LM3 - HG Manual (August 2005)
LM3 - HG Manual (August 2005)
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
Addresses
Great Britain:
North America:
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
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
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
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
1 Introduction
1.1 The structure of the manual
The operating instructions have been conceived for two groups of users.
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.
Operating and maintenance staff trained on the correct operation
and maintenance of the installation.
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!
Revision 1.0
Basic version of documentation
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”
Page 40: Terminal declaration corrected (for componente1)
Page 32: Relay declaration corrected 250VAC/5A
Page 33: Kx- and Kx’-Declaration were interchanged
Revision 1.4
Page 105: Adaptation
CHAPTER 2
Definition weigh-feeder:
A weigh-feeder is a feeding device, its feed rate (= product quantity/time
unit) is sensed as follows:
the weighing of the hopper contents, the belt load or
the measurement of the flowrate.
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 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.
CHAPTER 3
GENERAL NOTES
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.
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.
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.
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.
CHAPTER 4
HARDWARE DESCRIPTION
4 Hardware description
4.1 Congrav L/M3: the types
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
4
3
6
(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.
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 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.
3. validate+return = CR
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:
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).
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.
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.
Figure 4-1: The rear view of Congrav® L/M3 for 4 weigh-feeders with optional extensions
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
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
Power
source
Release (opteration)
Motor line
depending
on the type
Power supply
Drive controll
24 VDC
DS-controller
Power supply
Digital speed
IO-Modul-DS-LM3 R1
serial load cell signal
Overview: the possible connections
BT1094A
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
LM3-MSIO
Manual Congrav® L/M 3 HG V_._
Page 27 of 132
Manual Congrav® L/M 3 HG V_._
The L/M3-MSIO
is the Memory-Serial-IO-card of Congrav® L/M3,
is always plugged into the first slot (XS1) and -XS1.1
-XS1
Both interfaces, XS1.1 and XS1.2, are a RS422 interface and have the
same pin functions.
The third RS422 interface XS1.3 permits to connect a modem for remote
maintenance/diagnosis.
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.
DRS2
TB TA RB RA
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
15VDC
10VDC
GNDP
Load cell RS485
R2
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.
The following points have to be taken into consideration for the following
terminal plan:
the functions of the digital inputs and of the digital output DO4 are
determined by the software configuration.
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".
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
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
Terminal strip 2
Incremental encoder DBW
bl rt ws Load cell RS485
- + Impuls
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
- + Impuls
+10V-supply, max. 120 mA
IDL/F-Load cell
Incremental encoder DBW Load cell RS485
I/O-Modul-DS-LM3 R2
I/O-Modul-DS-LM3 R2
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
digital inputs and
4 digital outputs
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
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,
if the slots 4-11 are equipped with DS-controllers and
if no bus-module is inserted into the 3rd. slot.
The analogue inputs and outputs are on the terminal strips of the I/O-
module I/O-module-analogue-LM3 Rx. The assignments
function Æ analogue input/output and
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
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:
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
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
CHAPTER 5
Cut-out
Fixing clamps
139,00
Front
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.
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
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 |
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:
switch off the mains supply,
eliminate the trouble cause and
reconnect the mains supply.
CHAPTER 6
INSTALLATION CONFIGURATION
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.
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:
6.5 Interlocking/stop
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.
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
Please see chapter 8.2.1, page 53, setpoint types, for a description of the
functions of the parameters setpoint ramp and setpoint threshold.
CHAPTER 7
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
28.05.97 23:46
K 01 Speed minimum reset
On menu page F210 you will find three functions that permit to clear defined memory
contents.
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.
Recipe init:
Initialises all recipes by the actual configuration.
CHAPTER 8
8.3 Selection
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.
CHAPTER 9
This chapter deals with the menu page F400 and the
corresponding submenu pages
F400: The actual values of the installation
F410: The actual values: setpoint, actual value,
throughput
F420: The actual values: weight, control
difference, speed
F430: Reset of throughputs
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
Setpoint: Quantity to be fed in kg or lb,
Actual value: Actual feed rate in kg/h or lb/h
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
Weight: With a tared weighing system the weight value is
corresponding to the product weight in the hopper of
the feeding device.
Difference: Actual control difference (setpoint – actual value).
Speed: The actual operating range of the feed drive. With
speed monitoring the speed will be displayed as
manipulated variable that has been emitted.
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.
CHAPTER 10
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.
10.3.4 Refill
This parameter is not available for DBW, CDW or CP.
Manual refill can be switched on and off.
Product parameter
Taring of a DDW or CP: H-type Feeder 01 Output=0
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 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
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).
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.
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.
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
10.4.6 Mode
10.4.6.1 Gravimetric feeding (GF)
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:
Before the start of the checking of the max. output the discharge
device is refilled with product by a short-term DI-operation.
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.
This mode can be interrupted at any time by pressing the stop-key
and started again with any new start.
Alarms that occur during the checking of the output are displayed as
"CM ERROR" after the program has run down.
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.
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.
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.
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 parameter control adaptation permits to adjust the values from the
table, if necessary. You have to enter a factor, i.e.:
CHAPTER 11
Chapter 11 describes
the menu page F500 and
the menu page Kxx5.
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®.
Memory module fault, to find the cause for these faults it is required to
contact the BRABENDER service department.
This report will be displayed after each data reset (F210) or after the
function "recipe init" has been carried out.
The minimum speed has been fallen short of, because either
the value determined for minimum speed is too high,
the parameter digital speed (CP20) has been adjusted incorrectly,
the speed reading of the Congrav® is defective,
the setpoint is to small for the dimensioning of the feeder or
the PID-controllers have been adjusted incorrectly.
The hopper filling level has fallen short of the min. quantity, because
the hopper has not been refilled,
the limit values underload and filling level min are to close to one
another,
the overload protections have been adjusted incorrectly or
the mode gravimetric discharge has been selected.
The minimum belt load has been fallen short of, because
no product or too little product on the belt
the feeding belt stands still (e.g. slippage on the drive roller),
the slide valve on the inlet has been adjusted incorrectly or
the parameterisation is not adjusted to the operating conditions.
The hopper filling level has exceeded the max. quantity, because
the limit values overload and filling level max are too close to one
another for the refill operation or
too much product been refilled into the hopper,
the DDW has been overloaded by an external charge.
The min. filling level has not been exceeded within the determined refill
time, because
the feeder has not been refilled (failure in the upstream filling
device),
the digital output refill is defectuous or
the refill quantity is too small compared to the setpoint.
The control difference took longer than the alarm cut-out time, because
either
the PID controllers have been adjusted incorrectly,
the PID controllers build up due to external perturbations,
the filter limits are constantly violated and thus the control is too
much attenuated,
the screw is not filled with product (e.g. bridging) or
product pours out of the upstream filling station
the control difference took longer than the alarm cut-out time, because
either
the PID controllers have been adjusted incorrectly,
the PID controllers build up due to an inhomogeneous product layer
on the belt or
the belt slides over the drive roller (slippage!)
The violation of the filter limits took longer than the AV-cut-out time,
because either
the filter limits that have been entered are too small,
due to external perturbations the filter limits have been continuously
violated or
the PID controllers have been adjusted incorrectly.
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.
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:
FC-Error 1 Overload Load in the feeding tray too Reduce the product layer in
heavy the feeding tray.
FC-Error 2 Calibration error Reverse poling of the tacho Check the wiring
connection Change the poles of the tacho
Damaged tacho connection connection
Damaged tacho Substitute the damaged tacho
K015 I=off | GF GF GF GF GF GF GF GF
| GF GF GF GF GF GF GF GF
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.
CHAPTER 12
I/O-configuration
the digital input 1 of the DS-controller **-type feeder 01
Dig. input 1 0 3=F 4=S
the digital input 4 of the DS-controller Dig. input 4 0
the digital input 4 of the DS-controller Dig. output 4
Load cell type
0
1 1=IDL 2=AED 3=A
the serial interfaces of the DS-controller LC RS422/485
Drive control
1
1
1=422 2=485
1=FC 2=VC 3=A
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
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.
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
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).
For the duration of the corresponding function the digital outputs supply a
24VDC-signal. The only exception is the function "throughput".
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.
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.
Figure 12-1 shows an overview of the standard weighing systems and the
possible signal forms. The communication modules are external sub-
assemblies for
the electrical supply and
the electrical connection of the load cells to the Congrav® and
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.
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
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
Each analogue cards offers the following extensions for the hardware of
Congrav® L/M3
8 digital inputs and outputs
4 analogue inputs and outputs
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
As far as the analogue inputs and outputs of the optional analogue card
are concerned, two types of functions are distinguished:
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.
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.
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.
Analogue input
The parameter "analogue input" permits to define the analogue input by
the input of the continuous number of the analogue input.
Total output
With an analogue actual value output the value entered is assigned to a
10VDC-signal.
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.
In the illustration:
"K016" means that the definitions are valid for component 01.
At present, the following functions are supported
Load cell, analogue input for the analogue weight reading,
Speed, analogue input for the analogue speed reading,
Control, analogue input for the analogue single control,
Manipulated variable, analogue output for the analogue speed
signal to the drive controller,
Actual value, analogue output for the actual value of the component,
supported.
12.2.2.2.1 The definition of the signal range for the analogue I/O
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
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: Dial
Start dialling
F160: Interrupt
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.
F120: Bus-Mode
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
CHAPTER 13
Special function with the mode volumetric regulation (DDW): Special function
Input of max. flowrate in [l/min]
The input of the maximum output in kg/h or lb/h is required for the
following functions:
Input limitation for the setpoints
Assignment of 20mA to the optional actual value outputs
The input in % is a function of the usable weighing range and defines the
minimum hopper contents (DDW) or the minimum belt load (DBW).
The input in % is a function of the usable weighing range and defines the
maximum hopper contents (DDW) or the maximum belt load (DBW).
The input defines the number of measuring values for the calculation of
the average values.
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.
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.
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
Determination and refresh time for actual value and time base for short-
term actual value.
The input in litres is meant for the screw trough and the hopper.
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.
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.
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.
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%
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.
With this calibration point the time for sampling and the component
mode "checking max. output" (CM) is defined.
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.
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.
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.
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.
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):
Input of all necessary feeder-specific data
Activation of the general start automatic.
Input of an output value
Fulfilment of the other start conditions.
After the input of a setpoint the installation can be started. The start
of the installation is computed as follows:
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.
Adjustment of the actual value filtering for the actual value calculation:
0 = old act. val. calculation 1 = weak .... 5 = strong filtering
Correction factor for small differences between the setpoint of the DBW
(weigh-belt feeder) and the actual value of sampling.
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
Adaptation factor for the weight value and the weight weight value
APact = ⋅ AP
display of a DBW, Coriolis and CP-FlowMeter. weight display
The factor 2 results from the ratio of the rated belt speed (=100%) to the
adjusted speed (here: 50%).
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.
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.
This function is employed for the CP-FlowMeter or the Coriolis Mass Flow
Scale.
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.
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%.
Time that runs off after the start of the Coriolis Mass Flow Scale, before
the actual value computation and the weight monitoring starts.
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.
AP19 = AP20
The second drive controller is operated with a constant manipulated
variable.
AP19 = AP20 = 0
The second drive controller is not addressed.
CHAPTER 14
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.
The menu pages Kxx3 display the status of all inputs and outputs of the
corresponding component.
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.
Kxx4: Test:
Switching on/off test functions.
CHAPTER 15
GLOSSARY
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.
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.
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.
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
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.
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.
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.
APPENDIX
16 Appendix
16.1 Technical data
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.
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
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".
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).
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
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
F110 I=off |
Stopped
Installation modes
Single
Group
100% group
Master/Slave
M/S-actual value
Return
F130 I=off |
Stopped
Text switch
German
English
French
English lb
Italian
Danish
Spanish
Return
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
F160 I=off |
Stopped
Modem
Status
Baud rate 9600
Dial
Interrupt
Maximum timeout 060 s
F170 I=off |
Stopped
Installation configuration
F200 I=off |
Stopped
Printer configuration
F210 I=off |
Stopped
Delete
RAM Delete
Delete all data
Init recipe
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
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
F400 I=off |
Stopped
Actual
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
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 |
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 |
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
K012 I=off |
Stopped
Control parameter
**-type feeder 01
K013 |
Stopped
Indication of I/O periphery
**-type feeder 01
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
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