
Congrav® PT03-L.

F120: Baud rate


Adjustment of the transmission speed on the host interface.

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12.5.2 Configuration of the ProfiBus DP-operation

The ProfiBus-interface is only available in combination with the optional


ProfiBus-module. The systems file (GSD-file) is required for the identifi-
cation of the Congrav® L/M3 on the ProfiBus. This file is delivered on a
Important
disk together with the manual of the ProfiBus-interface.

The bus interface is configured on the menu page F120.

F120: Bus address


The input of the bus address for the ProfiBus-operation permits to activate
the corresponding bus interface. After the input of the bus address the ID-
code Com-DPS is displayed to the right of the bus address. This code
identifies the Congrav® L/M3 on the ProfiBus.

F120: Bus-Mode

Determination of the transmission in real number format


00: Standard
01: High and Low-Byte exchanged

Example:
Real number 1,052 in hex: 3F 86 A7 EE
Bus mode = 00 86 3F EE A7
Bus mode = 01 3F 86 A7 EE

12.5.3 Configuration of the ControlNet interface

The ControlNet interface is activated automatically, if a ControlNet-


module is plugged into the Congrav® L/M 3.

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CHAPTER 13

THE CALIBRATION PROGRAM

The chapter describes the calibration parameters on menu


page F600, in short: the calibration program.
The calibration program consists of a list of parameters
required for the adaptation of the software to the feeding
system employed. Further parameters are managed by the
additional calibration program.
Push the F6-key to call up the calibration program. The
calibration program is managed as a function of the
components. Push the K-keys to select the component. For this
reason, the operations level (K-pages) cannot be called up by
means of the K-keys, if the calibration program is opened.
To quit the calibration program you push one of the function
keys F1 .... F5.

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13 The calibration program


The calibration program contains all feeder parameters that are required
for an adaptation of the weigh-feeder. To protect the calibration
program, there are two ways to interlock it:
ƒ With the standard software the calibration program is interlocked
after each mains reset or reset of the RAM or EEProm. The only way
to release it is to enter the code 0843 directly after the call-up of
menu page F600 without having activated the cursor. The calibration
program can be interlocked manually, if you enter a random figure
(e.g. 0) instead of the code if the device is released.
ƒ The calibration program is generally interlocked, if the digital input
key switch is set. To release it you have to reset the key switch
(possibly you will have to enter the code as well). The key switch can
also be set via the serial host computer interface (see interface
description).

Inputs into the calibration program lead to a complete change of the


feeding behaviour of the weigh-feeder. For this reason the changes must
only be done by authorised and specially trained operating staff. The
changes have to be noted in the corresponding lists, so that they are Attention
available in case of a possible service support by telephone.

They are divided into two parameter lists.


ƒ the feeder parameters and
ƒ the additional parameters
The F6-key calls up the feeder parameters. To call up the additional
parameters you activate the F6-key and then the right cursor key. A jump
back to the feeder parameters follows after a new activation of the F6-
key.
The calibration parameters can only be changed if the feeder is stopped.
Only exception: the following parameters can be changed if the feeder
has been started:
Filling level min (CP17), Filling level max (CP18), maximum refill time
(CP21), stabilisation time (CP23) and control difference (CP11).

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13.1 The feeder parameters

Feeder parameters Value range Standard Input


01 Feeder type H/-/C/G/- 0-5 0
02 Weighing range 0.1 - 10000 kg 60
03 Maximum output 0.01 - 999999 kg/h 100
04 Underload 1 - 100 % 10
05 Overload 1 - 100 % 90
06 Coarse tare 0 - 100 % 0
07 Average weight acq. 2 - 32 8
08 Throughput divisor 0.001 - 1000 kg 1
09 Speed minimum 0 - 100 % 2
10 Speed maximum 0.1 - 100 % 99
11 Control difference 0.1 - 100 % 1
12 Alarm cut-out time 1 - 600 s 60
13 Type of interlocking 0-3 0
14 Indication of actual value 1 - 20 s 2
15 Lever arm factor 0.1 - 10000 1
16 Hopper volume 1 - 100000 l 200
17 Filling level minimum 1 - 100 % 30
18 Filling level maximum 1 - 100 % 60
19 Window/K1/Filter 1 - 10 6
20 Digital speed 0–6 kHz 0
21 Maximal refill time 1 - 600 s 60
22 Refill optimise 0 - 100 0
23 Stabilisation time 1 - 60 s 15
24 Sampling time 1 - 600 s 60
25 AV-cut-out time 1 - 600 s 90
26 PID controller access time 0.2 - 60 s 0,5
27 Control automatic 0 - 15 1
28 Filter limits 120 - 5000 % 500
29 Adapt. of actual value 0-5 3
30 Adapt. of manip. variable 0 - 100 % 0
31 Adapt. of actual val. VR 0.1 - 10 1
32 Alarm delay time 0 - 600 s 8
33 Length weighing bridge 0.1 - 10 m 0.412
34 Weight test value 0.1 - 10 1
35 Adaptation 0.1 - 10 1
36 Auto-tare range 1 - 50 % 10
37 No load time auto-tare 0 - 600 s 60
38 Rated belt speed 0.01 - 1000 m/min 20
39 Belt length 0.01 - 1000 m 2.390
40 Dead-time way 0.01 - 10 m 0.8
Parameters in bold type can be changed after the start of the feeder

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13.2 Explanation of the functions of the feeder parameters


13.2.1 CP01 - Feeder type H/G/C

Input of the feeder type of the connected weigh feeder.


0, 2, 5: Æ must not be selected
1: Loss-in-weight feeder (H-type)
3: CP-FLowMeter (C-type)
4: Weigh-belt feeder (G-type)

13.2.2 CP02 – Weighing range

Input of the actual weighing range of the weigh-feeder, it results from


multiplication of the weighing range value of the load cell with the
mechanical lever of the loss-in-weight feeder (DDW).
In case of a weigh-belt feeder (DBW) and a CP-FlowMeter the input
equals the weighing range of the load cell.

The actual weighing range of the weigh-feeder must never be exceeded,


as the load cell risks to be damaged despite the mechanical protections.
The damaged load cell must not be treated as equivalent to a load cell
that is out of function, because it also means a modification of the load Attention
cell characteristics (linearity). This would lead to an inaccurate feeding.

Definition: usable weighing range


The usable weighing range that is available for the feeding operation is
computed from the following feeder parameters:
(act. weighing range x lever factor) – tare ⇔ (CP02 x CP15) - CP06
(hopper contents x bulk density) ⇔ CP16 x bulk density
if
(hopper contents x bulk density) < (act. weighing range x lever factor)

Special function with the mode volumetric regulation (DDW): Special function
Input of max. flowrate in [l/min]

13.2.3 CP03 – Maximum output

The input of the maximum output in kg/h or lb/h is required for the
following functions:
ƒ Input limitation for the setpoints
ƒ Assignment of 20mA to the optional actual value outputs

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13.2.4 CP04 – Underload

The input in % is a function of the usable weighing range and defines the
minimum hopper contents (DDW) or the minimum belt load (DBW).

13.2.5 CP05 - Overload

The input in % is a function of the usable weighing range and defines the
maximum hopper contents (DDW) or the maximum belt load (DBW).

13.2.6 CP06 – Coarse tare

The input in % is a function of the actual weighing range (CP02). The


tared weight value is subtracted during the computation of the weight.
The parameter has the function the reduce mechanical preloads so far
that an auto-tare operation can be carried out. For this purpose, coarse
tare is determined in such a way that with an empty weigh-feeder a
positive weight value < 5%* weighing range can be displayed after the
input of the coarse tare value.

13.2.7 CP07 - Average weight acquisition

The input defines the number of measuring values for the calculation of
the average values.

13.2.8 CP08 - Throughput divisor

The input in kg or lb determines the value for the throughput counter of


the component. The throughput divisor can be defined in a range
between 0.001 to 999999 [kg] or [lb]. The input should be selected so
that the internal counter has at least 0.1% of the max. output of the
component.
The max. value of the throughput display depends on the throughput
divisor:
ƒ Divisor < 60g max. value = 16,7772 106 x divisor
ƒ Divisor = 1kg: max. value = 999,999kg
ƒ Divisor = 10kg: max. value = 999,990kg
ƒ Divisor = 1,000kg: max. value = 999,000kg etc.
The throughput counter is reset taking into account the carry after having
reached the maximum value. At present no digital output is available for
the connection of an external counter.

Rated output of the component = 1000 kg/h Example:


max number of pulses = 3600/h
max. allowed divisor = 1000/3600 = 0,27777
recommended input = 0.280 kg or higher

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13.2.9 CP09 - Speed minimum

The input in % determines the minimum speed.

13.2.10 CP10 – Speed maximum

The input in % determines the maximum speed.


CP09 and CP10 define the limit values for the speed monitoring. If one
of the limit values is violated, there will be an alarm report with/without
alarm cut-out according to the alarm configuration (see 11.4).

13.2.11 CP11 – Control difference

The input in % is a function of the setpoint and defines the allowed max.
control difference. The control difference is only computed and monitored
in the component modes "gravimetric feeding" (GF), "gravimetric
discharge" (GD) and "volumetric regulation" (VR). If the calculated control
difference exceeds the max. permitted control difference this will be
displayed in the mode display by "D+" or "D-" and the alarm cut-out
delay time (CP12) expires.

13.2.12 CP12 - Alarm cut-out time

The alarm cut-out time entered determines the maximum time in which a
violation of the permitted control difference is allowed. If the violation of
the permitted control difference is still present after elapse of the alarm
cut-out time, there is an alarm cut-out or an alarm report. The alarm cut-
out time is reset if the violation of the permitted control difference is no
longer on.

13.2.13 CP13 - Type of interlocking

Determination of the logic of the digital input "interlocking" (DI4) and the
digital output "alarm" (DO2).
0: Interlocking = 24V Alarm output = 24V
1: Interlocking = 0V Alarm output = 24V
2: Interlocking = 24V Alarm output = 0V
3: Interlocking = 0V Alarm output = 0V

The digital input "installation interlocking" (DI1 on the LM3-CDIO) always


has the positive logic (interlocking = 24VDC).

13.2.14 CP14 - Indication of actual value

Determination and refresh time for actual value and time base for short-
term actual value.

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13.2.15 CP15 – Lever arm factor

Adaptation factor for the static weight adjustment of the loss-in-weight


feeder.

13.2.16 CP16 - Hopper contents

The input in litres is meant for the screw trough and the hopper.

13.2.17 CP17 - Filling level minimum

The input in % is a function of the usable weighing range and defines the
filling level value at which automatic switch over from feeding operation
to refill mode occurs.

13.2.18 CP18 – Filling level maximum

The input in % is a function of the usable weighing range and defines the
filling level value at which automatic-switch over from refill mode to
stabilisation time (= end of refilling) occurs.

13.2.19 CP19 - Window/K1/Filter IDL/F, AED

Generally, the value that has been entered will only be sent to the
corresponding load cell by means of the stop function. The definition of
the load cell filtering has an influence on the inertia of the signal and thus
on the control of the feeding operation.

IDL(-F), MD, ED60 load cell types


0 Filter switched off
1 .. 9 1 = weak .... 9 = strong
>9 Refresh time of the weight value = input x 20ms
The filter setting 6 should be sufficient for most of the applications. As a
general rule, a strong filter setting leads to a high interference immunity
but also a high inertia of the signal.

EMS-load cell with an AED-module:


1= no filtering .......................... 8= very strong filtering

13.2.20 CP20 – Digital speed

This parameter permits to configure the speed monitoring. Three different


types can be selected.

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13.2.20.1 Standard motion monitoring

Input <= 50Hz


The manipulated variable is displayed as speed. If the manipulated
variable is inferior to the limit value "speed min", there will be an alarm
cut-out after 6s with the report "speed min". If less than 10 pulses per
minute are sensed, there will be an alarm cut-out because of "speed min."
within 12s to 18s.

13.2.20.2 Motion monitoring for the FlexWall®plus-feeder

50Hz < input <= 500Hz


The manipulated variable is displayed as speed. The manipulated
variable is displayed as speed. If the manipulated variable is inferior to
the limit value "speed min", there will be an alarm cut-out after 6s with the
report "speed min". The cycle time for the sensing of the least number of
necessary pulses has been reduced to 2s. If less than 3 pulses are sensed
within 2s, there will be an alarm cut-out because of "speed min" within 4
to 6s.

13.2.20.3 Digital speed reading

Input > 500Hz


Input of the number of pulses with nominal speed (=100%). The alarm
report "speed min." will be displayed, if
the number of pulses read falls short of the limit value speed min. for 6s
the pulses read fall short of the dynamic limit value. The dynamic limit
value is a function of the value that has been entered in CP20. The
dynamic limit value is calculated from the integer divisor input/200. The
measuring interval for the dynamic limit value is 500ms. There will be an
alarm cut-out after 5s.

13.2.20.4 Recommended inputs

Standard : 0.010 kHz


FlexWall®plus : 0.100 kHz
Digital speed reading : the maximum speed in [kHz]

13.2.21 CP21 - Maximum refill time

Refilling is finished off on reaching filling level max or at latest after


elapse of the maximum refill time. The alarm report (with/without cut-out)
will be activated, if the refilling has not exceeded the filling level filling
level min.

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13.2.22 CP22 - Refill optimise

Inputs > 0 activate the refill optimisation. During the first refilling after the
activation the manipulated variable before refilling will be emitted during
refilling. After the refill procedure and the subsequent stabilisation time
the gravimetric feeding operation will be continued. After the start of the
gravimetric feeding operation an average manipulated variable will be
computed. The manipulated variable thus computed will be taken into
respect for the next refilling. The constant speed of the next refilling is
computed from the adjusted factor multiplied by the memorised speed.
The speed that has been computed for the refilling will be adopted if the
feeder refills and the Congrav recognises an increase in weight. The
factor will be reset after elapse of the stabilisation period, so that the
feeding starts with the memorised speed. The memorised average speed
is reset by a modification of the parameters bulk density, output, fill. level
min., overload and switching off the refill optimise.

Example:
Input = 0.9 average speed = = 30%
Speed during RF = 27%
Speed after ST = 30%

13.2.23 CP23 - Stabilisation time

After the refill period the material stabilisation time starts. After elapse of
the material stabilisation time follows the switch over to the selected
component mode.

13.2.24 CP24 - Sampling time

With this calibration point the time for sampling and the component
mode "checking max. output" (CM) is defined.

13.2.25 CP25 - AV-cut-out time

If a filter limit value is violated the AV cut-out time starts. If the filter limit
violation is still on after elapse of the AV cut-out time there is an alarm
cut-out or an alarm report. The AV cut-out time is reset if the violation of
the filter limit value is no longer on.

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13.2.26 CP26 – PID controller access time

The access time of the PID-controller can be changed. The access time
can only be a multiple of the computer cycle time of 0.2s sec.

13.2.27 CP27 - Controller automatic

Input Function
0 no function
1 controller automatic selected
4 non-repetitive start automatic selected
5 non-repetitive start and controller automatic selected
8 general start automatic selected
9 general start and controller automatic selected

The a.m. inputs are required for the activation of the corresponding
function. Other inputs in a range 0 – 15 have no function.

13.2.27.1 The controller automatic

With an activation of the controller automatic the manual controller


parameterisation on menu page Kxx2 will be blocked and automatic
setting of the parameters will be activated. The controller automatic
employs the controller parameters as per the following table:

Output in kg/h P1 I1 D1
0 - 0.2 50 0,1 2
>0.2 - 0.5 50 0,1 1
>0.5 - 1 40 0.2 0
>1 - 10 30 0,2 0
>10 - 50 30 0,3 0
>50 - 150 30 0,5 0
>150 - 250 25 0,5 0
>250 - 500 20 0,5 0
>500 - 1000 15 1 0
>1000 10 1 0

The controller dimensionings listed in the table are only reference values.
Deviations from these reference values may occur as a function of the
type of the installation and the product. This is why you have the
possibility to adjust the controller automatic with the parameter controller
adjustment to the actual feeding conditions on menu page Kxx2.

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13.2.27.2 The start automatic

If on commissioning the component mode "checking max. output (CM)"


cannot be carried out, the output must always be entered. A wrong
output has a negative impact on the complete control behaviour of the
feeder. Worst case: it might cause an alarm cut-out. With the start
automatic it is possible to determine the output after the start of
component mode gravimetric feeding during a volumetric start period
and to memorise this value subsequently.

13.2.27.2.1 Non-repetitive start automatic

The non-repetitive start automatic is selected by means of the respective


input of an output value and activated by means of an output change.
The non-repetitive start automatic is only used after the first start of the
installation and after activation of this function. All subsequent changes of
the manipulated variable due to a setpoint change or a new start of the
installation will be made with the calculated output. This results in the
following sequence for the non-repetitive start automatic:
ƒ Input 4 or 5 for CP27
ƒ Change the output (Kx10).
The chronological order of this process must always be observed because
an activation of the non-repetitive start automatic is not possible without
activation. The activation is maintained even after the non-repetitive start
automatic has been carried through, so that each change in the max.
output reactivates the non-repetitive start automatic again. The non-
repetitive start automatic is deactivated by changing the input in CP27
accordingly.

13.2.27.2.2 General start automatic

The general start automatic is carried through with each new start of the
installation. Selection and activation of the general start automatic is
made by means of the respective input (8 - 15):
ƒ Input of all necessary feeder-specific data
ƒ Activation of the general start automatic.
ƒ Input of an output value
ƒ Fulfilment of the other start conditions.
ƒ After the input of a setpoint the installation can be started. The start
of the installation is computed as follows:

y = DI_SP x (7,5V x w/Outp) y: manip.variable Outp: output w: Setpoint


DI_SP = discharge setpoint in %

In order to avoid overfeeding the manipulated variable of the start will be


reduced by the discharge setpoint (≤ 100%). Thus the security factor of

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the start automatic can be adjusted manually. If the discharge setpoint is


set to 0%, the manipulated variable of the start will be reduced by 40%.

The more exactly the output is known, the smaller the reduction may be.
In general, the setting has to permit that the start automatic can be
carried through in a speed range > 10%. Important

After the start there will be a period of volumetric feeding that will be
followed by a so-called check phase. During this check phase the loss in
product will be checked. If no loss in product can be observed, the check Product reduction =
phase will automatically be extended by 1 s each. If the max. time of the IDL,EMSAED 50ppm
4digits
check phase has been exceeded (CP12), there will be an alarm report
D+ with/without cut-out.
After the check phase the filling level will be checked. If the filling level is
located within the underload range there will always follow an alarm cut-
out. With the overload range and the alarm configuration "overload
report only" the system will feed with the manipulated variable of the start
until the filling level is beyond the limits of the overload range.
The measuring phase starts after the check phase. During this measuring
phase (total duration 20 s) 6 samples that take 15 s each, are measured.
The samples are started with a delay of 1 s with respect to the others. The
minimum and the maximum value out of these six values are not taken
into consideration, and the average value will be calculated from the
remaining 4 sample values and memorised. Directly after the start
automatic the gravimetric feeding will start with a manipulated variable
for the start that is a function of the calculated output.

Strong external perturbations might have a negative impact on the


measurement of the output and thus cause bad conditions for a safe
control.

13.2.28 CP28 – Filter limits

The control process is encompassed by a band filter during the


gravimetric feeding period. Thus, the influence of disturbances from
outside will be reduced. The absolute filter limit values are employed to
determine the maximum feeding range of an undisturbed control. If this
range is violated , e.g. by external pulse spikes, there will be an AV-
period with volumetric feeding and the start of the AV-alarm cut-out time.
I.e., the influence of the external pulse spikes is eliminated so that after
the fading of the disturbance and control will soon return to its former
sequence.
The absolute filter limit values are entered in percent as a function of the
feed rate in g/cycle. The actual filter value is displayed on menu page
Kxx3 (Fi = xxx %).

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13.2.29 CP29 – Adaptation of actual value

Adjustment of the actual value filtering for the actual value calculation:
0 = old act. val. calculation 1 = weak .... 5 = strong filtering

With the mode volumetric regulation the actual value is computed


from the average value read in. The input determines the number of Number = 2 input
average values.

13.2.30 CP30 - Adaptation of manipulated variable

Compensation of the non-linear characteristic line of the RMS1- power


unit.
The parameter setting >0 must only be employed with a RMS1- power
unit.

13.2.31 CP31 - Adapt. of actual value VR

In the component mode volumetric regulation the flow quantity or


the throughput of the product is determined by means of suitable
measuring methods. If there are measuring instruments which are I con
not suitable for calibration, i.e. these instruments cannot provide a APnew = ⋅ APold
I act
standard signal, this calibration point can be used for an adaptation
between the actual value displayed on the Congrav® (ICon) and the
real actual value (Iact).

13.2.32 CP32- Alarm delay time

After the start of the mode volumetric regulation, all possible


disturbances, like speed min. etc., are not taken into
consideration so that there will be neither a display nor a cut- ycon = 100% ×
setpo int
out caused by this disturbance. First, the system will be started output
with the constant manipulated variable ycon and after elapse
of half of the alarm delay time the control will start.

13.2.33 CP33 - Length of weighing bridge (LWB)

Correction factor for small differences between the setpoint of the DBW
(weigh-belt feeder) and the actual value of sampling.

13.2.34 CP34 - Weight test value (WTV)

Factor for the static weight adjustment of Weight test value act =
weight value
⋅ weight test vale
the strain gauge load cell of a DBW. weight display

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13.2.35 CP35 - Adaptation (AP)

Adaptation factor for the weight value and the weight weight value
APact = ⋅ AP
display of a DBW, Coriolis and CP-FlowMeter. weight display

13.2.36 CP36 - Auto-tare range

The input in % is related to the weighing range, it


determines the allowed maximum auto-tare range of a
DBW. If the mode auto-tare computes a belt load that 0 < tare value < tare range
exceeds this range or that is inferior or equal to zero, the
alarm report auto-tare error will be displayed.

13.2.37 CP37 - No load time auto-tare

Duration of the run-up phase during auto-tare.

13.2.38 CP38 - Rated belt speed

Belt feeder with dc drive:


ƒ Start discharge mode with a setpoint of 50%.
ƒ Computation of the rated belt speed:

vn = nominal belt speed in m/min


Z1 nM = outgoing speed of motor gear in rpm
Vn=2 nM⋅ dm⋅ π⋅ Z2
dm = drive roller diameter dA + belt thickness (dA = 0,12m)
π = 3,14159 Z1 = no. of teeth motor side Z2 = o. of teeth drive roller side

The factor 2 results from the ratio of the rated belt speed (=100%) to the
adjusted speed (here: 50%).

Belt feeder with threephase drive and incremental encoder:


ƒ Start discharge mode with a setpoint of 50%.
ƒ Measurement of the frequency of the incremental encoder (you can
for instance employ a digital multimeter with a frequency measuring
range).
ƒ In standard, the incremental encoder generates 100
pulses/revolution. With the use of special devices, please see the
technical documentation for the specification of the
pulses/revolution.
ƒ Computation of the rated belt speed:

vn = nominal belt speed in m/min


f m • 2 • 60 • d m • π • Z1
vn = fm = frequency of the incremental encoder in Hz with 50% rated belt speed
iU • I • Z 2
dm = drive roller diameter dA + belt thickness (dA = 0,12m)
π = 3,14159 Z1 = no. of teeth motor side Z2 = no. of teeth drive roller side
iU = rated speed I = pulses/R

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13.2.39 CP39 - Belt length

Total length of the belt of the weigh-belt feeder.

13.2.40 CP40 - Dead-time way

If after the weigh-belt feeder has been started there are less than 50 g of
product on the belt, the belt will run for this distance without regulating
and without giving alarms. (Distance between inlet and centre of
weighing bridge.)
Gravimetric feeding will be activated automatically after elapse of the
dead-time way or with a belt load > 50g.

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13.3 Additional parameters

Feeder parameters Value range Standard Input


01 Calibration 20% 0 - 10 0
02 Calibration 40% 0 - 10 0
03 Calibration 60% 0 - 10 0
04 Calibration 80% 0 - 10 0
05 Calibration 100% 0 - 10 0
06 Reserve
07 Reserve
08 Reserve
09 Reserve
10 Reserve
11 Usable weighing 0.1 - 10000 kg 5
range
12 Drop-Out 0-1
13 Tacho mode 0-2 0
14 Slip influence 0 - 10 0
15 Slip value 0 - 100 % 0
16 Tacho adaptation 0 - 10 1
17 No load time 0 - 6000 s 20
18 AT-time 1 - 600 s 5
19 Drive control 2 min. 0 – 100 % 0
20 Drive control 2 max. 0 – 100 % 0

13.3.1 AP01 - 05 Calibration

CP-FlowMeter or Coriolis-Mass Flow Scale (C-type):


Calibration values for the calibration of the CP-FlowMeter. The
calibration values 20%, 40%...100% are assigned to the corresponding
operating points. In standard the value calibration 20% is okay.

Loss-in-weight feeder (H-type):


If the H-type is selected, the individual CM-steps of the output that has
been computed are displayed. An input is not possible.

13.3.2 AP11 - Usable weighing range

The usable weighing range is the weight loading (= weight display) of the
Coriolis Mass Flow Scale with maximum flowrate. The input is rounded
up to the next integral value. I.e. with a display of app. 5,6 kg, the usable
weighing range to be noted is 6 kg.

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13.3.3 AP12- Drop-Out

This function is employed for the CP-FlowMeter or the Coriolis Mass Flow
Scale.

0 The function is deactivated. Falling short of the underload limit is


processed according to the alarm configuration.
1 If the filling level falls below the underload limit, the feeding
device remains started, while the computation of the actual value
and of the throughput are stopped and the report "Drop-Out" is
displayed. The computation of the actual value and of the
throughput are started again if the weight value exceeds the limit
value 1,1*underload.

13.3.4 AP13 - Tacho Mode

0 The speed of the drive motor of the Coriolis Mass Flow Scale is
measured by means of a tacho and controlled by the drive
regulator. The drive motor runs without slippage.
1 The speed of the drive motor of the Coriolis Mass Flow Scale is
read into the Congrav®. The slip influence on the actual value
computation is taken into account for the compensation.
2 No tacho reading in, actual value compensation by means of the
slip value.

13.3.5 AP14 - Slip influence

0 No increase of the actual value


x Decrease of the speed of the drive motor of e.g. 5% leads to an
increase of the actual value by (x * 5%).

13.3.6 AP15 - Slip value

Compensation of the influence of slippage on the actual value


computation, if there is no speed reading in. The slip value is a correction
factor that is computed as follows:
(Rated speed without load - rated speed with load)

13.3.7 AP16 - Tacho adaptation

Adaptation factor for the speed display of the Coriolis drive on menu
page Kxx3. With rated speed under no load this factor sets the speed
display to 100%.

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13.3.8 AP17 - No load time

Time that runs off after the start of the Coriolis Mass Flow Scale, before
the actual value computation and the weight monitoring starts.

13.3.9 AP18 - AT-time

Duration of the auto-tare operation with a Coriolis Mass Flow Scale. With
auto-tare operation the Coriolis Mass Flow Scale is started without
product flow and computes the average weight value for the fixed
duration. This average weight value is then stored as auto-tare value and
subtracted from the weight display.

13.3.10 AP19 - Drive control 2 min.

Configuration for a second drive controller (e.g. for a separate paddle or


agitator drive). The second drive controller receives a setpoint signal that
is proportional to the first drive controller. Drive control 2 min is assigned
to a 0%-signal for the 1st drive controller.

The parameter only configures the serial manipulated variable for a


second drive controller.
With an analogue operation of the drive controllers it has no function. Attention

13.3.11 AP20 - Drive control 2 max.

Drive control 2 max is assigned to a 100%-signal for the 1st drive


controller.

The parameter only configures the serial manipulated variable for a


second drive controller.
With an analogue operation of the drive controllers it has no function. Attention

13.3.12 Notes on AP19 and AP20

AP19 = AP20
The second drive controller is operated with a constant manipulated
variable.

AP19 = AP20 = 0
The second drive controller is not addressed.

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CHAPTER 14

HARDWARE TEST FUNCTIONS

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14 Hardware test functions


14.1 F140: Test of I/O-periphery (installation)

The printer interface and the digital F140 I=off | GF GF


| GF GF
GF GF
GF GF
GF GF
GF GF
GF GF
GF GF
inputs/outputs for the installation are
available with the optional extension card Test of I/O-periphery

LM3-CDIO.
Test off
Test: Dig.in. : 0 0 0 0 0 0 0 0 0 0 0 0
Dig.out. : 0 0 0 0 0 0 0 0 0 0 0 0 0
Test printer interface
Switches on/off the test functions. System check Rx Tx Rx Tx
Dig.in.
Displays the status of the digital inputs (1 = activated, 0 = not activated)
Dig.out.
Display of the status of the digital outputs.
With Test=on the digital outputs (1 - 12) can be set or reset. For this, the
cursor has to be set to the corresponding position and the status can be
changed by pushing the CR-key (0=not set, 1=set).
Point 13 permits to set all digital outputs at the same time.

During the test operation the digital outputs are physically activated. To
avoid failures caused by wiring please undo the plug connections of
<Undo wiring>
the optional L/M3-CDIO-card.

Test printer interface:


Output of the string: "Brabender Technologie"

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14.2 Kxx3: Status display of I/O-periphery

The menu pages Kxx3 display the status of all inputs and outputs of the
corresponding component.

01 Analogue inputs Display = 0 - 100%


Analogue input 1: analogue load cell signal 0 - 10VDC (=100%)
Analogue input 2: analogue speed signal 0 - 10VDC (=100%)

02 Analogue outputs Display = 0 - 100%


Analogue output 1: anal. manip. variable signal 0 – 20mA (=100%)
Analogue output 2: analogue act. value signal 0 – 20mA (=100%)

03 Digital inputs Display = 0 or 1


The display of the digital inputs shows the software adjustments, the
functions are listed according to their order. 0 means that the
corresponding digital input with the function belonging to is not set, 1
means that it is set. The order is as follows:
Interlocking Start Stop Alarm reset RF GD Immediate Reserve
stop

04 Digital outputs Display = 0 or 1


The display of the digital outputs shows the software adjustments, the
functions are listed according to their order. 0 means that the
corresponding digital output with the function belonging to is not set, 1
means that it is set. The order is as follows:
Operation Alarm RF Alarm report UN D+/- Reserve OL

05 Load cell Display = ppm


No serial data communication E
Preload was too small 0E
Unstable weight value 0X
Stable weight value 0Y

06 Freq. converter Display= xxx%


No serial data communication Err
Serially transmitted manipulated variable in % xxx

07 Filter limits Display= xxx%


The actual filter limits of a gravimetric feeding operation. The second
value indicates the maximum value of the last minute.

08 Coriolis drive Display= xxxkHz xxx%


The digital speed of the Coriolis drive in kHz and in %

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14.3 Kxx4: Test functions and simulation


14.3.1 The simulation mode

The simulation mode activates the digital and the analogue inputs and
outputs. To avoid false functions, the plug connections to the
corresponding interposition modules have to be disconnected on the
Congrav® L/M3 and the corresponding I/O-modules. If available, the
plug connection of the digital inputs and outputs of the optional LM3- <Undo wiring>
CDIO-card also has to be disconnected.

The simulation permits feeding operation without a feeding system being


connected. During the simulation mode no weight signal and no speed
will be read in. The simulation computes a weight value and reads in the
manipulated variable as speed. For this reason a connected feeding
system must not be operated in simulation mode. The weight functions
(refilling, filling levels, etc.) as well as the speed monitoring refer to the
simulated input values.

Commissioning of the simulation:


ƒ Select simulation Kxx4; menu point simulation
ƒ Fulfil start conditions
ƒ Enter setpoint F300
ƒ Refill Kxx0; menu point refill

14.3.2 Testing of the inputs/outputs (component)

Kxx4: Test:
Switching on/off test functions.

Kxx4: Ana. output


With Test=on the analogue outputs can be set by pushing of the CR-key
in steps of 12,5%. Only analogue outputs that have been configured for
the corresponding component will be addressed.

Kxx4: Dig. output


With Test=on the digital outputs (1 - 8) can be set or reset. For this, the
cursor has to be set to the corresponding position and the status can be
changed by pushing the CR-key.
Point 9 permits to set all digital outputs at the same time.

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CHAPTER 15

GLOSSARY

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15 Glossary
AED-module (digital sensor electronics):
An analogue EMS-load cell that conforms with the technical specifications
of the AED-module is connected to the AED-module. The AED-module
supplies the necessary voltage for the load cell and converts the mV-
weight signal into a serial weight signal. The processing of the weight
signal of the load cell is made by means of a digital filter that can be
configured via the software of the controller.

Gauging
For a fixed period (e.g. T = 60s) product is fed into an empty receptacle,
the empty weight of which is known. After this time feeding will be
stopped and the product quantity Q that has been fed out is weighed by
means of a scale.

Operating unit:
Some controller types (e.g. L/M3 B or ISC-CM) do not offer a possibility
for the parameterisation or operation. For this purpose, an operating unit
(e.g. RC3 or RC4) has to be connected serially.

Congrav®
The Congrav®-series includes several feeding controllers for gravimetric
feeding. The so-called single-controllers (= for one feeding device) and
multi-component controllers.

Digital inputs/outputs (24VDC)


The digital outputs are realised via transistors and switch the supply
voltage to the corresponding connection (= set) or block this connection
(= not set).
The digital inputs are set by connecting a 24VDC voltage between the
GND and the corresponding connection of the input. The digital inputs
and outputs are separated galvanically via optocoupler, however, they
are interconnected by means of the common GND.
Please see the chapter on technical data for the technical data of the
digital inputs and outputs.

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EMS
EMS is the abbreviation for elongation measuring strip. The EMS change
their ohmic resistance as a proportional function of their change in
length.

Loss-in-weight feeder
A loss-in-weight feeder (DDW) is a weigh-feeder that is composed of a
feeding device and a weighing system. The weighing system of the loss-
in-weight feeder weighs the content of the hopper, the weight is then read
into the feeding controller and processed.

Feeding device
A feeding device is employed for various bulk solids and liquids. A
feeding device permits to feed product out of a storage hopper. Possible
feeding devices: screws, vibrating trays, pumps, feeding belts etc. with
suitable drive motors.

Feed rate
The feed rate is the product quantity that is fed per time interval. In
standard, the units [g/h], [kg/h] or [t/h] are employed for the feed rate.

Feed rate curve


Feed rate measuring for different speed values. The feed rate curve is
measured by means of gauging.
Feed rate = Q x 3600/T [kg/h]

Weigh-feeder:
General designation of a feeding system. Please note that different types
of weigh-feeders might possibly require a specific software for the feeding
controller. The software manual indicates the weigh-feeder types that are
supported.

ED60:
Digital two-wire load cell with integrated filter technology. The connection
to the controller is provided via the corresponding processor module or
directly to the controller (ISC-CM).

Release
Electrical input of an electrical subassembly. If the release is activated, the
subassembly will be started. With a frequency converter the release
permits to start and stop the frequency converter without switching the
mains supply.

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Frequency converter
Drive controller for threephase current drives. The frequency converter
controls the threephase current drive by means of the speed input (e.g.
20%), so that the motor runs with the desired speed (not taking into
consideration the slippage etc.). The speed setpoint depends on the type
of frequency converter employed via a potentiometer or a control signal.
Generally, the speed setting is a function of the rated speed (= 100%).

Control signal
The speed setpoint for feeding is determined by an external analogue
signal (0-10VDC, 0-20mA etc.).

Gravimetric feeding:
With this mode the software calculates the actual feed rate (=actual
value) on the base of the weight signal and then compares it to the
setpoint that has been entered. The difference between the setpoint and
the actual value will be sent to the control circuit that will then change the
speed of the feeding device due to its parameters and due to the
difference.

Lever factor:
The lever factor is a constant factor that is taken into consideration for the
computation of the weight value.

Identnumber:
The identnumber is adjusted to the hardware of the ISC-CM. The
identnumber clearly characterises the ISC-CM, so that it can be
addressed via the ISC-field bus.

IDL/F:
Digital one-wire load cell with integrated filter technology. The
connection to the controller is provided via the corresponding processor
module or directly to the controller (ISC-CM).

ISC-system:
The ISC-system is a control system for gravimetric feeding based on a
field-bus. With an ISC-system the connection between the individual
feeding devices and the feeding controller is made by means of the ISC-
field bus. For an operation in an ISC-system the necessary ISC-
components are mounted to the feeding device or very close to it.
ISC-CM, the control module
ISC-CM, the drive controller module

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ISC-drive controller:
The weigh-feeder is equipped with a drive for the feeding device.
Threephase drives, vibrating conveyors or unbalance drives are employed
as a function of the execution of the feeding device. A suitable drive
controller is required for the control of the motor. At present we employ
the drive controller types ISC-FC and ISC-VC for the ISC-system.

ISC-FC:
Drive controller for a threephase drive or an unbalance drive.

ISC- VC:
Drive controller for a vibrating conveyor.

ISC-field bus:
Serial interface connection between the individual ISC-CM-modules and
an operating unit. The serial interface has been conceived for bus-
operation. A maximum of 16 ISC-CM units and an operating unit can be
connected to an ISC-field bus. The identnumber of the ISC-CM permits
the identification of the individual ISC-CM components on the ISC-field
bus.

Reproducibility:
Reproducibility means, that if you put on and take off a defined test
weight, this will always lead to the same increase or decrease of the
weight value. The reproducibility of weight sensing will be lost if the free
motion of the load cell is no longer guaranteed.

Software :
The software determines the functions of the complete controller system.

Manipulated variable:
Control signal from the controller for the drive controller. The
manipulated variable sets the speed or the vibration amplitude of the
drive motor to the drive controller. A serial interface or an analogue
output (option) permit to transmit the manipulated variable.

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Transport catches:
Transport catches permit to lock in position the mobile part of a weighing
system to a fixed point. They protect the load cell during transports and
maintenance or conversion work against an overloading of the load cell.
Especially, they protect the load cell against rotational or torsional forces.

Overload protection screw:


In most cases, overload protection screws are protective equipment for
the load cell. They permit to reduce the overloading of a load cell,
however, they do not permit to eliminate the overload. If the overload is
too big, the load cell still risks to be destroyed. Opposite to the transport
catches, the overload protection screws do not protect against rotational
or torsional forces.
The setting of the overload protection screw is protected by a paint layer
and must only be adjusted by an authorised technician specialised on
scales.

Volumetric feeding:
With this mode the program uses a constant manipulated variable. The
feed rate is not controlled via a change of the speed.

Preload:
The preload defines the minimum load that is required for an operation.
It defines the zero point for the operating range of the load cell.

Weighing range:
The weighing range of a loss-in-weight feeder is calculated from the
mechanical lever multiplied by the weighing range of the load cell. The
weighing range of the load cell is indicated on the nameplate.

Weighing system:
General designation for a weighing structure. It can consist of a simple
platform scale or of a more complex construction with an integrated load
cell.

Load cell:
The load cell measures the weight loading of the weigh-feeder, i.e. the
belt load or the hopper contents. The weight signal of the load cell is
processed by the controller according to the software.

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APPENDIX

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16 Appendix
16.1 Technical data

Voltage range 85 - 250 VAC Congrav L/M3


Frequency range 47 - 63 Hz Basic device
19 VA (basic configuration)
Power input
40 VA (max. configuration)
Ambient temperature 0 to +45°C
Transport/storage -25°C to +65°C
Humidity up to 85% without condensation
Protection Front IP65
Housing IP30
Dimensions (HxWxD) 138x280x300 mm
+ angled connector approx. 370 mm
Weight approx. 6,9 kg

Logic positive Digital inputs


Rated voltage 24 VDC
Logical "1" 10 - 28VDC
Input current 7 mA at 24 VDC
Number 8 (DS), 6 (CDIO), 8 (analogue card)

Output type Transistor Digital outputs


Logic positive
Rated voltage 24 VDC
Voltage range 21 - 28 VDC
Rated current/output 0,25 A with 50% simultaneity
Number 8 (DS), 6 (CDIO), 8 (analogue card)

Input voltage 24 VDC Frequency input


Input current 10 mA
Frequency range 0 - 10kHZ
Number 2 (DS) 2 (analogue card)

Input voltage 0 - 10VDC Analogue inputs


Resolution 14 Bit
Input resistance ~20MΩ Analogue card
Number 4

Output current 0(4) – 20mA, impressed Analogue outputs


Resolution 12 Bit
max. burden 500 Ω Analogue card
Number 4

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The potential of the analogue inputs and outputs is isolated from the
ground. The analogue inputs and outputs on a card refer to a common
ground, thus they have no potential insulation between one another.

Internal cycle time 200ms Software


MSIO-card 3 x RS485/422 (serial)
Interfaces
isolated potential
ProfiBus-module (optional) Connection to ProfiBus DP

16.2 Electromagnetic compatibility

Radio interference Conforms to EN 50081-1


Limit value A as per EN 55011
Limit value B as per EN 55022
Noise immunity Conforms to EN 61800-3
Requirement Standard Class
ESD EN 61000-4-2 4
HF-radiation EN 61000-4-3 4
Burst EN 61000-4-4 4
Surge EN 61000-4-5 4

16.3 Spare parts list

Item Designation
E000741 Basic device Congrav L/M 3A
E001143 Basic device Congrav L/M 3B
E001150 DS controller DE2404 R1
E001151 Analogue card DE2405 R1
E001000 I/O-module DS-LM3 R2
E000097 1.0m adapter cable for I/O-module-DS-LM3 R1
E000098 3.0m adapter cable for I/O-module-DS-LM3 R1
E001097 I/O-module-analogue-LM3
E001153 1.0m adapter cable ANALOGUE
E001155 1.0m adapter cable DIGITAL
E001154 3.0m adapter cable ANALOGUE
E001156 3.0m adapter cable DIGITAL
E001152 LM3-CDIO
E002031 Interposition element UBE-D/15F for DIGITAL
E002060 1.2m adapter cable DIGITAL
E002061 3.0m adapter cable DIGITAL
E000072 Fixing clips
E000075 Fuse MT5x20
E001337 Cable socket 43R01.1111

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16.4 List of the possible mode displays

The following table lists all possible mode displays, no matter whether
feeding is started or stopped.

Mode Meaning
GF Gravimetric feeding mode has been activated and feeding is
within the allowed tolerance.
VF Volumetric feeding mode has been activated.
VR Volumetric regulation mode is activated and the feeding
operation is within the allowed tolerance.
VS Volumetric setting mode has been activated.
DI Discharge mode is activated.
GD Gravimetric discharge mode has been activated and feeding is
within the allowed tolerance.
CM Calculation of max. output mode is activated.
D+, Feeding lead to a positive or negative control difference. The
D- difference between the actual value and the setpoint has
exceeded the max. allowed value.
RF Refill mode has been activated.
MS Stabilisation period runs off after refilling.

Mode Meaning
AV Anti-vibration protection of the feeder has been activated.
S-, S+ Minimum or maximum speed has been fallen short of or
exceeded.
UN, Hopper contents inferior to filling level limit value underload or
OV superior to filling level limit value overload.
CO Communication error between the Congrav and the ISC-CM.
WS The serial load cell signal cannot be received.
ST A start condition is not fulfilled and the feeding operation
cannot be started. Exception: "Weight < Min".

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16.5 Configuration form I/O-module-analogue-LM3

The 24VDC (terminal 15, 39) must only be used for the digital inputs
of the analogue card.
The 24 VDC supply is fed in via the terminals 1, 2 (24 VDC) and 3, 4 Important
(GND).

I/O-module-analogue-LM3 connected to the analogue card

Terminal Digital outputs Function Terminal Digital inputs Function


Te 1: 5 DO 1 Te 1: 11 DI 1
6 DO 2 12 DI 2
7 DO 3 13 DI 3
8 DO 4 14 DI 4
9 GND 15 24 VDC
10 Screen 16 Screen
Te 2: 29 DO 5 Te 2: 35 DI 5
30 DO 6 36 DI 6
31 DO 7 37 DI 7
32 DO 8 38 DI 8
33 GND 39 24 VDC
34 Screen 40 Screen

Analogue Analogue
Terminal Function Terminal Function
inputs outputs
Te 1: 17 AI 1 + Te 1: 23 AO 1 +
18 AI 1 - 24 AO 1 -
19 Screen 25 Screen
20 AI 2 + 26 AO 2 +
21 AI 2 - 27 AO 2 -
22 Screen 28 Screen
Te 2: 41 AI 3 + Te 2: 47 AO 3 +
42 AI 3 - 48 AO 3 -
43 Screen 49 Screen
44 AI 4 + 50 AO 4 +
45 AI 4 - 51 AO 4 -
46 Screen 52 Screen

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16.6 Listing of the menu pages

F000 |
Stopped
BRABENDER TECHNOLOGIE

Check
Software : LM3 A |
HG V1.81 | o.k.
IO address: 1 |
:
:
MS-Board: RC Batt. | o.k.
CD-Board: 1 |

F100 I=off |
Stopped
Installation configuration
Congrav RC 4 HG V1.45 26.06.02 09:00

Mode Single
Analogue configuration

Host comp operation off


Text switch English
Interlocking/stop off

F110 I=off |
Stopped
Installation modes

Single
Group
100% group
Master/Slave
M/S-actual value

Return

F120 I=off | F121 I=off |


Stopped Stopped
Host computer parameter Host computer procedure

Procedure off Off


Ident number 01 Brabender PT03
Baud rate 9600 Siemens RK512
Bus address 00 00-99 Siemens RK512-L
Bus mode 00 00-01
Return Return

F130 I=off |
Stopped
Text switch

German
English
French
English lb
Italian
Danish
Spanish
Return

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F140 I=off |
Stopped
Test of I/O-periphery

Test: off
Dig.in. : 0 0 0 0 0 0 0 0 0 0 0 0
Dig.out. : 0 0 0 0 0 0 0 0 0 0 0 0 0
Test printer interface
System check Rx Tx Rx Tx

Bus status:

F150 I=off |
Stopped
Recipe management

Recipe number : 01
Load recipe
Store recipe

Setpoint ramp : 000 s


Setpoint threshold : 010 %
Start operation 0000 s

F160 I=off |
Stopped
Modem

Status
Baud rate 9600

Phone number 0049,203,9984133

Dial
Interrupt
Maximum timeout 060 s

F170 I=off |
Stopped
Installation configuration

analogue control off 0-10V 0.00%


Analogue input 00

analogue act.value off 0-20mA 0.00%


Analogue output 00

Total output 1000.00 kg/h


Throughput divisor 100.000 kg

F200 I=off |
Stopped
Printer configuration

Print time 000 Min.


Screen page F 000
Alarm printout off
Print CP data 01-16 00

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F210 I=off |
Stopped
Delete
RAM Delete
Delete all data
Init recipe

L/M3 program load

ISC program load 00

F300 I=off |
Stopped
Setpoint input Total 0.000 kg/h
No | Setpoint % | Setpoint kg/h | Select
01 | 0.000 | 0.000 | Off
02 | 0.000 | 0.000 | Off
03 | 0.000 | 0.000 | Off
04 | 0.000 | 0.000 | Off

05 | 0.000 | 0.000 | Off


06 | 0.000 | 0.000 | Off
07 | 0.000 | 0.000 | Off
08 | 0.000 | 0.000 | Off

F310 I=off |
Stopped
|Delay time / s|
No | Start | Stop | Alarm Stop
01 | 000 | 000 | Off
02 | 000 | 000 | Off
03 | 000 | 000 | Off
04 | 000 | 000 | Off

05 | 000 | 000 | Off


06 | 000 | 000 | Off
07 | 000 | 000 | Off
08 | 000 | 000 | Off

F400 I=off |
Stopped
Actual

Total setpoint 0.000 kg/h


Total actual value 0.000 kg/h
All totals 0.000 t

F410 I=off |
Stopped
Indication of actual value
No | Set. kg/h | Act. kg/h | Total kg
01 | 0.000 | 0.000 | 0.000
02 | 0.000 | 0.000 | 0.000
03 | 0.000 | 0.000 | 0.000
04 | 0.000 | 0.000 | 0.000

05 | 0.000 | 0.000 | 0.000


06 | 0.000 | 0.000 | 0.000
07 | 0.000 | 0.000 | 0.000
08 | 0.000 | 0.000 | 0.000

F420 I=off |
Stopped
Indication of actual value
No |Weight kg | Diff.% | Speed %
01 | 0.000 | 0.000 |
02 | 0.000 | 0.000 |
03 | 0.000 | 0.000 |
04 | 0.000 | 0.000 |

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05 | 0.000 | 0.000 |
06 | 0.000 | 0.000 |
07 | 0.000 | 0.000 |
08 | 0.000 | 0.000 |

F430 I=off |
Stopped
Reset all totals
SE 0.000 t R Total 0.000 t R
01 0.000 kg R 09 0.000 kg R
02 0.000 kg R 10 0.000 kg R
03 0.000 kg R 11 0.000 kg R
04 0.000 kg R 12 0.000 kg R

05 0.000 kg R 13 0.000 kg R
06 0.000 kg R 14 0.000 kg R
07 0.000 kg R 15 0.000 kg R
08 0.000 kg R 16 0.000 kg R

F500 |
Stopped
Alarm messages + Start conditions

01 |09
02 |10
03 |11
04 |12

05 |13
06 |14
07 |15
08 |16

F600 |
Stopped
Calibration data **-Type Feeder 01
----------------------------- H+G-Param.
01 Feeder type H/-/C/G/- 1.000 kg
02 Weighing range 60.000 kg
03 Maximum output 100.000 kg
04 Underload 10.000 %
05 Overload 90.000 %
06 Coarse tare 0.000 %
07 Average weight aqc. 8.000
08 Throughput divisor 1.000 kg
09 Speed minimum 2.000 %
10 Speed maximum 99.000 %
11 Control difference 1.000 %
12 Alarm cut-out delay time 60.000 s
13 Type of interlocking 0.000
14 Indic. of actual value 2.000 s
15 Lever arm factor 1.000
16 Hopper volume 200.000 l
17 Fill level minimum 30.000 %
18 Fill level maximum 60.000 %
19 Window/K1/Filter 6.000
20 Digital speed 0.000 kHz
21 Maximal refill time 60.000 s
22 Refill optimize 0.000
23 Stabilization time 15.000 s
24 Sampling time 60.000 s
25 AV cut-out time 90.000 s
26 PID contr. access time 0.500 s
27 Control automatic 1.000
28 Filter limits 500.000 %
29 Adapt. of actual value 3.000
30 Adapt. of manip.variable 0.000 %
31 Adapt. of actual val. VR 1.000
32 Start delay time 8.000 s
33 Length weighing bridge 0.412 m
34 Weight test value 1.000
35 Adaptation 1.000
36 Autotare range 10.000 %
37 No load time autotare 60.000 s
38 Rated belt speed 20.000 m/min
39 Belt length 2.390 m
40 Dead-time way 0.800 m

F610 |

Brabender Technologie, 2005-08 Page 129 of 132


Manual Congrav® L/M 3 HG V_._

Stopped
Calibration data **-Type Feeder 01
----------------------------- C-Param.
01 Calibration 20% 0.000
02 Calibration 40% 0.000
03 Calibration 60% 0.000
04 Calibration 80% 0.000
05 Calibration 100% 0.000
06 Reserve 0.000
07 Reserve 0.000
08 Reserve 0.000
09 Reserve 0.000
10 Reserve 0.000
11 Usable weighing range 5.000 kg
12 Drop-Out 0.000
13 Tacho Mode 0.000
14 Slipping influence 0.000
15 Slipping value 0.000 %
16 Tacho adaptation 1.000
17 No load time 20.000 s
18 AT-time 5.000 s
19 Drive control 2 min 0.000 %
20 Drive control 2 max 0.000 %

K010 I=off |
Stopped
Feeder control
**-type feeder 01
Start | Setpoint 100.000 kg/h
Stop | Actual value 0.000 kg/h
Alarm reset | Control diff. 0.000 %
Refill | Weight 0.000 kg
| Speed %
|
Thr. reset | Throughput 0.000 kg
Start sample| Sample 0.000 kg/h
Start tare | Tare 0.000 kg

K011 I=off | K011 I=off |


Stopped Stopped
Product parameter Operating modes
**-type feeder 01 **-type feeder 01
GF Gravimetric feeding
VR Volumetric regulation
Auto-tare 0.000 kg VS Volumetric setting
Check max. output 0.000 kg/h DI Discharge
Bulk density 0.000 kg/l CM Check.maximum output
Vol. max. output 0.000 l/h GD Gravimetric discharge
Decade switch 0.000 VF Volumetric feeding
Mode GF M Measuring
Return

K012 I=off |
Stopped
Control parameter
**-type feeder 01

01 Control 1 P-term 5.000


02 Control 1 I-term 1.000s
03 Control 1 D-term 0.000 s
04 Control adaptation 1.000
05 Grav.calc.maximum output 1.000

Brabender Technologie, 2005-08 Page 130 of 132


Manual Congrav® L/M 3 HG V_._

K013 |
Stopped
Indication of I/O periphery
**-type feeder 01

Ana. inputs 1: 0.00 2: 0.00 3: 0.00


Ana. outputs 1: 0.00 2: 0.00
Dig. inputs 0 0 0 0 0 0 0 0
Dig. outputs 0 0 0 0 0 0 0 0
Load cell
Freq. converter 000.00
Fi 0.000 % 0.000 %
Coriolis motor 0.000 kHz 0.000 %

K014 I=off |
Stopped
Test functions
**-type feeder 01

Simulation off
Test off
Ana. output 1: 0.00 2: 0.00
Dig. outputs 0 0 0 0 0 0 0 0
Test interfaces

K015 I=off |
Stopped
Alarm configuration
**-type feeder 01

S+ Speed minimum cut-out


S+ Speed maximum cut-out
D- Control diff. negative cut-out
D+ Control diff. positive cut-out
OV Overload cut-out
UN Underload cut-out
RF Refill cut-out
AV Anti-vibration cut-out

K016 I=off |
Stopped
Analogue configuration
**-type feeder 01

AI Reserve 00
AI Reserve 00
AI Reserve 00

AO Manip. var. 00
AO Act. value 00

K017 I=off |
Stopped
Digital configuration
**-type feeder 01
DI Interlocking 00 DO Operation 00
DI Start 00 DO Alarm 00
DI Stop 00 DO Refill 00
DI Al. reset 00 DO Alarm report 00

DI Refill 00 DO Underload 00
DI G-discharge 00 DO Control diff+- 00
DI Immediate stop00 DO Reserve 00
DI Reserve 00 DO Overload 00

K018=off |
Stopped
I/O-configuration
**-type feeder 01
Speed input 0 2=A 3=F 4=S
Reserve 0
Reserve 0

Brabender Technologie, 2005-08 Page 131 of 132


Manual Congrav® L/M 3 HG V_._

Load cell type 1 1=IDL 2=AED 3=A


LC RS422/485 1 1=422 2=485
Drive control 1 1=FC 2=VC 3=A
St RS422/485 2 1=422 2=485
Analogeingang 0 1=0-10V 2=2-10V
Analogue output 0 1=0-20mA 2=4-20mA

Brabender Technologie, 2005-08 Page 132 of 132

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