DT9 manual.pdf

Pro du ct User Ma nu al for the

DT_9 Mic rop roc esso r Cont rol and Vari abl e Frequ enc y Dri ve Feeder Conversion fo r

TENUGHAT VIDYUT NIGAM LIMITED

Customer: Apex Industrials Purchase Order No.: AI/3133/13 Stock Redler I ndi a Private Limi ted Job No: 1272−0000 Stock Redler India Private Limited

WBS No: VK/9113000317

Revis io n 0 - Novemb er 2013 Stock Redler India Private Limited. # 3(Old No. 18 & 23),3rd Main, 1st Phase, Peenya Indusrial Area, Bangalore – 560058, INDIA. (080) 30403705/706/707 Telefax (080) 30403708

DT_9 Microprocessor Control and Variable Frequency Drive Feeder Conversion

For TENUGHAT VIDYUT NIGAM LIMITED (2 X 210 MW- Unit -2) TENUGHAT VIDYUT NIGAM LIMITED

OWNER:

(A Govt. of Jharkhand undertaking)

CUSTOMER:

Apex Industrials

MANUFACTURER:

STOCK REDLER INDIA PRIVATE LIMITED

P.O NO. : AI/3133/13

O & M MANUAL

DOCUMENT TITLE: SRIPL’s

Document No. –1272-0000

PREPARED & CHECKED NAME Mechanical

Electrical

SRIPL JOB NO.: 1272

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DATE

REV: 0

REVIEWED (QA & QC) NAME

SIGN

DATE

REVIEWED (Service) NAME

SIGN

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APPROVED NAME

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THIS PAGE INTENTIONALLY LEFT BLANK

1.0 Installation

Stock Redler India Private Limited

How to Use this Manual This equipment manual is divided into sections which separate the material according to its principal use at the site. Section 1.0, for use by the equipment installers, covers receiving inspection, storage instructions, storage maintenance procedures required, if any, and equipment installation procedures. Section 2.0, oriented to the operations personnel, contains a system component description of the major items of equipment supplied, an initial start-up sequence, and procedures for typical operation. The maintenance staff, contains an inspection schedule, lubrication information, adjustment and calibration procedures, and any necessary troubleshooting guides. Sections 3.0 through 5.0 contain the schematic and connection diagrams, assembly drawings, and parts lists. For ease in locating specific drawings, as well as to bring together all drawings of a similar nature, Section 3.0 contains all the drawings certified for the specific project; Section 4.0 contains all mechanical drawings; and Section 5.0 contains electrical and electronics drawings. The drawings within each section are arranged in the section index in alphanumerical order except that supportive drawings, such as parts lists and schematics, are indented and listed immediately beneath the related assembly drawing. To the left of the drawing titles, the Stock Equipment Company part numbers are listed to specify the particular assembly supplied from a tabulated drawing. The drawings themselves are then arranged exclusively in alphanumeric order following the section index. Section 6.0 contains vendor bulletins with specific adjustment, calibration, or service information. Section 7.0 and following are included when necessary to present optional equipment supplied and recommended spare parts. These sections are self-contained and are each arranged according to the organizing principles employed in Sections 1.0 and 2.0 above, with a section index followed by the operation and maintenance text and relevant drawings. To keep the manual current, revision packages may be supplied for it as necessary. A Record Of Changes form is provided in front of Section 1.0 to record these revisions as they are received and processed. It is recommended that the instruction sheet from each revision package be filed behind the record of changes for future reference.

Note The drawings and p arts lists incorporated in this m anual ar e correct for the equipm ent sup plied. The ti tle block descriptive inform ation may no t always agre with the inform ation provided in the srcinal propo sal or contract, but the drawing con tents are correct for the equipment sup plied.

Note This equipm

ent manual is designed to s

upp lement,

not replace,

the srcinal

equipment manual supplied with the feeder. It deals only with additional considerations pertaining to the weighing system electronics and feeder microprocessor controls.

November 2013 1272-0000 Revision 0

e

INTRODUCTION


Proprietary Note The information in this m anual, including technical data a nd co pies of drawings, embod ies information prop rieta ry to Stock Equipm ent Company. T his manu al i s provid ed to the user of e quipm ent purchased from Stock Equipment Comp any for use only in operation or maintenance of such equipm ent. Such inform ation in this man ual is not to be us ed, disclosed, copied, reproduced in w hole or part for a ny us e oth er than that indicated above, or for any oth er purpos e detrimenta l to the interests of Stock Equipm ent C omp any. Pate nts own ed by Stock Equipment Com pany have been issued or are pending on so me of the information in this m anual. Any un autho rized use of this sub ject matt er of such patents is a viola tion of such pate nts and is proh ibited by law .

Electrostatic Sensitive Devices Caution The ele ctronic controls contain ESD ( Ele ctrostatic Discharge) sensitive part s and assemblies that can b e damaged by static ele ctricity. The following static contro l precautions are required when testing, servicing, or repairing the ele ctronic assemblies.

1.

Disconnect power at the main disconnect switch or circuit breaker.

2.

Only qualified personnel are permitted to perform and install the electronic controls.

3.

Wear a wrist type grounding strap that is grounded to the control cabinet chassis.

4.

When replacing the electronic circuit board, do not remove the board from the static shielding bag it came in until you are ready to install the board.

5.

When removing any electronic circuit board, immediately place it in a static shielding bag.

6.

Stock Equipment Company advises that all printed circuit boards should be returned to the factory for repair since our technicians are trained to work with electrostatic sensitive components.

Note If you are not familiar with static control procedu res, before replacing ele ctronic com pon ents, refe r to US Department of Defense DOD – HDBK -263, Electrost atic Discharge Control Handbook for protection of electronic parts, assemblies, and e quipm ent.

7.

Contact Stock Equipment Company’s Parts Department for a returns good authorization number to facilitate the return of an electronic circuit board. Boards should be shipped in static shielding type bags. If packing materials are used, they should be static-dissipative material.


1.0 Installation


Table of Contents PRODUCT USER MANUAL FOR THE DT_9 MICROPROCESSOR CONTROL AND VARIABLE FREQUENCY DRIVE FEEDER CONVERSION Manual Content Section 1.0

Installation

Section 2.0

DT_9 Operation & Maintenance

Section 3.0

Certified Drawings

Section 4.0

Mechanical Drawings and Parts Lists

Section 5.0

Electrical/Electronic Drawings and Parts Lists

Section 6.0

Vendor Information

Section 7.0

Recommended Spare Parts


INTRODUCTION


Notice Revised refe rence materia l, writte n text and d rawings may b e furnished as required to up date t he information c ontained within this m anual. When revisions to the con tent of this m anual are sub mitted, util iz e the Re cord o f Changes form p rovided to reco rd all re visions. Specifi c instruc tions m ay be provided in the Revision Packet for recording and inserting all changes affe cting th is manu al.

Record of Changes Change Number

Date Entered

Description of Changes

Signature



1.0 Installation

1.0 Installation

Section Index Topic 1.1 1.2

RECEIVING INSPECTION STORAGE PROCEDURES

1.3 1.4 1.5 1.6

SCOPE OF CONVERSION CONTROL CABINET INSTALLATION DT_9 MICROPROCESSOR VFD CONVERSION KIT INSTALLATION ELECTRICAL CONVERSION KIT INSTALLATION


1-1

2.0 DT_9 Operation and Maintenance

1.1


RECEIVING INSPECTION Upon delivery, inspect the equipment for shortages or evidence of physical damage and make a report to the independent carrier.Also, notify the Contracts Department of StockRedler India Pvt. Ltd., to arrange for the shipment of replacement parts.

1.2

STORAGE PROCEDURES Prior to shipment from the factory, provisions have been made to protect the equipment in the event that prolonged storage is required at the job site. These storage procedures are provided as recommendationsto aid in maintaining the equipment in a warrantable and ready condition. 1.2.1 Storage areas shall be periodically inspectedto ensure cleanliness. Discardedpackaging and trash shall be removed. Access shall be limited to authorized personnel. Upon placing an item in storage and prior to its removal, the packaging and protective covers should be visually inspected to ensure that all closures are intact. Any defects in the packaging may be repaired, after insuring that the packaged material is intact and undamaged, using the srcinal method of packaging. Surface preservatives may be reapplied or touched up as required. 1.2.2 Equipment is to be stored in such a manner as to provide ready access for inspection and maintenance with a minimum of handling. Items should be positioned so that any markings or labelings can be easily identified without excessive handling. Shipping documents are attached to the outside of each crate . to identify the equipment contained inside 1.2.3 All feeders with electronic enclosures mounted to them must be stored in a heated, ventilated building where ambient temperatures may be controlled between 5°C minimum and 50°C maximum. Control enclosure access doors must be tightly closed to engage the sealing gaskets.

1.3

SCOPE OF CONVERSION 1.3.1

The conversion consists of the following: a.

S11154

Remote Power Cabinet With DT_9 Microprocessor assembly

b.

S11160

Feeder Integral Cabinet Assembly

c.

D43566

VFD Motor 7.5HP Upgrade Kit with Dual Tacho

d.

Motor , Loadcell And Calibration Field Cable

Note System installat ion, schematic, a nd c onnection drawings are provided in Section 3. 0, Certifie d Drawing s . Assembly drawings and parts lists ar e provided in Section 4. 0, Mechanic al D rawing s and Parts Lists and Section 5 .0 , Electrical/E lectron ic Drawings and Parts Lists

1-2

.


1.0 Installation


Important Before perform ing any work inside the feeder , de- energiz e the feede r by locking the main circuit breaker or disco nnect switch in th e OF F position .

Important Safe ty c onsiderations require that electri connected to safet y groun d.

1.4

cal apparatus and enclos

ures be so lidly

DT_9 MICROPROCESSOR CONTROL CABINET INSTALLATION

Note System installat ion, schematic, a nd c onnection drawings are provid ed in Section 3. 0, Certifie d Drawing s . Assem bly drawings and parts lists a re provided in Section 4. 0, Mechanic al Dra win gs and Parts L ists and Section 5.0, Electrical/ Electronic Drawings and Parts Lists . 1.4.1

Close the inlet valve above the feeder and empty the belt.

1.4.2

De-energize the feeder and close the seal air supply if the feeder is so equipped.

1.4.3

If provided, close the feeder discharge valve.

1.4.4

Open all feeder side and end access doors.

1.4.5

Refer to Drawing S11154 and the drawings in Section 3.0, Certified Drawings. Mount the DT_9 microprocessor cabinet assembly onto the feeder by following the instructions provided on the drawings.

Important Do no t energiz e the fee der or the pow er to the contro l cabinets until a Stock service engin eer is p rese nt. I f a service enginee r is n ot present wh en the feede r or the pow er to the con trol cabinets are e nergiz ed, damage to the equipment, injury o r loss of life may occu r.


1-3



Note Electri cal control enclo sures m ust b e la tched and imm ediate access to them is required, both as a safet moisture damage to components.

1.5

1.6

seal ed at al l times unless y m ea sure and to prevent

VFD CONVERSION KIT INSTALLATION 1.5.1

Refer to Drawing D43566. Install the VFD conversion kit by following the instructions provided on the drawing.

1.5.2

Refer to Section 2.0 DT_9 Operation and Maintenancefor information on programming and calibration.

ELECTRICAL CONVERSION KIT INSTALLATION

Caution The ele ctronic contro ls co ntain ESD (E lectrostat ic Discharge) sensitive parts and assemblies that can be damag ed by s tati c electri city. The following s tati c co ntrol precautions are required when testing, servicing, or repairing the ele ctronic assemblies. 

Disconnect power at the main disconnect switch or circuit breaker.



Only qualified personnel are permitted to perform and install the electronic controls.



Wear a wrist type grounding strap that is grounded to the control cabinet chassis





When replacing the electronic circuit board, do not remove the board from the static shielding bag it came in until you are ready to install the board Stock Equipment Company advises that all printed circuit boards should be returned to the factory for repair since our technicians are trained to work with electrostatic sensitive components.

Note Electri cal contro l enclosures m ust b e lat ched and seal ed at all ti mes u nless imm ediate access to them is required, both as a safety measure a nd to prevent moisture damage to components.

1-4


1.0 Installation


Note Befo re install ing electronics cards, a ll fie ld w iring for the fee der control system m ust be checked and verifi ed. I mp roper wiring may result in s ever e damage to the ele ctronics cards when p ower is applied.

1.6.1

Refer the drawings in Section 3.0, Certified Drawings and Section 5.0, Electrical/Electronic Drawings and Parts Lists .

1.6.2

Remove the new electronics cards from their individual packages and install them into the microprocessor assembly by following the instructions provided on the drawings.

1.6.3

Refer to Section 2.0, D T _ 9 Operation and Maintenance for programming and calibration information.


1-5




1-6




2.0 DT_9 Operation and Maintaenance

DISOCONT® Tersus (DT-9) Weighfeeder VCF Instruction Manual

BV-H6411 GB




PASS - A service you can count on. Fast, compreh ensive and anywhere in the world.

Quality and reliability are the cornerstones of our company ’s philosophy. That is why we consider a comprehensive service concept simply par for the course, from strict quality control, installation and commissioning through to seamless support across the entire life cycle of our products. With over 30 service stations and over 180 service specialists, you can count on us to be there whenever and wherever you need us. During business hours, our service specialists from all business areas are ready to analyze problems and find the reasons for failures. You can find the Schenck Process location nearest to you on our website www.schenckprocess.com . Are you looking for individual and tailor-made service solutions? Then our modular PASS service system is just right for you. It includes the entire range of services from simple inspections all the way down to a complete service program. Further information can be found at www.schenckprocess.com. Service: Quality and reliability form the basis for our corporate philosophy all over the world.

In House Support (Monday through Friday from at least 8 oćlock to 5 p.m. CST). Service specialists are available for technical assistance to answer your questions or assist you in trouble shooting. STOCK EQUIPMENT COMPANY 16490 Chillicothe Rd. Chagrin Falls, OH 44023 , USA Phone: +1 440-543-6000 Fax: +1 440-543-6839 e-mail address: [email protected]

24 hour Emergency Support Are you experiencing a failure or problem outside normal office hours? You can reach our service technician at any time outside of our office hours for after hour emergency support.

Phone: +1 800-628-3347 (Please listen closely to menu for after hours support.) © by STOCK EQUIPMENT COMPANY A subsidiary of Schenck Process Group, Germany (www.schenckprocess.com) All rights reserved. Any reproduction of this documentation, regardless of method, without prior permission by STOCK EQUIPMENT in writing, even by excerpt, is prohibited. Subject to change without prior notice. Note: The srcinal manual is in English

(srcin: 9007199363029899 V2)

1-8



Table of Contents

Table of Contents

1

About This Manual ......................................................................................................................................

1

2 Safety notes................................................................................................................................................ 3 2.1 Signal Words ................................................................................................................................................5 2.1.1 Signal Words for Safety Warnings ................................... ................................. ...................................5 2.1.2 Signal Words for Application Notes .....................................................................................................6 2.2 Five Safety Rules of Electrical Engineering .................................................................................................6 2.3 Damaged / Defective Electrical Components ...............................................................................................7 3 Overview .................................................................................................................................................... 9 3.1 What is the DISOCONT Tersus/DT-9? ....................................................................................................... 9 3.2 Definitions ...................................................................................................................................................10 3.3 Measuring Principle ....................................................................................................................................10 3.4 Operating Modes - Remote ........................................................................................................................12 3.4.1 Gravimetric .........................................................................................................................................12 3.4.2 Volumetric ..........................................................................................................................................12 3.4.3 Volumetric Control..............................................................................................................................12 3.5 Operating Modes – OFF/Maintenance .......................................................................................................12 4 DT-9 Setup ............................................................................................................................................... 15 4.1 Setup Notes ...............................................................................................................................................15 4.2 Startup and Functional Check ....................................................................................................................16 4.3 Setup Parameters ......................................................................................................................................17 4.3.1 Commonly Changed Parameters.......................................................................................................17 4.4 Calibration ..................................................................................................................................................20 4.4.1 Performing Calibrations......................................................................................................................20 4.4.2 Weigh Roller Adjustment ...................................................................................................................21 4.4.3 Basic (CAL 1) ....................................................................................................................................22 4.4.4 Span (CAL 2) ....................................................................................................................................23 4.4.5 TC: Span Calibration .........................................................................................................................25 4.4.6 LB: Pulses per Belt ............................................................................................................................26 4.4.7 TA: Tare .............................................................................................................................................26 4.5 Analog Trim Function .................................................................................................................................27 4.6 Belt Monitoring............................................................................................................................................28 4.6.1 Belt Drift Monitoring............................................................................................................................28 4.6.2 Belt Influence Compensation (BIC)....................................................................................................30 4.6.3 Belt Slippage Monitoring ........................................................................................................ ............30 4.6.3.1 Monitoring Standstill after Startup ......................................................................................................30 4.6.3.2 Belt Slippage with Belt Marking .........................................................................................................30 4.6.3.3 Two-Sensor Belt Slippage Monitoring................................................................................................31 5 Operating and Control Access .................................................................................................................. 33 5.1 Connection between a VHM Operating Panel and a Scales Controller (VCU) ..........................................33 5.1.1 Connection via Ethernet Cable ..........................................................................................................34

DISOCONT® Tersus (DT-9) Weighfeeder VCF, Instruction Manual Schenck Process Group November 2013 1272-0000 Revision 0

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Table of Contents


5.1.2 Connection via Bluetooth ...................................................................................................................34 5.1.3 Connection via RS485 .......................................................................................................................34 5.2 Connecting a PC with EasyServe to a Scales Controller (VCU) ................................................................35 5.2.1 Connection via Ethernet .....................................................................................................................35 5.2.2 Connection via RS-232 ......................................................................................................................35 5.2.3 Connection via WLAN ........................................................................................................................35 5.2.4 Connection via Bluetooth ...................................................................................................................36 5.3 Connection between a Web Browser and a VCU Scales Controller ..........................................................36 5.4 Web Server in the Scales Controller VCU..................................................................................................37 6 Operation Using the Touch Screen HMI .................................................................................................... 39 6.1 Initial Configuration ....................................................................................................................................39 6.1.1 The 'Network' Screen ........................................................................................................................39 6.1.2 The 'Display Settings' Screen ...........................................................................................................40 6.1.3 The 'Feeder' Screen ..........................................................................................................................40 6.1.4 The 'Configuration' Screen ................................................................................................................40 6.1.5 The 'Communication' Screen ............................................................................................................40 6.1.6 The 'Calibration' Screen ....................................................................................................................40 6.1.7 Exiting HMI Configuration .................................................................................................................40 6.2 Display Functions ......................................................................................................................................40 6.2.1 The 'Home' Screen ............................................................................................................................40 6.2.1.1 Operating the HMI in 'Off/Maintenance' Mode ...................................................................................41 6.2.1.2 Operating the HMI in 'Remote' Mode .................................................................................................41 6.2.2 The 'Trend' Screen ............................................................................................................................41 6.2.3 The 'Values' Screen ..........................................................................................................................41 6.2.4 The 'Setup' Screen ............................................................................................................................42 6.2.4.1 Data Log Values.................................................................................................................................42 6.2.4.2 Event Log Values ..............................................................................................................................42 6.2.4.3 Values ......................................................................................................................42 6.2.4.4 Parameter Parameter Log Setup ...............................................................................................................................42 6.2.4.5 Trimming the Analog Inputs and Outputs .........................................................................................43 6.2.4.6 Restoring the Factory Default Settings .............................................................................................44 6.2.4.7 Simulation Mode ...............................................................................................................................44 6.2.4.8 Calibrating the Feeder .......................................................................................................................44 6.2.4.9 Setting the Current Time and Date ...................................................................................................45 6.3 Typical Operating Procedures ................................................................................................................... 45 7

Operation Using the 196NT Display ................... .......................................................................................

47

8 Operation Using EasyServe ...................................................................................................................... 49 8.1 Program EasyServe VPC 20150 ................................................................................................................49 8.2 Minimum System Requirements ................................................................................................................49 8.3 Installation...................................................................................................................................................49 8.4 Start Program and Connect to Feeder ....................................................................................................... 49 8.4.1 Connecting to Feeder.........................................................................................................................50 8.4.2 Access to Feeder Commands and Parameters .................................................................................51 8.5 Parameter Set.............................................................................................................................................51 8.5.1 8.5.2 8.5.3 8.5.4

.PAR Files ..........................................................................................................................................52 Read/change Parameters ..................................................................................................................52 Loading Custom Default Parameters .................................................................................................52 Loading Factory Default Parameters .................................................................................................53

BV-H6411GB, 1221 - 10 -

DISOCONT® Tersus (DT-9) Weighfeeder VCF, Instruction Manual Schenck Process Grou November 201 1272-0000 Revision 0


Table of Contents

8.5.5 Expert Mode .......................................................................................................................................53 8.5.6 Print Parameters ................................................................................................................................53 8.6 Operating the Feeder .................................................................................................................................54 8.6.1 Scale Operation Screens ...................................................................................................................54 8.6.2 Events ................................................................................................................................................54 8.6.3 Calibration ..........................................................................................................................................54 8.6.4 Service Values ...................................................................................................................................54 8.6.5 Trends ................................................................................................................................................55 8.6.6 Setting Time .......................................................................................................................................56 8.6.7 Options ...............................................................................................................................................56 9 Testing .................................................................................................................................................... 57 9.1 Calibration Weight Test .............................................................................................................................. 57 9.2 Chain Test ..................................................................................................................................................57 9.3 Material Test ...............................................................................................................................................58 10 Parameters ............................................................................................................................................... 59 10.1 General Information ....................................................................................................................................59 10.2 DT-9 Parameter List ...................................................................................................................................65 10.2.1 Parameter Overview ..........................................................................................................................66 10.2.2 Parameter Details ..............................................................................................................................82 10.2.2.1 Parameter Block 01 - Hardware Modules ..........................................................................................82 10.2.2.2 Parameter Block 02 - Feeder Definition .............................................................................................84 10.2.2.3 Parameter Block 03 - Control Sources ..............................................................................................91 10.2.2.4 Parameter Block 04 - Rated Data ......................................................................................................97 10.2.2.5 Parameter Block 05 - Feeder control ...............................................................................................100 10.2.2.6 Parameter Block 06 - Feeder Monitoring .........................................................................................101 10.2.2.7 Parameter Block 07 - Belt Monitoring ..............................................................................................108 10.2.2.8 Parameter Block 08 - Filters.............................................................................................................113 10.2.2.9 Parameter Block 09 - Limit Values...................................................................................................114 10.2.2.10 Parameter Block 10 - Calibration Data ............................................................................................118 10.2.2.11 Parameter Block 11 - Rate controller ...............................................................................................121 10.2.2.12 Parameter Block 12 - Moisture.........................................................................................................125 10.2.2.13 Parameter Block 13 - Cleanout control ............................................................................................128 10.2.2.14 Parameter Block 14 - Analog Outputs .............................................................................................130 10.2.2.15 Parameter Block 15 - Digital Inputs .................................................................................................134 10.2.2.16 Parameter Block 16 - Digital Outputs...............................................................................................143 10.2.2.17 Parameter Block 17 - Analog calibration..........................................................................................150 10.2.2.18 Parameter Block 18 - 2-Sensor Slip.................................................................................................154 10.2.2.19 Parameter Block 19 - Maintenance interval .....................................................................................156 10.2.2.20 Parameter Block 20 - Data Logging .................................................................................................157 10.2.2.21 Parameter Block 21 - Communication EasyServe...........................................................................159 10.2.2.22 Parameter Block 22 - Communication Fieldbus...............................................................................160 10.2.2.23 Parameter Block 23 - Ethernet.........................................................................................................165 10.2.2.24 Parameter Block 24 - PLC Outputs..................................................................................................166 10.2.2.25 Parameter Block 25 - Fixed mode configuration..............................................................................168 10.2.2.26 Parameter Block 26 - FCB analog outputs ......................................................................................172

10.2.2.27 Parameter Block 27 - FCB digital outputs ........................................................................................177 10.2.2.28 Parameter Block 28 - Configuration HMI Values .............................................................................180 11 Event (Error) Messages ...........................................................................................................................183


BV-H6411GB, 1221 -3-

Table of Contents


11.1 Events Details........................................................................................................................................... 184 11.1.1 Event Group: Calibration ..................................................................................................................184 11.1.2 Event Group: Controller ...................................................................................................................185 11.1.3 Event Group: Electrical System .......................................................................................................185 11.1.4 Event Group: Interlock .....................................................................................................................186 11.1.5 Event Group: Material Flow..............................................................................................................187 11.1.6 Event Group: MAX ...........................................................................................................................188 11.1.7 Event Group: Mechanic....................................................................................................................190 11.1.8 Event Group: MIN ............................................................................................................................193 11.1.9 Event Group: Sequence Monitoring .................................................................................................194 11.1.10

Event Group: System Message .......................................................................................................197

12 Default I/O Points.....................................................................................................................................199 12.1 Default Digital Inputs ................................................................................................................................ 199 12.2 Default Digital Outputs..............................................................................................................................200 12.3 Default Analog I/O ....................................................................................................................................201 13 Trending Data .........................................................................................................................................203 14 Appendix .................................................................................................................................................207 14.1 Calculating the setpoint ............................................................................................................................ 207 14.2 Switch-on logic.......................................................................................................................................... 208 14.3 Measuring the feed rate (MEASURE) ......................................................................................................210 14.4 Feed rate controller (CTRL)......................................................................................................................214 14.5 Belt slip identification ................................................................................................................................218 14.5.1 Motion monitoring (BMM) .................................................................................................................218 14.5.2 2-sensor slip monitoring ...................................................................................................................218 14.6 Belt drift and slip identification via mark in the belt................................................................................... 220 14.7 Monitoring the mechanism .......................................................................................................................222 14.8 Moist correction (MOIST) .........................................................................................................................223 14.9 The procedure for adjusting the frequency output.................................................................................... 223 14.10 PLC Functionality (Optional).....................................................................................................................224 14.10.1 Handling the Function Blocks...........................................................................................................225 14.10.2 Function Blocks for Binary Signals ..................................................................................................225 14.10.3 Function Blocks for Analog Signals .................................................................................................227 14.11 Serial Networks ........................................................................................................................................229 14.11.1 Ethernet Hardware ...........................................................................................................................230 14.11.1.1 Ethernet Addressing......................................................................................................................... 231 14.11.2 RS-485 Hardware ............................................................................................................................233 14.12 Basics of EMC-Compliant Cabling ...........................................................................................................235 14.12.1 Thoughts on the Cable Connections................................................................................................236 14.12.2 Screened Cables..............................................................................................................................236 14.12.3 Unscreened Cables..........................................................................................................................236 14.13 Checking the Weight Measurement Instrumentation ...............................................................................236 14.14 Technical Data VCU 20103 ......................................................................................................................237 14.14.1 Dimensions and Position of the Plugs .............................................................................................238 14.14.2 General Technical Data ...................................................................................................................239 14.14.3 14.14.4 14.14.5 14.14.6

Power Supply ...................................................................................................................................239 Auxiliary Voltage for External Subscribers .......................................................................................240 Load Cell Input VME0120 ................................................................................................................240 Digital Connections ..........................................................................................................................243

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Table of Contents

14.14.6.1 Digital inputs.....................................................................................................................................243 14.14.6.2 Digital Outputs..................................................................................................................................247 14.14.7 Analog Connections .........................................................................................................................250 14.14.7.1 Integrated Analog Input ....................................................................................................................250 14.14.7.2 Integrated Analog Outputs ...............................................................................................................250 14.14.7.3 Optional Analog Channels ...............................................................................................................250 14.15 Touchscreen Operating Panel VHM ........................................................................................................ 252 14.15.1 General Technical Data ...................................................................................................................253 14.15.2 Power Supply ...................................................................................................................................254 14.15.3 Data Interfaces .................................................................................................................................255 14.15.3.1 Ethernet ............................................................................................................................................255 14.15.3.2 Serial Interfaces: ..............................................................................................................................255 14.15.4 Housing Models ...............................................................................................................................256 14.15.4.1 Built-In Console Panel Units ............................................................................................................256 14.15.4.2 Portable Devices ..............................................................................................................................260 14.15.5 Connecting and Commissioning the Operating Panel .....................................................................263 14.15.5.1 Connecting the VHM Operating Panel via Ethernet ........................................................................263 14.15.5.2 Connection via RS-485 ....................................................................................................................264 14.15.5.3 Connection via Bluetooth .................................................................................................................265 14.16 Connecting EasyServe .............................................................................................................................266 14.17 Prefabricated system cables .................................................................................................................... 266 14.18 WLAN access point ..................................................................................................................................270 14.19 Basics of EMC-Compliant Cabling ...........................................................................................................271 14.19.1 Thoughts on the Cable Connections................................................................................................272 14.19.2 Screened Cables..............................................................................................................................272 14.19.3 Unscreened Cables..........................................................................................................................273 14.20 EC Declaration of Conformity ...................................................................................................................273 Index .......................................................................................................................................................275


BV-H6411GB, 1221 -5-

About This Manual

1 About This Manual This instruction manual describes the controller VCU 20103 loaded with software VCF 20170. This type of controller is designed for controlling a weighbelt feeder, especially for feeding coal into a pulverizer. It is usually used together with an operator panel type VHM. For easy retrofits in existing installations with STOCK Equipment controller type 196NT a different type of ® DISOCONT Tersus is provided. Please contact STOCK for details on that variant, if needed. Additional details on the hardware components and the interfaces of the DISOCONT ® Tersus system are found in the system manual BV-H2406 and the electrical schematics provided with the equipment. For service purposes a PC or notebook with software EasyServe (type VPC 20150) can be connected. For details on EasyServe besides the information in this manual see instruction manual BV-H2185. The controller provides optional means for communication via serial fieldbus of various types to the host plant control. Details on this communication are found in the separate fieldbus interface manual BV-H2418. Additional copies of these instructions may be ordered from the Parts Department at Stock Equipment Company, Chagrin Falls, Ohio. Refer to Part No. ATPDT9VCU20103.

Proprietary Note The information in this manual, including technical data and copies of drawings, contains information that is proprietary to Stock Equipment Company. This manual is provided to the user of equipment purchased from Stock Equipment Company for use only in operation or maintenance of such equipment. Information in this manual is not to be used, disclosed, copied, reproduced in whole or part for any use other than that indicated above, or for any purpose detrimental to the interests of Stock Equipment Company.inPatents ownedAny by Stock Equipmentother Company have been issued or are pending on some of the information this manual. unauthorized use of this subject matter of such patents is a violation of such patents and is prohibited by law.

Electrostatic Sensitive Decices Caution: The electronic controls contain ESD (Electrostatic Discharge) sensitive parts and assemblies that can be damaged by static electricity. The following static control precautions are required when testing, servicing, or repairing the electronic assemblies.

1. Disconnect power at the main disconnect switch or circuit breaker. 2. Only qualified personnel are permitted to perform and install the electronic controls. 3. Wear a wrist type grounding strap that is grounded to the control cabinet chassis. 4. When replacing the electronic circuit board. Do not remove the board from the static shielding bag it came in until you are ready to install the board. 5. When removing any electronic circuit board, immediately place it in static shielding bag. 6. Stock Equipment Company advises that all printed circuit boards should be returned to the factory for repair since our technicians are trained to work with electrostatic sensitive components.


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About This Manual

7. Contact the Stock Equipment Company Parts Department for a returns good authorization number to facilitate the return of an electronic circuit board. Returned components should be shipped in static shielding type bags. If packing materials are used, the y should be made of a static dissipative material. Note: If you are not familiar with static control procedures, before replacing electronic components, refer to US Department of Defense DOD - HDBK-263, Electrostatic Discharge Control Handbook for protection of electronic parts, assemblies, and equipment.

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Safety notes

2 Safety notes To avoid personal injury and equipment damage, follow the safety regulations stated below. Additionally, you should observe: ▪

Safety hints given in order-specific documentation

▪

Safety hints relating to mechanical components

▪

Instructions and safety tips for parts manufactured by sub-suppliers or that are not part of Schenck Process's scope of delivery.

When performing installation, comm issioning and service work, observe all applicable local regulations.

Intended Application The measuring system and its connected mechanical components are exclusively designed for weighing and controlling tasks. Any use other than srcinally intended is considered inappropriate.

Sources of Risk If the measuring system has been correctly installed and commissioned, it does not pose any danger during weigh operations. Hazards may arise when the system is used for control operations or for transporting weighed goods. Potential hazards may then arise from e.g. additional devices through which the weighed goods are passed or metered. Minor risks may arise in these situations if the measuring system is used or operated by untrained personnel. The measuring system can be part of a more complex plant. The system operating company is fully responsible for the operating safety of the system.

Personnel Preparation, assembly, commissioning, operation, maintenance and servicing may only be carried out by qualified personnel. All persons working on the system are required to observe the safety hints and know the parts of the technical documentation relevant to their work. The operating company is responsible for instructing his operators to observe all regulations and instructions given.

Changing Parameters The measuring system's functionality is determ ined by parameters. Only personnel familiar with the device's mode of operation may alter these parameters (e.g. after training by Schenck Process). Incorrectly set parameters may cause injury or material damage. Furthermore they may also cause considerable disruption to weigh operations.


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Safety notes

Password Passwords safeguard the parameters against unauthorized alteration. The measuring system operating company must ensure that the password is handled safely.

Acknowledging Event Messages Error messages may be acknowledged only after cause of fault has been remedied. Ensure that any connected peripheral devices are functioning correctly before acknowledging an event. Any connected control systems in particular must be in safe state.

Service and Maintenance ▪

▪

All warning and instruction signs on the scales must be observed. The measuring system must be shut down before work is performed on mechanical equipment or peripheral devices (control systems in particular). Tak e appropriate action to ensure that the m easuring system cannot be inadvertently restarted.

▪

Before performing work on the electrical equipment, disconnect the power supply.

▪

The devices may be operated only in the provided housings. There is danger of contacting live parts.

Moisture and Humidity All scales parts, electrical components in particular, must be protected from moisture and humidity when the housing is opened for e.g. maintenance and service. In other respects the protection classes of the housing must be observed.

Design Modifications Unauthorized modifications to the system and/or use of replacement parts not supplied by Schenck Process voids Schenck Process's liability for any resulting damages. This especially applies to alterations which could affect the operating safety of the system.

Replacing Components Spare parts must meet the technical specifications indicated by Schenck Process. To ensure this requirement is met, only genuine Schenck Process spare parts should be used. When using other spare parts, the warranty will be void.

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Safety notes

2.1

Signal Words

2.1.1

Signal Words for Safety Warnings

Potential dangers will always exist when working with technical devices. Dangers will arise if the machine ▪

is incorrectly installed,

▪

is started up incorrectly,

▪

is operated by untrained personnel or

▪

is repaired by unqualified personnel

The following signal words indicate throughout this manual dangers that may arise when handling this machine:

DANGER This signal word indicates a danger that can immediately cause the most severe injuries up to and including death.

Follow all instructions to prevent this from occurring.

WARNING This signal word indicates a danger that can cause serious injuries up to and including death.


CAUTION This signal word indicates a danger that can cause slight or medium injuries.



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Safety notes

2.1.2

Signal Words for Application Notes

Signal words for information on material damages and on the optimal use of the machine

STRICTLY OBSERVE Signal word used to identify situations in which material or environmental damage could occur.


HINT Signal word used to identify information on using the product economically and at an optimal level of efficiency.

2.2

Five Safety Rules of Electrical Engineering

These fives safety rules must be followed in the order shown before work is begun on electrical systems. Once the work is finished, they are to be applied in reverse order.

DANGER Electric shock from live components.

There is a danger of life from an electric shock. – Take all possible precautions to ensure safety before work is begun on live components. Observe, among other things, the following: 1. Disconnect the components. 2. Secure them against inadvertent restart. 3. Ensure that the components have been de-energized. 4. Above 1 KV: earth and bypass the cables. 5. Cover or shield adjacent, live components.

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Safety notes

2.3

Damaged / Defective Electrical Components

DANGER Live damaged or defective components

There is a danger of life from an electric shock. – Always have qualified personnel ensure that the components are neither damaged nor defective. 1. Qualified personnel must immediately replace or, if possible, repair damaged or defective electrical components.


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Overview

3 Overview This chapter explains the principle functions of the DISOCONT Tersus system used in conjunction with a Stock coal feeder.

3.1

What is the DISOCONT Tersus/DT-9?

The DISOCONT Tersus is a versatile family of modular weighing electronics for use with weighing and feeding systems. The DISOCONT Tersus performs all weighing and processing functions required for the measuring and feeding of bulk solids. It is designed for continuous measuring and control tasks as well as discontinuous batching. Used in conjunction with the specific application software for weighing and feeding tasks, the DISOCONT Tersus can be used in the following industries: ▪

Power

▪

Steel

▪

Basic Materials

▪

Cement

▪

Food

▪

Chemical.

In connection with the corresponding mechanical equipment, the following systems are supported: ▪

▪

Belt Scales

▪

Weigh Feeders Solids flow meters (chutes)

▪

Solids flow feeders

▪

Loss-in-weight, gain-in-weight feeders

▪

Mass flow meters (Coriolis meters)

▪

Mass flow feeders (Coriolis feeders)

▪

Filling systems.

The Stock DT-9 configuration of the DISOCONT Tersus is a modified version, optimized for feeding coal in power plant environment. There are two different versions of the DT-9. One is a completely redesigned and updated version that is used in new installations. The second one uses the same components and software but has been optimized for use as an upgrade to existing Stock 8085, 196, and 196NT installations. This version uses the 196NT connectors and mounting footprint. VCU 20103 – Designed for new installations where backwards compatibility is not required. This version is identified by the steel m ounting frame and screw type electrical connectors. A T ouch Screen HMI is always used when a VCU 20103 is installed. VCU 20104– Designed as a drop in replacement for the 196NT in existing installations. This version is identified by the brown Amp style electrical connectors. The VCU 20104 can be used with either a Touch Screen HMI or with an existing 196NT display.


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Overview

3.2

Definitions

The table below explains some basic terms used in this manual. Abbreviation

Meaning

Explanation

Unit

I

Actual feed rate

The actual amount of material delivered per unit time

Lbs/hr, Lbs/min, USTons/hr, Kg/hr, Kg/min or Metric Tons/hr

P

Feedrate setpoint

The desired amount material delivered perof unit time

Lbs/hr, Kg/hr, Kg/min Lbs/min, or MetricUSTons/hr, Tons/hr

Z

Totalized amount

Weight of material delivered since last counter reset

Lbs, US Tons, Kg or Metric tons

V

Belt speed

Feeder belt speed

Inches/sec, m/sec

Q

Belt load

Weight of material per unit of belt length.

Lbs/inch, Kg/m

QB

Platform load

Y

Controller magnitude

Output signal magnitude

Xd

Deviation

Difference between the % actual feedrate and the feedrate setpoint.

3.3

Lbs, Kg mA

Measuring Principle

The belt weighing system is designed to continuously weigh the amount of material transported on the feeder belt. The actual weight of material transported is calculated by multiplying the feeder belt load, in lbs/inch, times the feeder belt speed. The s ystems used to measure these two values are described below. Belt Load

The feeder weight signal is generated by two load cells that support a single weigh roller. Two weigh span rollers are located on each side of the weigh roller to accurately define the length of belt (and amount of coal) being supported by the weigh roller.

Since the load cells only support half of the weight on the weigh span (each load cell supports 25 percent of the total weight) the effective platform length (Leff) is calculated as: Leff = Lg / 2 Leff = Effective platform length Lg = Total platform length

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Overview

The microprocessor computes the feeder belt load by repeatedly reading the voltage signal from each load cell and converting the signal into a digital value (binary number) using an analog to digital (A/D) converter. Each value is then compared to parameters stored in permanent memory to determine if the signal is within acceptable limits, and if it is, it is stored for use. The same operation is then performed on the other load cell, and the signals are compared to each other to test their validity. If the signals are determined to be invalid, the feeder is switched to volumetric operation and the controller uses a simulated belt load calculated from an historical average stored in memory. If the signals are determined to be valid, the two load cell signals are summed, the tare is subtracted and the result is multiplied by a scaling factor based on the load cell data specified in P04.01 LC Characteristic Value and P04.02 LC Rated Capacity to determine the nominal weight of material on the belt. This nominal value is then multiplied by the three range correction factors (P10.03, P10.04 and P10.05) to determine the actual weight (QB).

The belt load (Q) is computed from the total weight (QB) as follows:

Q = QB / Leff

Q = Belt load in kg/m QB = Weight of load on platform in kg

Note: The 196NT parameter 10 Weigh Span Length is the full distance between the two weigh span rollers. The DT-9 parameter P04.03 Effective Platform Length is half the distance between the two weigh span rollers. For any given feeder, the value used by the DT-9 should be one half of the value used by the 196NT.

Belt Speed

During normal feeder operation, the belt speed is calculated from the motor RPM rather then being measured directly. The relation ship between motor speed and belt speed is determ ined during calibration and is displayed as P10.02 Pulses per length.

Feedrate Control and Totals

The weigh and speed information is used to calculate the actual feedrate as shown.

Feedrate (I) = Belt load (Q) x Belt Speed (V)

The feeder control accepts a feedrate set point from the source selected using parameter P03.02 Feedrate Setpoint . This signal is com pared with a computed feedrate derived from m easured weight and speed signals to generate the system error signal which is used to adjust the speed of the motor. Compensation for system stability is provided in the software using parameters P11.01 P-Component KP and P11.02 I-Component TN. These


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Overview

calculations are repeated periodically and at each iteration, the actual feedrate is multiplied by the time interval to calculate the totalizer increment. Separate totals are kept for gravimetric and volumetric operation.

3.4

Operating Modes - Remote

The Remote Operating Mode is provided for normal operation, with the feeder feeding coal under control of the plant control system. The source for the Start/Stop signal is designated by P03.01 Feeder Start and the source for the feedrate setpoint is designated by P03.02 Feedrate Setpoint. Analog feedback signals are generated based on the entries to parameter block 14 Analog Outputs. Digital feedback signals (relay outputs) are generated based on the entries to parameter block 16 Digital Outputs. While in the Remote Operating Mode, the feeder can use one of three systems to generate the required belt speed set point. Details for the different modes can be found in the appendix.

3.4.1

Gravimetric

Gravimetric Mode is the normal mode of operation. The feed rate is calculated using the belt speed and the actual belt load, and is controlled by the feed rate demand signal supplied by the plant control system. Parameter P03.05 Maximum Feedrate , corresponds to the maximum demand signal and the m inimum feed rate is set by parameter P03.06 Minimum Feedrate. Parameter P02.05 Nominal Flow Rate should always match parameter P03.05 Maximum Feedrate . The system can be set to produce an error if the demand signal is outside to normal range.

3.4.2

Volumetric

Volumetric Mode is used when an error is detected in the weighing system. The actual feed rate is calculated using the belt speed and an assum ed belt load based on the average value over the last several hours, and is controlled by the feed rate demand signal supplied by the plant control s ystem. Parameter P03.05 Maximum Feedrate, corresponds to the maximum demand signal and the minimum federate is set by param eter P03.06 Minimum Feedrate. Parameter P02.05 Nominal Flow Rate should always match parameter P03.05 Maximum Feedrate. The system can be set to produce an error if the demand signal is outside to normal range.

3.4.3

Volumetric Control

Volumetric Control Mode is a variation of the gravimetric mode that is used when the feeder weigh system is working correctly but the material on belt switch indicates that the belt is empty. The displayed feedrate and the customer feedback signal is still based on the actual material being fed and the gravimetric total is still being incremented but the belt speed is determined as if the feeder were in volumetric mode. This mode is used to prevent the feeder from running to maximum belt speed when material flow is lost.

3.5

Operating Modes

–

OFF/Maintenance

The OFF/Maint mode is is provided so that the feeder can be isolated from the plant control system during startup, calibration and other maintenance operations. In this operating mode, the plant start/stop and demand

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Overview

signals are ignored and feedback signals are not generated. The feeder must be in OFF/Maint mode before a system calibration can be performed. When the feeder is operated in the OFF/Maint mode, the belt speed is set based on the value of parameter P02.16 Maintenance Speed. This is an open loop signal calculated as a percentage of the full scale signal to the motor speed control (see parameters P11.04 Lower Limit, P11.05 Upper Limit and P01.06 Controller Magnitude Offset).

In OFF/Maint mode belt can be started via the buttons on the VHM, via the Local key on the 196NT keyboard or a digital input as defined by P15.25 DI: Local Start .


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DT-9 Setup

4 DT-9 Setup This section describes the startup process when a new feeder is installed or when an existing DT-9 is replaced.

CAUTION Installing the DT-9 in a feeder that uses the Stock Load Cell Amplifier

Installing the DT-9 in a feeder that uses the Stock Load Cell Amplifier will damage the DT-9. The old style Load Cell Amplifier must be replaced with the new version before the DT-9 can be used.

CAUTION DO NOT connect a normal Ethernet cable to X 96 (red RJ45 connector).

This connector uses normally unused wires in the CAT 5 cable to provide power to the touch screen display. Failure to follow this warning may result in damage to the DT-9 or to the attached network device.

HINT The weigh span is specified using parameter P04.03 Effective Platform Length .

This parameter is the distance between the weigh roller and either one of the weigh span rollers. This is one-half the value used by the 196NT, which is the distance between the weigh span rollers.

4.1 ▪

Setup Notes

This section is a general description of the feeder setup process. This process can be performed using either the touch screen HMI or a PC loaded with the EasyServe software. Section Operation Using the Touch Screen HMI [➙ 39] describes the Touch Screen HMI and Section Operation Using EasyServe [➙ 49] describes EasyServe.

▪

Events (Error conditions) are usually defined using three parameters. The first, which is usually hidden by default, defines the input signal that initiates the event, the second specifies the delay between the time when the error is detected and the time when the event is generated, and the third, specifies the type of event that is generated (A, W1, W2 or IG). In most cases, the Event (error) can be disabled by setting the

▪

type of event to IG. The DT-9 has 15 digital inputs (DI 1 through DI 15) and 13 digital outputs (DO 1 through DO 13). Each is assigned to a specific function, and wired to the appropriate external device. These assignm ents are hidden and should not be changed. See chapter ‚Default I/O Points ’ for a list of the default assignments.


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DT-9 Setup

▪

▪

The DT-9 has one analog input (AI 1) and two analog outputs (AO 1 and AO 2). AI 1 is normally used as the customer demand signal, AO 1 is normally used to control the motor speed control and AO 2 is normally used as the customer feedback signal. These assignments are hidden and should not be changed. The DT-9 has four slots for auxiliary analog I/O cards (channels A10-A13). These channels are not normally used. Contact Stock engineering if special analog I/O signals are required.

4.2

Startup and Functional Check

This procedure verifies that the feeder and its controls are operating properly, simulates feeder trip conditions, and checks the principal input/output connections. 1. Apply power to the feeder. 2. Insure that the feeder is in OFF/Maint mode and that the touch screen HMI is set to the home screen. 3. Set the feeder parameters as described in section Setup Parameters [➙ 17]. 4. Interpret event messages, if any, and correct faults. 5. Unbalance the load cells by engaging the calibration weight on one side of the weigh roller. The display should indicate volumetric mode. Unbalance each load cell in order to check both sides, then remove the calibration weight(s). 6. Press and maintain the Jog>> button to verify that belt travel is in the in correct direction. 7. Run the feeder in LOCAL mode by pressing the Run>> button. The feeder will operate at the maintenance speed programmed in P02.16 Maintenance Speed. Check the motor speed for stability. 8. Run the feeder in LOCAL by pressing the Run>> button. Set the Belt Drive Motor (Run Enable) switch to the STOP position. The feeder should stop and the display should show a IL01 Event: Run Disabled error message. Acknowledge the event and return the Belt Drive Motor switch to its normal position. 9. Stop the feeder and deflect the material-on-belt limit switch paddle to simulate a loaded belt. Run the feeder in the LOCAL mode to verify that the feeder trips. If it does not, check the adjustment of the paddle switch cams. 10. Check the event displa y or the event line on EasyServe. They should both show a WM12 Event: Coal on Belt alarm message with a time stamp. Acknowledge the event and return the coal-on-belt paddle to its normal position 11. Calibrate the feeder as described in section Calibration [➙ 20]. 12. Align the analog inputs and outputs as described in section Analog Trim Function [➙ 27]. 13. Hang the calibration weights. Produce or simulate a feeder start permissive. Check feedrate and feedback linearity by applying demand signals of 100, 75, 50, and 25 percent. Com pare each demand signal applied to the feedback signal output. Compare the demand feedrate setpoint (service value 4) with the measured feed rate of the feeder for each signal. 14. Energize the feeder in the REMOTE mode and deflect the discharge pluggage alarm (or touch the discharge pluggage sensor with a metal rod). After the preset delay in P15.10, the feeder should be de-energized. If the feeder does not trip, check the adjustment of the cams for the paddle switch or the sensitivity setting of the sensor according to the procedure in the srcinal equipment manual.

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DT-9 Setup

15. Check the event displa y or the event line on EasyServe. They should both show a WM07 Event: Discharge Pluggage alarm with a time stamp. Acknowledge the event and return the discharge switch to its srcinal state. 16. Return the feeder to REMOTE operation.

4.3

Setup Parameters

The microprocessor controller is tailored to specific feeders and customers needs by the setup parameters. Feeder-specific physical dimensions must be entered as well as user-selectable display modes and set points. These values are stored in perm anent memory and are only entered once. See section Parameters [➙ 59] for a complete list and description of the parameters. Note: In any given application, the majority of the DT-9 parameters are either not used, or fixed by the design of the feeder and cabinet. These param eters can be viewed using EasyServe in expert mode (default password 7353) but should not be changed.

The controllers will com e preprogrammed from Stock Equipment Company but if changes are needed, there are two ways to do this: ▪

Using EasyServe Software (See section Parameters [➙ 59])

▪

Using the Touch Screen HMI (See Section The 'Setup' Screen [➙ 42])

4.3.1

Commonly Changed Parameters

The following is a list of parameters that are commonly changed during startup. Their values should be recorded for future reference. See section Parameters [➙ 59] for a complete list and detailed descriptions.

P-No.

P-Name

Actual

The following parameters set the feedrate associated with a 100 % demand signal (usually 20 mA). They must always be set to the same value. See project specific documentation for the correct value. P02.05

Nominal Flow Rate

P03.05

Maximum Feedrate

The following parameter is the belt speed associated with the nominal (maximum) feedrate and the nominal material density. It is calculated as: P02.05 Nominal Flow Rate) / (300 X Nom. Density X P04.10Load cross section Inputs are in lbs/hour, lbs/cubic ft and square feet. Results are in inches/sec. P02.06

Nominal Speed

The following parameter sets the minimum feedrate clamp. See project specific documentation for the correct value. P03.06

Minimum Feedrate


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DT-9 Setup

P-No.

P-Name

Actual

The following parameter selects the text string displayed on the top line of the touch screen HMI. P02.03

Scale Name

The following parameters select the units and formats that are used to display the various feeder information on the display. P02.01

Language

P02.02

Units

P02.07

Display Formats

P02.08

Flow Rate Units

P02.09

Counter 1 Unit

P02.10

Counter 2 Unit

P02.11

Counter 3 Unit

The following parameter selects the demand signal to the motor speed control when the feeder is running in local mode. It is normally set to 50 %. P02.16

Maintenance Speed

%

The following parameter specifies the length of belt that is supported by the load cells. It must be set to the distance between the first weigh span roller and the central weigh roller (one half the distance between the weigh span rollers). See project specific documentation for the correct value. P04.03

Effective Platform Length

The following parameter specifies the characteristics of the motor tachometer. See project specific documentation for the correct value. P04.09

Tachometer: Pulses per Rev

P/rev

The following parameter specifies the area under the leveling bar. See project specific documentation for the correct value. P04.10

Load cross section

P07.02 sets the maximum time between Belt Motion Monitor (BMM) pluses and P07.03 selects the type of event that is generated when this limit is exceeded. Set P07.03 to IG if a BMM is not installed. See project specific documentation for the correct values. P07.02

Belt Motion Monitor Delay

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s


DT-9 Setup

P-No.

P-Name

P07.03

Event: Belt Motion Monitor

Actual

A / W1 / W2 / IG

The following parameter specifies the distance between the calibration probe bosses. See project specific documentation for the correct value. P10.01

Calibration Probe Span

The following parameter specifies the actual value of the calibration weigh. This value is stamped on the weight. P10.08

Calibration Weight

The following parameters specify the cleanout conveyor duty cycle. Set P13.02 to zero to run the cleanout conveyor continuously. P13.02

CleanOut ON Time

Hours

P13.03

CleanOut OFF Time

Hours

The following parameters control the ‘Loss of Material on Belt’ event. Setting P05.14 to A causes the feeder trip (stop the feeder) when the coal on belt signal is lost during normal operation. Setting P05.14 to W1 or W2 will produce a warning. P05.13 sets the delay between the time that the signal is lost and the time that the event is generated (This is normally set to one second). Set P05.14 to IG to disable this feature. P15.13

Loss of Flow Trip Delay

P15.14

Event: Loss of material

A / W1 / W2 / IG

The following parameters are used to control the Level/Temperature Sensor event. The Level/Temperature Sensor input is normally connected to either a flow monitor in the downspout or a temperature switch at the feeder discharge. Setting P15.21 to A causes the feeder trip (stop the feeder) when the coal flow monitor indicates a loss of flow in the downspout. Setting P15.21 to W1 or W2 will produce a warning. P15.20 sets the delay between the time that the signal is detected and the time that the event is generated. Set P15.20 to 100 lbs for a quick response. Set P15.21 to IG to disable this feature. See project specific documentation for the correct value. P15.20

Level/Temperatur Sensor Delay

P15.21

Event: Coal Flow

A / W1 / W2 / IG

The following parameters specify the Ethernet communications address. The default values should not be changed unless the DT-9 is connected to a local network. P23.01

IP Address

P23.02

Net Mask

P23.03

Gateway


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DT-9 Setup

4.4

Calibration

The feeder should be calibrated at startup, after one month of initial operation and every six months there after. Calibration should also be performed following a weigh roller adjustment or replacement of the belt, the CPU board, or a load cell module. The controller should also be calibrated after the controller firmware is updated or a Load Default Values operation is performed. Calibration is accomplished in two separate steps. Step one of calibration consists of the elimination of system tare, which includes the weight of the weigh roller, load cell support assembly, and the feeder belt. It also involves measuring belt speed and its relationship to motor speed. Step two calibrates the load cell output with a known weight. Cancellation of feeder tare is performed by measuring the average weigh system output over exactly two belt revolutions (eight tape passes) and then subtracting this amount from the total weight measurement. When the belt is running empty, it produces a zero average contribution to the totalized weight. In normal operation, the average tare is automatically subtracted from the gross weight of the belt. Therefore, only the material weight on the belt is reflected as totalized weight. While the empty belt is being weighed, the belt speed is also being accurately measured. This is done by measuring the time it takes a retro-reflective marker, attached to the belt, to travel between two fixed points on the feeder body. This parameter is measured eight times to determine repeatability and to compensate for variations in belt thickness. From this data, the belt speed is calculated and the relationship between belt speed and motor speed is established. The feeder operates with zero belt slippage. Therefore, the ratio of belt speed to average motor speed is constant. This ratio is stored in memory and is used to determine the belt speed for any motor speed. The span of the weighing system is set after the tare has been measured. A known weight is applied to the weigh roller and the average output over exactly two belt revolutions (eight tape passes) is measured. This calibrated span factor is stored in memory and used to accurately determine the value of the weight of the material on the belt. Note: The DT-9 parameter P04.03 Effective Platform Length is the distance from either weigh span roller to the central weigh roller, which is supported by the load cell. This is half the distance between the two weigh span rollers. For any given feeder, the value used by the DT-9 should be one half of the value used by the 196NT.

4.4.1

Performing Calibrations

The calibration process consists of the following three steps. 1. Weigh Roller Adjustment. 2. Basic (Cal 1) – Belt speed and tare calibration. 3. Span (Cal 2) – Belt Speed and span calibration. Note: At least one Basic (Cal 1) must be perform ed prior to performing a Span (Cal 2).

The following special calibration processes can be preformed for testing or special m aintenance operations, but are not normally required. 1. TC: Span calibration - Chain test calibration. 2. LB: Pulses / Belt - Belt speed calibration.

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DT-9 Setup

3. TA: Tare - Tare calibration. Note: Calibration is considered a local operation. No totalization takes place and analog feedback signals are set to minimum.

4.4.2

Weigh Roller Adjustment

For the feeder to weigh accurately, the central weigh roller must be aligned with the weigh span rollers within 0.002 inch (0.05 mm). Refer to Fig. Note: The parts shown may differ from those that actually shipped. This figure is to be used as a general guideline. Weigh Roller Adjustment Procedure

1. Mount the calibration weight on both load cells. 2. Insert the checking bars (A2451-1) through the discharge end access door of the feeder, adjacent to the sides of the belt, and with their machined surfaces resting on the weigh span and weigh rollers. 3. Beginning on either side, insert a 0.005 in. shim between each of the three rollers and the machined surface of the checking bar (three places).

Fig. 1: Weigh Roller Adjustment

1 Weigh Roller

6 Adjustment Block

2 .005 SHIM

7 Plug

3 Checking Bar

8 Jam Nut

4 Belt

9 Drag Link

5 Load Cell


BV-H6411GB, 1221 - 21 -

DT-9 Setup

1. Loosen the jam nut, and then turn the adjustment block to lower the weigh roller. 2. Slowly turn the adjustment block to raise the weigh roller until the shim is touching both checking bar and weigh roller (slip fit). Tighten the jam nut. 3. Similarly, adjust the weigh roller on the opposite side of the feeder. 4. Remove the checking bars. 5. Remove the calibration weights. 6. The feeder must be recalibrated after weigh roller adjustment. (See procedure on next page.)

4.4.3

Basic (CAL 1)

This operation measures the tare factor and the belt speed factor and updates the following parameters. ▪

P10.02 Pulses per length

▪

P10.10 Basic Tare

▪

P10.11 Belt Circuit No.

Note: The calibration results are not saved to the parameter table until the operator accepts them buy pressing in EasyServe, on the (optional) Touch Screen HMI or on the 196NT display.

Requirements: ▪

The weigh span must be level prior calibration. If the weigh roller height has been adjusted, a complete calibration (Basic (Cal 1) and Span (Cal 2)) must be performed.

▪

▪

The calibration probes must be installed and in the correct location. – Cal probe A is located closer to the feeder inlet. – De-energize the DT-9 before installing the probes. Four retro-reflective tape clips must be installed on the belt. – The tape clips must be farther apart than the distance between the cal probes or a Probe Error will be generated and the calibration will not complete. – Four tape clips are normally used but two can be used if the feeder is very shot or eight can be used if the feeder is very long or slow. If two tape clips are used, the feeder will be calibrated over four belt revolutions, instead of two, and P10.11 Belt Circuit No. will be twice the correct value. If eight tape clips are used, the feeder will be calibrated over one belt revolution and P10.11 Belt Circuit No. will be half the correct value.

▪

The feeder must NOT be in volumetric mode.

▪

The feeder must be in OFF/Maint mode.

▪

The feeder belt must be empty.

▪

The calibration weights must NOT be installed.

Calibration Procedure: Before starting the calibration, record the values of parameters P10.02 Pulses per length and P10.10 Basic Tare 1. These will be used later to verify that the calibration results are consistent.

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DT-9 Setup

2. If the calibration is being performed using EasyServe, navigate to the calibration window using the Tools | Calibration Programs menu items. If the (optional) touch screen HMI is being used, first log in, then go to the calibration display by pressing the and buttons. 3. Select Basic (Cal 1) 4. Initiate the Basic (Cal 1) calibration process by pressing the button in EasyServe or the (optional) Touch Screen HMI, or the button on the 196NT display. 5. The feeder will begin to run and go through a stabilization process. – The motor will first run at a one-half the value specified in P02.16 Maintenance Speed, then at the full value of P02.16. 6. After Stabilizing, the feeder will go through eight tape passes. The DT-9 will display the pass number and tachometer pulses on the screen. 7. Upon completion of the calibration four values will be displayed on the screen: – Deviation (Variation between belt speed measurements) – Belt Circuit No (P10.11) – Basic Tare (P10.10) – Pulses per Length Value (P10.02). 8. After successful completion, the screen will prompt you to either save or cancel the calibration values. Note: If the calibration results in bad values, correct any mechanical issues and run the calibration program again. 9. Press the , < ENTER> or button to store the new calibration values, or the or button to abort the calibration leaving the parameters unchanged. 10. After the calibration has been performed, verify that the results are consistent by comparing the latest values of P10.02 and P10.10 to the previous values (Recorded in step 1). Calculate the percent change using the formula [100 x (new value - old value) / (new value)]. If the result is greater then 0.25 %, check for mechanical errors in the weigh system and repeat the calibration.

4.4.4

Span (CAL 2)

This operation measures the load cell span factor and the belt speed factor, and updates the following parameters. ▪

P10.03 Range Correction TW

▪

P10.11 Belt Circuit No.

Note: The calibration results are not saved to the parameter table until the operator accepts them buy pressing in EasyServe, on the (optional) Touch Screen HMI or on the 196NT display.

Requirements: ▪

The weigh span must be level prior calibration. If the weigh roller height has been adjusted, a complete calibration (Basic (Cal 1) and Span (Cal 2)) must be performed.

▪

The calibration probes must be installed and in the correct location. – Cal probe A is located closer to the feeder inlet. – De-energize the DT-9 before installing the probes.


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DT-9 Setup

▪

▪

Four retro-reflective tape clips must be installed on the belt – The tape clips must be farther apart than the distance between the cal probes or a Probe Error will be generated and the calibration will not complete. – Four tape clips are normally used but two can be used if the feeder is very shot or eight can be used if the feeder is very long or slow. If two tape clips are used, the feeder will be calibrated over four belt revolutions, instead of two, and P10.11 Belt Circuit No. will be twice the correct value. If eight tape clips are used, the feeder will be calibrated over one belt revolution and P10.11 Belt Circuit No. will be half the correct value.

▪

The feeder must NOT be in volumetric mode. The feeder must be in OFF/Maint mode.

▪


▪

A Basic (Cal 1) had been performed.

▪

▪

Enter Parameter P10.08 Calibration Weight. Ensure that the value entered matches the total value stamped on the calibration weight(s). Mount the calibration weight(s) on the load cells.

Calibration Procedure: 1. Before starting the calibration, record the value of parameters P10.02 Pulses per length and P10.03 Range Correction TW . These will be used later to verify that the calibration results are consistent. 2. If the calibration is being performed using EasyServe, navigate to the calibration window using the Tools | Calibration Programs menu items. If the (optional) touch screen HMI is being used, first log in, then go to the calibration display by pressing the and buttons. 3. Select Span (Cal 2) 4. Initiate the Span (Cal 2) calibration process by pressing the button in EasyServe or the (optional) Touch Screen HMI, or the button on the 196NT display. 5. The screen will prompt to add the calibration weight. The top line of the display will show the value entered in P10.08 and the bottom line show what the load cells are measuring based on the current calibration parameters. Press the or button to proceed with calibration. 6. The feeder will begin to run and go through a stabilization process – The motor will run at the value specified in P02.16 Maintenance Speed. 7. After Stabilizing the feeder will go through eight tape passes – The pass number and tachometer pulses will be displayed on the screen 8. Upon completion of the calibration, four values will be displayed on the screen. – Deviation (Variation between belt speed measurements) – Belt Circuit No (P10.11) – Range Correction TW (P10.03) – Pulses per length. Value (P10.02) 9. After successful completion, the screen will prompt you to either save or cancel the calibration values. Note: If the calibration results in bad values, correct any mechanical issues and run the calibration program again.

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DT-9 Setup

10. Press the , < ENTER> or button to store the new calibration values, or the or button to abort the calibration leaving the parameters unchanged. 11. After the calibration has been performed, verify that the results are consistent by comparing the latest values of P10.02 and P10.03 to the previous values (Recorded in step 1). Calculate the percent change using the formula [100 x (new value - old value) / (new value)]. If the result is greater then 0.25 %, check for mechanical errors in the weigh system and repeat the calibration.

4.4.5

TC: Span Calibration

This operation performs a chain calibration using the values in P10.07 Simulation Travel (Belt Rev.) and P10.09 Test Chain Weight. The results are used to update the following parameter. ▪

P10.04 Range Correction TC.

Note: The calibration results are not saved to the parameter table until the operator accepts them buy pressing in EasyServe, on the (optional) Touch Screen HMI or on the 196NT display. Note: The calibration probes are not used during this operation and do not need to be installed.

Requirements: ▪

The weigh span must be level prior calibration. If the weigh roller height has been adjusted, a complete cali-

▪


▪


▪


▪

The calibrated test chains must be installed.

bration (Basic (Cal 1) and Span (Cal 2)) must be performed.

Calibration Procedure: 1. Before starting the calibration, record the value of parameter P10.04 Range Correction TC . This will be used later to verify that the calibration results are consistent. 2.

If the calibration is being performed using EasyServe, navigate to the calibration window using the Tools | Calibration Programs menu items. If the (optional) touch screen HMI is being used, first log in, then go to the calibration display by pressing the and buttons.

3. Select TC: Span Calibration. 4. Initiate the TC: Span Calibration process by pressing the button in EasyServe or the (optional) Touch Screen HMI. This process cannot be performed using the 196NT display. 5. The screen will prompt to add the calibration weight (test chain). The top line of the display will show the value entered in P10.09 and the bottom line show what the load cells are measuring based on the current calibration parameters. Press the button to proceed with calibration. 6. The feeder will begin to run and go through a stabilization process – The motor will run at the value specified in P02.16 Maintenance Speed . 7. After Stabilizing the feeder will run for the number of belt revolutions specified in P10.07. – The percentage complete will be displayed on the screen 8. Upon completion of the calibration, four values will be displayed on the screen.


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DT-9 Setup

– TC: Ready (Simulated weight delivered) – Range Correction TC (P10.04)

9. After successful completion, the screen will prompt you to either save or cancel the calibration values. 10. Press the , < ENTER> or button to store the new calibration values, or the or button to abort the calibration leaving the parameters unchanged. Note: If the calibration results in bad values, correct any mechanical issues and run the calibration program again. 11. After the calibration has been performed, verify that the results are consistent by comparing the latest value of P10.04 to the previous value (Recorded in step 1). Calculate the percent change using the formula [100 x (new value - old value) / (new value)]. If the result is greater then 0.25 %, check for mechanical errors in the weigh system and repeat the calibration.

4.4.6

LB: Pulses per Belt

The LB: Pulses per Belt calibration process is not intended for use in coal feeder applications and should not normally be preformed.

4.4.7

TA: Tare

This operation measures the weight of the empty belt (tare factor) for a period of time based on the value of P10.11 Belt Circuit No. times P10.07 Simulation Travel (Belt Rev.) , and updates the following parameter. ▪

P10.10 Basic Tare

Note: The calibration results are not saved to the parameter table until the operator accepts them buy pressing in EasyServe, on the (optional) Touch Screen HMI or on the 196NT display. Note: The calibration probes are not used during this operation and do not need to be installed.

Requirements: ▪

The weigh span must be level prior calibration. If the weigh roller height has been adjusted, a complete cali-

▪


▪


▪


▪

The calibration weights must NOT be installed.

bration (Basic (Cal 1) and Span (Cal 2)) must be performed.

Calibration Procedure: 1. Before starting the calibration, record the value of parameter P10.10 Basic Tare. This will be used later to verify that the calibration results are consistent. 2. If the calibration is being performed using EasyServe, navigate to the calibration window using the Tools | Calibration Programs menu items. If the (optional) touch screen HMI is being used, first log in, then go to the calibration display by pressing the and buttons. 3. Select TA: Tare calibration.

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DT-9 Setup

4. Initiate the TA: Tare calibration process by pressing the button in EasyServe or the (optional) Touch Screen HMI. This process cannot be performed using the 196NT display. 5. The feeder will begin to run and go through a stabilization process – Run the motor at the value specified in P02.16 Maintenance Speed. 6. After Stabilizing, the feeder will run for the specified time (P10.07 times P10.11). The DT-9 will display the percent completion and the current tare value as a percentage of the rated belt load. The nominal belt load is defined as the nominal flow rate divided by the nominal belt speed. 7. Upon completion of the calibration two values will be displayed on the screen: – Deviation – Percent deviation between the new tare value and the previous value. – Tare – Tare value as a percentage of the nominal belt load.

8. After successful completion, the screen will prompt you to either save or cancel the calibration values. 9. Press the , < ENTER> or button to store the new calibration values, or the or button to abort the calibration leaving the parameters unchanged. Note: If the calibration results in bad values, correct any mechanical issues and run the calibration program again. 10. After the calibration has been performed, verify that the results are consistent by comparing the latest value of P10.10 to the previous value (Recorded in step 1). Calculate the percent change using the formula [100 x (new value - old value) / (new value)]. If the result is greater then 0.25 %, check for mechanical errors in the weigh system and repeat the calibration.

4.5

Analog Trim Function

The feeder controls respond to a feed rate demand signal and return isolated analog feedback signals. When the input and output modules associated with these signals are used with the plant ’s control system, they must be adjusted prior to operating the feeder under remote control. To perform this procedure, Stock Equipment Company recommends the Fluke Model 87 Digital Multimeter or equivalent. The DC accuracy for milliamps should be ±0.2 % and the DC accuracy for voltage should be ±0.1 % plus 1 digit. It also must have a 4½ digit highresolution mode. ▪

▪

Setting analog trim values using the touch screen HMI (See section Operation Using the Touch Screen HMI [➙ 39]) Setting analog trim values using EasyServe (See section Operation Using EasyServe [➙ 49])

Note: The plant combustion control system is the preferred source of the demand signal. This will precisely align the feeder to the control s ystem.

The DT-9 has one built in analog input (4 - 20 mA or 0 – 10 VDC) and two built in analog outputs (4 - 20mA only). These I/O channels are described below. 1. AI 1: Connected to wires SIG+ & SIG- (X6-3, X6-4 or X6-3, X6-5). This input is normally used for the customer demand signal. The value in P03.02 Feedrate Setpoint (normally hidden) should be set to AI 1. 2. AO 1: Connected to wires 142, 143 & 144 (X6-6 and X6-7). This output is normally used for the motor speed control (VFD). The value in P11.03 AO: Motor Speed Control should be set to AO 1. 3. AO 2: Connected to wires 139, 140 & 141 (X6-8 and X6-9). This output is normally used for the customer feedback signal. The value in P14.04 AO: Actual Flow Rate should be set to AO 2.


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DT-9 Setup

In addition to the built in analog channels, there are four slots in which analog I/O cards can be installed. Parameter group 1 is used to assign each slot to an analog I/O channel (AI 2 through AI 5 or AO 3 through AO 6). Slots can be either input or output, depending on the type of card installed. Each card is individually isolated. 1. A10: Connected to terminal blocks X12-1 and X12-2. Can be assigned to AI 2 or AO 3. 2. A11: Connected to terminal blocks X12-3 and X12-4. Can be assigned to AI 3 or AO 4. 3. A12: Connected to terminal blocks X12-5 and X12-6. Can be assigned to AI 4 or AO 3. 4. A13: Connected to terminal blocks X12-7 and X12-8. Can be assigned to AI 5 or AO 6.

4.6

Belt Monitoring

The DISOCONT Tersus has an expanded belt monitor integrated into it that monitors belt drift and slippage. Belt drift monitoring is activated by configuring the source for the belt sensor in the P07.04 DI: Source Belt Sensor parameters. Monitoring may only be activated if the conveyor is equipped with a belt with integrated triangular markings and if the sensor has been installed. Additionally, differences in weight across the belt, unavoidable despite its high quality, can be identified over one belt circuit and be compensated for (BIC). This function is activated by the P07.05 BIC Active parameters. Belt-drift switches feed to inputs used for the identification of external events. Furthermore, belt motion can be monitored using additional (1 or 2) sensors (parameter group ' 2-Sensor Slip').

4.6.1

Belt Drift Monitoring

The sensor records the position relative to the feeder frame of the triangles integrated into the belt. The result is presented after one complete belt circuit.

Fig. 2: Principle of belt-drift monitoring

The departure of the course of the belt from the neutral position can be shown in the operating area Setup.

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DT-9 Setup

Activating the monitoring

Set the relevant parameters: Parameters

Value and details

P07.04

Defines the input channel used to connect the sensor that monitors the triangle in the belt and activates the function.

P07.08

Defines system behavior if the sensor and the triangles identify belt slippage.

P07.09 The length L of the triangle, measured in the direction of belt motion (value is given in the scales data sheet), as per the diagram.

P07.10

The factory defaults are suitable for most situations. P07.11

The width W of the triangle, measured transverse to the direction of belt motion (value is g iven in the scales data sheet), as per the diagram.

P07.12

Measured value for the neutral position relative to the feeder frame. Upon commissioning, the sensor must be set such that the display for deviation from the neutral position indicates zero. Small deviations can be adjusted later via parameters.

P07.14 - P07.18

Tolerance thresholds and reactions to events belt-drift (advance warning) and belt-drift (critical condition).

The factory defaults are suitable for most situations.

The factory defaults are suitable for most situations. Tab. 1 : Parameter for BIC and for belt motion monitoring

Procedure to be followed Step

Task

1

Enter the parameters as per the list given above

2

Set the scales so that the belt runs centered.

3

Execute the adjustment program ' LB: Pulses/Belt' and use the result after two complete belt circuits.

4

Set the sensor relative to the belt so that the course indicator shows zero. Small deviations can be adjusted via P21.01. For example: For P07.12 = 0, display of belt drift = 0.2 then For P07.12 = -0.2, display of belt drift = 0

5

By altering the value of P21.01, belt drift can be simulated and the system's reaction to this condition can be observed. Set P07.12 back to its o riginal value after the test.

Tab. 2 : Sequence for adjustment and commissioning


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DT-9 Setup

4.6.2

Belt Influence Compensation (BIC)

The automatic belt influence compensation (BIC = Belt Influence Ccompensation) monitors and corrects the influence of the belt on the material weight measurement. As with belt monitoring, it requires a sensor and a marking in the belt. BIC improves feed consistency and batch accuracy, if batch mode is preset. For the initial commissioning, we recommend switching BIC off (P07.05 = NO). The belt-drift monitoring [➙ 28] must be activated to enable this function. After commissioning, BIC can be activated once normal bulk material conditions have been established on the belt (P07.05 = YES). The parameters for the belt drift monitoring must have been set. The BIC will have measured the belt influence after around 10 belt circuits and will be able to correct the weight value accordingly. It does not require setting.

4.6.3

Belt Slippage Monitoring

Belt slippage is defined as the difference between the speed of the belt as set by the head pulley and the actual speed of the belt. Belt slippage can result from an excessively high removal force on the bulk material from the hopper, from soiling of the drive roller or from excessively low belt tension. Slippage influences directly measuring and feeding accuracy, as the measured value for belt speed is calculated using the rotational speed of the motor.

4.6.3.1

Monitoring Standstill after Startup

A carrying idler or the guide pulley is equipped with an impulse sensor. Standstill monitoring can only be used if the feeder is run with a minimum feed rate setpoint. If the belt can be run with a feed rate of zero, a different manner of belt slippage monitoring must be implemented if it is required. After a short waiting period after the feeder is switched on, the signal sent to the input channel defined in P16.23 is evaluated. If this signal transmits no impulse within the time defined by P07.02, it will be assumed that the belt is not moving. In this case the corresponding event is triggered (P07.03). Belt slippage of only a few percent cannot be detected using this method.

4.6.3.2

Belt Slippage with Belt Marking

If using a belt with a belt marking, this marking can be used to measure belt motion. The comparison between the belt motion expected as a result of the head pulley motion and the distance measured across the duration of two belt marking measurements allows the slippage to be detected with high accuracy. This method also allows errors in the belt speed to be identified that result from soiling of the drive roller. However, this method can only produce results after one complete belt circuit. A different method must be used if more rapid identification is required. In order to harness this method, the belt drift monitoring [ ➙ 28], the belt slippage threshold (in P07.07) and the reaction to the event (in P07.08 and P07.09) must be set.

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DT-9 Setup

4.6.3.3

Two-Sensor Belt Slippage Monitoring

Two sensors whose signals supply information on the belt speed are required for this form of belt slippage monitoring. A comparison of both signals gives information on the reliability of each signal and the belt slippage between both measuring points. The information given by the impulse tachometer on the motor can be used for one of the signals, and can also be used for the feed rate calculation. A second signal is generated by a pulse sensor on a carrying idler or guide pulley. The ratio of the speeds measured by the two sensor signals gives a measured value for belt slippage. Setting the two-sensor belt slippage monitoring Parameter

Setting

P18.01

= YES activates the monitoring system

P18.02

Select the source for the first speed signal Speed: the main tacho on the belt drive is used DIxx: an additional sensor is used

P18.04

Characteristic value of the first sensor in impulses per section

P18.05

Signal input for the second measuring channel

P18.06

Characteristic value of the second sensor in impulses per section

P18.07

Tolerance threshold level for the difference of the speed measured across both measuring channels in relation to the actual speed.

P18.08

Definition of behavior if slippage above the permissible threshold is identified.

P18.09 Tab. 3 : Setting and adjusting the two-sensor belt slippage monitoring


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Operating and Control Access

5 Operating and Control Access DISOCONT Tersus can be operated using the following approaches:

Operating source

Operation under normal circumstances X

VHM Operating Panel (fixed) VHM Operating Panel

Service work

User Interface Type

X

VHM touch

X

VHM touch

(mobile per cable or wireless) Fieldbus from the control computer

X

(X)

Host computer

Web browser via PC

X

EasyServe PC software

X

VHM with PC keyboard EasyServe

Tab. 4 : Operating access

DANGER Feeding can be started with the operating panel. This switches on drives and bulk material may flow. The operator must ensure that no damage can be caused by beginning feeding before doing so. Dangerous situations may arise if communication is interrupted while the device is being operated via a non-permanent line (pluggable cable, wireless). Therefore, such methods of accessing control should be reserved for service work only.

5.1

Connection between VHM Operating Panel and Scale Controller (VCU)

After a loss of power at the operating panel, the console will try automatically to reconnect to the scales with which it was communicating before the power failure after a specific, adjustable period of time. During this time the 'Feeder' page can again be selected to select a different scale. If a data connection exists and communication with a different scales is to be activated, the existing connection must first be closed. This can be done after logging on as a privileged user with the key '<->Scale'. An error message is displayed on the screen if a connection is lost. If the connection cannot be re-established after several attempts, the operating panel will open the configuration dialog. The selection of a scales is shown in the following chapters, depending on the medium of communication.


BV-H6411GB, 1221 - 33 -


5.1.1

Connection via Ethernet Cable

Precondition: The VHM operating panel must be connected to the ethernet network to which the control unit VCU is also connected. The hardware requirements are described in the system manual BV-H2406.

The channel 'Ethernet' must be selected in the operating panel configuration (Configuring the Communication Path (Com)). Once the first connection has been made, the operating panel searches for VCU controllers in the network and displays the outcome on the page 'Feeder'. A scales can be selected and a data connection to it established by pressing the corresponding key.

5.1.2

Connection via Bluetooth

Preconditions: A bluetooth adapter must be connected both to the operating panel and the scales. The scale has to be in the range of the function. The hardware requirements are described in the system manual BVH2406.

The Bluetooth channel has to be selected (Configuring the Communication Path (Com)) in the configuration of the operator panel. Once the communication path has been selected, the console will search for bluetooth adapters within range. Other Bluetooth adapters can be found and displayed along with controller VCUs. The outcome is shown on the page „F eeder“. Note: A complete search for all bluetooth adapters can take several seconds. A progress indicator is displayed during the search. There will also be Bluetooth adapters shown that no connection can be established to, either because they are not DISOCONT Tersus controllers or there is already a different data connection.

Scales can be selected and a data connection to them established by pressing the corresponding key. It may take several seconds before a connection is established. The respective status will be shown in the header of the operating panel while a connection is being established. Note: Connection can be established to one scales only, assum ing the scales are not already connected to another bluetooth adapter. The other connection may first need to be closed. If there is another connection, the operating panel will try constantly to connect.

If bluetooth is used, the scales to whose bluetooth adapter a connection has been established is the only scales with which communication can be made. The ethernet destination address may not be changed in the VHM.

5.1.3

Connection via RS485

Prerequisites: The operator panel and controller have to be in the same RS485 network. The hardware requirements are described in the system manual BV-H2406.

The RS485 channel has to be selected in the configuration of the operating panel (Configuring the Communication Path (Com)). Once the communication path has been selected, the operator panel will switch to the Feeder page. This is where the address of VCU is set. The last digits of the Ethernet address (P25.07) of the scale controller will be used again for addressing at the RS485 bus.

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The system performs a check of the communication path once the address has been entered. If communication can be established under the address entered, this is indicated by a green marking beside the address number. Otherwise this marking will be red. Communication with the scales can be established with the key 'Con.Scale'. Note: The operating panel is the master at the bus. Therefore only one operating panel can be connected to the bus at any one time.

5.2

Connecting a PC with EasyServe to a Scales Controller (VCU)

5.2.1

Connection via Ethernet

If the connection is to be established by cable the connection should be made using ethernet. Preconditions: The EasyServe PC is connected with an ethernet cable to the scales network. Note: Use either an uncoded VCU socket or, if using a red-coded socket, use a special cable (yellow) for the connection.

The EasyServe address must be in the same ethernet subnetwork as the scales' address. If necessar y the address can be changed by EasyServe in the scanner. A scales can also be addressed using a router if the network has already been configured. The scales address would then be entered manually, not using the scanner. The PC must then have an IP address in the directly connected subnetwork. The EasyServe Connection I Ethernet (Scanner) menu item is the easiest way to select. This will display all of the scales available in the network. The scales' connection parameters can be altered and a connection to the scales made here. If the scale is connected to a different subnet, it can be selected manually using Connection | Ethernet (manual) and entering the IP address of the scale.

5.2.2

Connection via RS-232

RS-232 is used to make a connection in special cases only, e.g. when no connection can be made via ethernet. It may be necessary to establish a connection via RS-232 if there is a power failure to a device while a software program is being loaded into it in order to re-load the software. Precondition: The PC serial interface (COM) is connected by cable to VCU socket X97. For details see the system manual BV-H2406.

Use the EasyServe menu item 'Connection | Serial...' to connect. The only permissible transfer format is 38400 baud, 8-O-1. Select the PC COM port and the address of the scales. The is stored in scales parameter P21.01 Own Address. Note: A software update can take up to 20 minutes using the RS-232 interface. Other functions work slower than they would if the connection was made using Ethernet.

5.2.3

Connection via WLAN

We recommend using WLAN to make a wireless connection to a scales.


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Preconditions: The scales have been connected with a WLAN modem to the Ethernet. The WLAN modem has been configuered as an access point and its ethernet address is in the same subnetwork as the scales. The PC also has a WLAN modem, and the IP address of the PC is in the same network as the scales' IP address.

In general the W LAN modem is configured using a browser before use. This configuration is described in the modem's user manual. The WLAN in the PC is activated and the WLAN access point selected. Once the connection to the WLAN access point has been made, all of the functions can be accessed on the PC as they would if an ethernet connection were made by cable.

5.2.4


A connection is more complicated to establish via bluetooth than via W LAN. The only scales that can be accessed is the one to whose bluetooth adapter the connection was established. Preconditions: Scales and PC are equipped with bluetooth adapters.

Establishing a connection: 1

Start the bluetooth adapter configuration program in the PC.

2

Select the desired scales from the list of adapters displayed. Note: It will be necessary to restart the PC if the name of the scales was changed in order to display the changed name.

3

Begin establishing a connection with the bluetooth adapter. Password: 7353.

4

The PC user must enter a PAN once the connection to the bluetooth adapter has been established.

5

The address of the bluetooth scales is one number lower than the scales' IP-subnetwork set by parameter. The PC address must be in the same subnetwork.

6

The scales can now be selected using the scanner or by means of a direct address input. Other scales in the network cannot be addressed.

5.3

Connection between a Web Browser and a VCU Scales Controller

Preconditions: The PC has an ethernet connection to the VCU. Java is installed on the PC and can be started. Temporary file storage may not be activated in Java as this can cause erroneous status messages to occur.

Establishing the connection: The URL of the operator interface homepage must be entered into the browser address line. This URL arises as follows:

< Adresse>/hmi/start_x.html Address: VCU IP address Scaling: size of the display on the screen. The values 2, 3 or 4 can be entered. Example: http://192.168.240.1/hmi/start_2x.html

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The user interface in the bro wser corresponds largely to the display on the VHM operating panel with the exception of the field in which a different scales can be selected, which is not available. The configuration dialogs for the VHM operating panel itself are also not available. Keyboard and mouse are used for operation so the entry keyboard is not shown on the screen.

5.4

Web Server in the Scales Controller VCU

The controller comes with a web server that opens a scales 'homepage'. This homepage is available in English only. Preconditions: The PC has an ethernet connection to the VCU. Establishing the connection: The IP address of the controller must be entered into the browser address line.

Various data from the controller can be called up in the left-hand navigation bar. Navigation entry

Function

HMI_2x

Open at a different scale the same controller interface as is in the operating panel. Also refer to: Connection between a Web Browser and a VCU Scales Controller [➙ 36]

HMI_3x HMI_4x

Events

Most recent stored events (alarms, warnings, etc.)

Parameter changes

Most recent parameter alterations

Command Log

List of certain commands, e.g. start / stop

Totalizer hourly

Table of hourly-saved totalizing integrators / counters. The values can also be viewed on the operating panel VHM.

Totalizer daily

Table of daily-saved totalizing integrators / counters.

The minute after the full hour at which the saving occurs can be set in P20.01.

The time after 00:00 at which the saving occurs can be set in P20.02. Tab. 5 : Functions available on the controller web page

Memory depth is approx. 1,000 entries. All entries are recorded with the entry time. The table is refreshed only when it is called up. The values can be exported into a PC file for analysis with standard programs using selectcopy-paste.


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Operation Using the Touch Screen HMI

6 Operation Using the Touch Screen HMI This chapter describes control of the DT-9 using the Touch Screen HMI (Human-Machine Interface). Notes:

1. The following values and settings remain stored after power failure: – Counter readings – Parameter settings – Setpoints – Service values – Counter pulses pending.

2. This manual uses the abbreviations "[Button Name...] button", e.g. [HOME] button, to describe the buttons displayed on the touch screen HMI. 3. Text entry fields on the HMI are indicated by a white box surrounded by a gray rectangle. To enter text, tap the desired text entry field to select it. A keyboard will appear on the screen. When you have finished entering text, press the [OK] button to save your changes and exit the keyboard. To exit the keyboard without saving changes, press the [EXIT] button. 4. In the event of a power failure while the feeder was running in remote mode, the system will restart in remote mode and, if the running contact is active, continue to feed coal.

6.1

Initial Configuration

When the DT-9 is first powered up, the HMI will automatically log in to the connected DT-9 controller. In order to change the settings of the HMI itself, it is necessary to log out of the DT-9 and log into the HMI via the following steps: 1. From the ‘Hom e” screen, press the [Login] button and enter the DT-9 password (the default is ”7353”). The “Hom e” screen will reappear and the [Login] button will change to [Logout] to indicate that you have successfully logged in to the DT-9. 2. Press the [Sel. Scale] button. A prompt will appear asking if you really want to exit the scale. Press [YES]. 3. The main HMI configuration screen will now appear. A list of available DT-9 controllers on the local subnet will be displayed on the upper left portion of the screen, and the main function buttons will be displayed along the right edge. The displa y function buttons are described in the following subsections. Most of the function buttons will be grayed out and unavailable. To gain full access, press the [Login] button and enter the HMI password (the default is ‘”7353”). Press the [Start] button to return to the main HMI configuration screen, or press the [Change Password] button to change the display password. All of the function buttons will now be available, indicating that you have successfully logged in to the HMI.

6.1.1

The 'Network' Screen

Press the [VHM Addr.] button to change the network settings of the HMI. This screen allows you to set the IP Address, Subnet, and Gateway of the HMI. These settings should be obtained from your network administrator. Press the [Save] button to save any changes you have made to these settings before exiting.


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6.1.2

The 'Display Settings' Screen

Press the [Display] button to adjust the HMI display settings. The “Inactivity Tim eout” parameter defines the length of time that the HMI will remain at full brightness after being touched before entering “Sleep Mode” and dimming the display. The “Working Brightness” parameter adjusts the brightness of the display during normal operation, and the “Sleeping Brightness” parameter adjusts the brightness of the display during “Sleep Mode”. Press the [Save] button to save any changes you have made to these settings before exiting.

6.1.3

The 'Feeder' Screen

Press the [Feeder] button to select the DT-9 controller that the HMI will connect to. A list of all available DT-9 controllers on the local subnet will be displayed, and the selected controller will be indicated with a check mark. To connect to a different DT-9, press the check box next to the desired controller and then press the [Select] button. The HMI will then connect to the new DT-9 the next time it is power cycled or when the [Con. Scale] button is pressed. To rescan the local subnet, press the [Scan] button.

6.1.4

The 'Configuration' Screen

Press the [Config] button to adjust the networking options of the HMI. The “URL of start page” parameter defines the start page of the DT-9 ’s embedded web server. The “Start timeout in seconds ” parameter defines the amount of time that the HMI will attempt to connect to the attached DT-9 before defaulting to the HMI configuration screen.

6.1.5

The 'Communication' Screen

Press the [Com] button to change the method by which the HMI will communicate with an attached DT-9 controller. The available options are “Ethernet”, “Bluetooth ”, and “RS485”. The factory default is “Ethernet ”, and this should not be changed.

6.1.6

The 'Calibration' Screen

Press the [Calibration] button and follow the on-screen prompts to calibrate the touch screen.

6.1.7

Exiting HMI Configuration

Press the [Con. Scale] button to exit the HMI calibration screen and return to the DT-9 “Home” screen.

6.2

Display Functions

6.2.1

The 'Home' Screen

The Home screen is the first screen displayed after the HMI has finished booting. It displays the current status of the feeder, and contains the main operating controls. The Mode Select buttons are located on the bottom left of the Home screen, and are used to select the operating mode of the feeder (See sections Operating Modes - Remote [➙ 12] and Operating Modes – OFF/Maintenance [➙ 12] for more information on operating modes).

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6.2.1.1

Operating the HMI in 'Off/Maintenance' Mode

Press the [Off/Maint] button to place the feeder in “Off/Maintenanc e” mode. The background color of the Home screen will turn yellow to indicate that “Off/Maintenanc e” mode has been selected. In this mode, the plant start/stop signals and demand signals are ignored. The feeder can be run in the forward or reverse directions by pressing the [Run >>] or [Run <<] buttons on the Home screen, as long as there is no material on the feeder belt. The feeder will run in the desired direction at the speed defined in P02.16 Maintenance Speed. The [Stop] button will stop the feeder. Pressing and holding the [<< Jog] or [Jog >>] buttons will cause the feeder to jog backwards or forwards for as long as the button is pressed. The jog speed is the same as the Maintenance Speed defined in P02.16. The feeder can be jogged with or without material on the belt.

6.2.1.2

Operating the HMI in 'Remote' Mode

Press the [Remote] button to place the feeder in “Rem ote” mode. The background color of the Hom e screen will turn white to indicate that “Rem ote” mode has been selected. At this point, the feeder is ready to receive commands from the plant’s control system. Upon receipt of a feeder start command and a demand signal from the control system, the feeder will begin to operate and the feeder graphic on the Home screen will indicate that the feeder is running in the forward direction. As material fills the belt, the Belt Load and Material Total values displayed on the Home screen will begin to update. The feeder will respond automatically to the changing demands of the plant’s control system until it receives a feeder stop command or until the [Off/Maint] button is pressed. If an alarm occurs, it will be displayed in a banner across the top of the Home screen and can be cleared by pressing the [Ack Event] button. If a trip occurs, the feeder will be stopped and the display will automatically switch to “Off/Maintenanc e” mode. The trip can be cleared by resolving the problem that caused the trip and pressing the [Ack Event] button. “Rem ote” mode can then be resumed by pressing the [Remote] button.

6.2.2

The 'Trend' Screen

The “Trend” screen is a custom izable line graph that can be used to plot various data item s that are logged by the DT-9 over time. See Appendix C for a list of available data items.

6.2.3

The 'Values' Screen

The “Values” screen displays information about the feeder on two sub screens, which can be accessed by pressing the [Values] or [Totals] buttons. The [Totals] button displays the following data: ▪

▪

Material Total is the total amount of material delivered by the feeder, and is the sum of the Gravimetric and Volumetric Totals. Gravimetric Total is the total amount of material delivered by the feeder while operating in Gravimetric Mode.

▪

Volumetric Total is the total amount of material delivered by the feeder while operating in Volumetric Mode.

▪

The [Reset] button will reset all three totalizers. The total values cannot be recovered after the [Reset] button

is pressed. The [Values] button displays the following data: ▪

Belt Speed shows the current speed of the belt in feet or meters per second.


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▪

▪

▪

Belt Load shows the weight of the material on the belt per unit of belt length in pounds per foot or kilograms per meter. Speed shows the shaft speed of the belt drive motor in revolutions per minute. Density shows the currently calculated density of the material on the belt in pounds per cubic foot or kilograms per cubic meter.

6.2.4

The 'Setup' Screen

The “Setup” Screen is used to configure the DT-9 and to access the various log files that are stored by the controller. The following buttons are initially shown on the “ Setup” screen: [Data Log], [Event Log], [Param Log], [Parameter], and [ ] (Right Arrow). →

Pressing the Right Arrow button causes the display to scroll to the following additional buttons: [Trim], [Defaults], [Simulation], [Calibration], and [Set Time]. Pressing the Right Arrow button again will cause the display to scroll back to the initial list of buttons. The [Trim], [Defaults], and [Calibration] buttons will be grayed out and unavailable unless the user is logged in to the DT-9. The user must also log in before changing any of the parameters that are accessed via the [Parameter] button. To log in to the DT-9, press the [Login] button, enter the DT-9 password (the default is ‘”7353”), and press [Login]. The previously selected screen will reappear and the [Login] button will change to [Logout] to indicate that you have successfully logged in to the DT-9. The following subsections describe the various screens that are accessed via the buttons on the “Setup” screen.

6.2.4.1

Data Log Values

The “Data Log Values” screen displays the hourly and daily material tota ls in pounds or kilogram s. The Up and Down Arrow buttons can be used to scroll from hour to hour or day to day to view the previously saved totals.

6.2.4.2

Event Log Values

The “Event Log Values” screen displays the Event Log and Comm and Log. The Up and Down Arrow buttons can be used to scroll through the various events and user commands that were recorded by the DT-9.

6.2.4.3

Parameter Log Values

The “Parameter Log Values” screen displays a log of all the DT -9 parameters that have been modified by the user. The Up and Down Arrow buttons can be used to scroll through the various parameter changes that were recorded by the DT-9.

6.2.4.4

Parameter Setup

The “Parameter ” screen is used to display and edit the various parameters available on the DT-9. Refer to Section 9 of this manual for a detailed description of the available parameters and settings.

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The top half of the “Parameter ” screen displays the current Parameter Block. The bottom half of the screen displays the various parameters that are available in the selected Parameter Block. Press the Up and Down Arrow buttons to scroll through the various blocks and parameters. To change the value of a parameter, press the [Edit] button (Note: the user must be logged in to change parameter values). If the parameter contains a list of possible settings, a set of Up and Down Arrow buttons will appear and can be used to scroll through the available options. If the parameter contains a discrete value, a text box will appear. Press the [Save] button to save any changes that were made to the parameter value, or press the [Exit] button to exit without saving any changes.

6.2.4.5

Trimming the Analog Inputs and Outputs

The “Trim ” screen is used to trim the analog inputs and outputs. Any active analog input or feedback must be matched or adjusted to the DT-9 controls. Two signals levels must be adjusted for each channel used. The first signal level, MIN, corresponds to the lower value being adjusted and is transmitted when the feed rate is at 0%. The second level, MAX, corresponds to the higher value being adjusted and is transmitted when the feed rate is at 100 %. Note: If the feeder is not equipped with a remote analog demand input, the input alignment can be omitted. If an analog output signal is not present, the output alignment section can be omitted. Note: Unlike the 196NT, it is necessary to trim the analog output channel (normally AO 1) that is used to control the motor speed control. I/O Channel Adjustment ▪

When setting the output channels use a meter to measure the signal on: – AO 1: Connected to wires 142, 143 & 144 (X6-6 and X6-7)

▪

– AO 2: Connected to wires 139, 140 & 141 (X6-8 and X6-9). When setting the input channel source the signal to: – AI 1: Connected to wires SIG+ & SIG- (X6-3, X6-4 or X6-3, X6-5).

Follow These Steps:

1. Press [Trim] to initiate the Trim function. Analog Output Channel 1 is always the first one displayed. To access other channels use the arrow up or down buttons. Press [Exit] to get back to the main screen. 2. When aligning the output channels, the minimum and maximum analog signals are sent by the DT-9. The user measures and enters the actual values. The AO 1 values are stored in P17.11 and P17.12, and the AO 2 values are stored in P17.13 and P17.14. a) Press the Down arrow button to scroll to the measure mode for output channel AO 1 Min. The DT-9 will output the minimum signal value. The display will ask for the measured value. Enter the value measured on your meter in the “Analog value measured” text box then press [Save] to store. b) Press the Down arrow button to scroll to the measure mode for output channel AO 1 Max. The DT-9 will output the maximum signal value. The displa y will ask for the measured value. Enter the value measured on your meter in the “Analog value measured” text box then press [Save] to store. c) Repeat steps a. and b. for output channel AO 2. d) Press the [Exit] button to exit the Trim function. 3. When aligning the input channel AI 1, the minimum and maximum analog demand signals are applied to the input signal wires of the DT-9. The analog demand is measured then stored in P17.01 Analog Input 1 Min


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and P17.02 Analog Input 1 Max . a) Press [Trim] then use the arrow keys to select Analog Input 1 Min. Press [Start] to enter the measure mode. The first value m easured is the minimum analog demand signal AI 1. Use either a precision source or, preferably, a minimum demand signal directly from the combustion control system. The display will show the value being measured from the source. Press [Save] to store the value. b) Press the Down arrow button to scroll to the maximum analog demand signal AI 1 and press [Start] to enter the measure mode. Use either a precision source or, preferably, a maximum demand signal directly from the combustion control system. The display will show the value being measured from the source. Press [Save] to store the value.

6.2.4.6

Restoring the Factory Default Settings

The “Defaults” screen allows the user to overwrite all parameter settings with the factory default values. The [Custom] button will overwrite all parameters with the srcinal values as set by Stock Equipment at the time that the feeders were shipped. The [Factory] button will overwrite all parameters with the factory default values. In general, the [Custom] button should always be used when resetting the parameters.

6.2.4.7

Simulation Mode

The Simulation Mode allows for operation of the feeder without material for test purpose, training or demonstration.

STRICTLY OBSERVE The feedrate indicated and the feedback signal diff er from the real rate of flow.

Wrong of missing coal feeding. Wrong material totalizer. When Simulation Mode the loadcell signal and the speed signal will be simulated in a way that the actual rate shown follows the demand signal. This allows for. ▪

Check of the interface to the plant control

▪

Check of fieldbus signals

▪

Demonstration and training

For coal feeding operation the Simulation Mode must be switched off again.

6.2.4.8

Calibrating the Feeder

The “Calibration” screen allows the user to access the various calibration functions. Refer to Section Calibration [➙ 20] of this manual for a complete description of the available calibration functions. Press the Up and Down Arrow buttons to select the desired calibration function, then press the [Start] button and follow the on-screen instructions. When the calibration function has completed, press the [Save] button to save the new calibration values or press the [Exit] button to exit without saving.

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6.2.4.9

Setting the Current Time and Date

The [Set Time] button allows the user to edit the current Date and Time. The current values are displayed, and can be edited via a text box.

6.3

Typical Operating Procedures

1. When filling the bunker, first close the inlet valve to minimize the filling pressure on the feeder and to avoid compaction of the material at the feeder inlet. This precaution is unnecessary if the bunker is refilled while at least 8 to 10 feet (2.43 to 3.05 meters) of material remain in it. 2. When starting the feeder, open the inlet valve slowly to load the belt at a controlled rate and to minimize compaction at the feeder inlet. 3. Energize the feeder controls at the disconnect switch in the control cabinet. Observe that the HMI is illuminated. 4. From the [HOME] screen, press the [Remote] button. Upon receipt of a customer-generated feeder start command and a demand signal from the combustion control system, the feeder begins to operate and the display indicates that the feeder is running forward. 5. As material fills the feeder belt, the display indicates that the feeder is feeding material. 6. The DT-9 will begin totalizing the weight and updating the current feeder information. 7. The feeder will respond automatically to the changing demands of the combustion control system until it is de-energized. 8. For a brief stop with a loaded belt, press the [OFF/Maint.] button 9. For a clean shutdown with an empty belt, close the inlet valve while the feeder is still running. When the belt is emptied, press the [OFF/Maint] button. This procedure is recommended whenever the feeder will be inactive for a long period of time, since it eliminates the possibility of material compaction at the feeder inlet due to consolidation caused by its own weight. 10. To jog the feeder belt forward, press the [OFF/Maint] button followed by the [Jog >>] button on the microprocessor keyboard for as long as motion is required. Pressing the [<< Jog] button will jog the feeder belt backwards. 11. To operate the feeder in the MAINTENANCE mode for inspection or servicing, press the [OFF/Maint] button followed by the [Run >>] button. The feeder will run forward at the speed programmed in P02.16 Maintenance Speed. Pressing the [<< Run] button will cause the feeder to run backwards at the same speed.


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Operation Using the 196NT Display

7 Operation Using the 196NT Display The VCU20103 does not support the 196NT displa y.


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Operation Using EasyServe

8 Operation Using EasyServe This chapter describes control of the DT-9 using EasyServe. See “Schenck Process EasyServe Operation Manual” (BV-H2185GB)

8.1

Program EasyServe VPC 20150

Designed as PC program for DISOCONT commissioning and servicing, EasyServe lets you perform any operat®

ing and calibrating operation. The program is operable under Microsoft Windows 2000/XP/Vista/7 operating systems. The control unit lets you perform all controlling and calibrating operations without restrictions. The menu control permits flexible and easy adjustment, lets you access service data, operate the scale for servicing, and customize the menu texts on PC screen and all operator units.

8.2

Minimum System Requirements

▪

Pentium or CPU-compatible

▪

900MB free hard disk space

▪

VGA display, 32768 color monitor recommended

▪

Operating systems Microsoft Windows® 2000/XP/Vista/7 with latest service packs

▪

Mouse or other type of pointer

▪

CD-ROM drive.

8.3

Installation

EasyServe

Insert CD VPC20150 into CD-ROM drive. Normally, installation starts automatically. If not, open Windows explorer select your CD-ROM drive. To open, double click on file. The automatic installation program prompts you through a number of dialogs, for you to confirm. Upgrade

If an old EasyServe version is available on your PC it must be removed (using Control Panel | Add or Remove Programs) before the installation can be performed. Attention

To be able to install the EasyServe program, your name must be registered as user in the group of administra® tors under Windows 2000/XP/Vista/7. To execute program, main user rights are required.

8.4

Start Program and Connect to Feeder

Before EasyServe can be used it must be installed on a laptop or PC, an Ethernet cable must be installed between the DT-9 and the PC and the PC must be configured for direct Ethernet communications. This process is described below.


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CAUTION DO NOT use the RJ45 connect or marked X96 to connect the DT-9 to a l aptop or PC.

This connector is designed to supply power for the Touch Screen HMI through normally unused connections. Connecting a PC to X96 could cause damage to the DT-9, the PC or both. A red cover is normally installed over this connector to prevent it from being used with a PC.

8.4.1

Connecting to Feeder

The EasyServe program and an Ethernet connection are used for most DT-9 Programming operations. The DT9 cannot generate an IP address for the computer running EasyServe so the PC must be set to a static IP address. The DT-9 default IP address is 192.168.240.1 and the PC must be on the same subnet. Set the PC address to 192.168.240.254 as starting point. One of several ways to do this is listed below. ®

Windows XP

1. Select Network Connections in Control Panel 2. Double click on the Local Area Connection line to bring up Local Area Connection Status dialog box. If you have more then one Local Area Connection you probably want to select the one that is not connected. 3. Click on the Properties button (under the General tab) in the Local Area Connection Status dialog box. This will bring up the Local Area Connection Properties dialog box. 4. Under the General tab, scroll down to Internet Protocol (TCP/IP) line, select this line then press the Properties button. This will bring up the Internet Protocol (TCP/IP) Properties dialog box. 5. In the General tab, the Obtain an IP address automatically button will normally be set, and the Alternate Configuration tab will be visible. Select the Alternate Configuration tab. 6. If an alternate IP address has already been entered, record this value. Select the User Configured button then enter the IP address (192.168.240.254) and the Subnet mask (255.255.255.0) to use with the DT-9. Leave the Default gateway field blank. Note: It is not necessary to remove the alternate IP address once the DT-9 update has been completed. When the Ethernet port is configured as described above, the PC/Laptop can be connected to a DT -9 or a company network without changing the settings.

7. If the Ethernet port has been set to a fixed IP address, the Obtain an IP address automatically button will not be set and the Alternate Configuration tab will not be visible. In this case either the fixed IP address can be changed, by changing the IP address and Subnet mask fields in the Use the following IP address: box, or by selecting the Obtain an IP address automatically button and following steps 5 and 6. In either case, the previous IP address and Subnet mask should be recorded prior to making any changes. 8. Select OK and back out. 9. Make the physical connection to the DT-9 by installing a CAT 5 cable (either straight through or crossover) between the PC Ethernet port and any of the RJ45 connectors on the DT-9 except X96. X96 uses normally

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unused connection to supply power to the Touch Screen HMI and connecting a PC to X96 could cause damage to the DT-9, the PC or both. See the warning above. 10. Start EasyServe and select the Connection | MODBUS TCP (Scanner) option. The controller if connected should be displayed. Select the controller and select Connect. 11. If there are more than one Ethernet connection on the computer EasyServe may have a problem deciding which one to use. Rebooting the computer (not just logging out) while the DT-9 is connected and running will usually fix this problem. If this doesn’t work the other connection may have to be disabled.

Windows® Vista

1. Select Network Connections in Control Panel. 2. Double click on Network and Sharing Center. 3. Click on the Manage Network Connections line, on the left side of the window. 4. Double click on the network connection that will be used to communicate with the DT-9. This is normally marked Local Area Connection. 5. In the Local Area Connection Status window, click on the Properties button. This will bring up the Local Area Connection Properties dialog box. 6. Proceed to step 4. above.

8.4.2

Access to Feeder Commands and Parameters

Once a feeder connection has been established, you have to register to make any parameter changes or operate the feeder. To do this click on the red lock toolbar button it will change to a yellow key (or go to Edit – Register or press F2 on the keyboard).

HINT Once registered any parameter changes or commands are sent to the feeder immediately.

To unregister click the yellow key toolbar button and make it go back to red lock (or go to Edit – Unregister or press F3 on the keyboard).

8.5

Parameter Set

Once connected to a DT-9 go to View – Parameter set: Online to access the parameter set. It’s displayed along the left side of the screen organized by parameter block. To view the parameters click on a block and they will be displayed on the right. At the bottom of the parameter set the events and hardware configuration can be accessed. ▪

Events


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– All the events for the DT-9 are listed here in groups similar to the parameters. Click on a group to see the event names and numbers on the right. The parameter that corresponds to the event will be listed after the name. If you click the event name on the right it will take you to the parameter that controls it. ▪

Hardware configuration – This contains a list of all the Analog inputs/outputs, digital inputs/outputs and Load Cells. Just like the event list if you click the event name on the right it will take you to the parameter that controls it.

8.5.1

.PAR Files

Feeder files for EasyServe are saved as .PAR files. To load a .PAR go to File | Open. Once the file has been opened, the parameters can be viewed and changed. The background color remains a bluish-gray as long as you are just editing a .PAR file and have not loaded it to a DT-9. To send the file, a feeder connection is required. Once the connection has been established, the background changes to white and displays the param eter set currently on the DT-9. Open the .PAR file you wish to load or go if it was already opened you can just go to View and select the parameter set by nam e. The background should go back to the bluish gray color as before. Go to File | Transmit, check the box of the parameter set to be loaded and click OK. Click OK on the next pop up saying it may take a minute.

8.5.2

Read/change Parameters

1. Loaded .PAR file – Once a file has been loaded, the parameters can be viewed and edited. The parameter set file will be displayed on the left hand side. Click on a parameter block on the left to display the parameters on the right. To edit the parameter click in the box and enter using the keyboard or use the pull down tab to set the desired value. 2. Connected to feeder controller – Once a connection has been established and you have registered the parameters can be edited as described in item 1).

8.5.3

Loading Custom Default Parameters

A set of custom default parameters can be loaded to the DT-9 controller. Loading custom defaults will load the parameters setup by Stock Equipment.

STRICTLY OBSERVE Edited parameters and calibrating values are reset.

We recommend that you print parameters using the Print Parameters function before loading default values.

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To load: ▪

Go to Tools | Commissioning | Load Custom Defaults . EasyServe will ask for verification that you want to load defaults. Click Yes to load the default parameters.

8.5.4

Loading Factory Default Parameters

A set of Factory default parameters can be loaded to the DT-9 controller. These are the controller default values, NOT the initial Stock values.

STRICTLY OBSERVE The Load Default Parameters operation will reset all calibration values and any parameters that have been edited, and will also reset the Custom Default Parameters.

Stock recommends that parameters be printed or saved to disk before loading default values. Stock does not recommend loading factory defaults except after a firmware update, or when a memory error is detected. To load: ▪

Go to Tools – Commissioning – Load Custom Defaults . EasyServe will ask for verification that you want to load defaults. Click Yes to load the default parameters.

8.5.5

Expert Mode

Parameter access permissions can be modified using expert mode. The three options available are: ▪

R: Read access only. The parameter cannot be edited.

▪

W: Writable. The parameter can be viewed and edited.

▪

H: Hide. The parameter cannot be viewed or edited unless in Expert mode.

To access Expert mode click Edit | Expert Mode (or press F6). EasyServe will prompt for a password to enter Expert Mode. The default password is 7353. Press enter or click ok once the password is entered. Now when viewing parameters, there will be a square to the left of the parameter value with one of the above letters in it representing the parameter state. Click on the square to change status.

8.5.6

Print Parameters

A printout of the parameter set can be done by going to File | Print. A window will pop up giving you a few checkbox options for what to include on the printout: ▪

Only changed Parameters – Parameters that have been changed since the last loading of a parameter file.

▪

Only visible Parameters – Does not print any parameters that have been set to hidden in expert mode.

▪

Hardware configuration – This will add a list of the analog/digital inputs/outputs, and Load cells to the end of the parameter set on the printout

Click print when ready to proceed with printout.


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8.6

Operating the Feeder

8.6.1

Scale Operation Screens

The main screen of EasyServe can either displa y the parameter set (as described above) or Scale (feeder) Operation 1 and 2. To change this go to View – then select one of the options above the line on the pull down menu. A DT-9 connection is required to access the scale operation or online parameter set screens. ▪

Scale Operation 1: – This is the screen to use when operating the feeder from EasyServe. The feeder can be placed in remote, local and jog from this screen. Feeder operation is the same as it is when using the 196NT display (See section Operation using the 196NT Display). This is also where the totalizers can be reset. Along with this real time feeder, information is displayed on the right side. Note: To operate the feeder, you must have a connection and be registered.

Remote - Click the remote button to put the feeder in REMOTE mode. The button will change to OFF/Maint and Remote will be displayed to the left. Click the button again to put the feeder back in OFF mode. ∎ Local - Click the RUN>> button to run the feeder in LOCAL mode. Click the button again to stop the feeder and place it back in OFF mode. The RUN<< button will run the feeder in reverse. ∎ Jog - Click and hold to JOG>> the feeder. Click and hold the JOG<< to jog the feeder in reverse. ∎ Reset Totalizer - Click button to reset the totalizer. ∎

▪

Scale Operation 2: – This screen gives status information only. The feeder can not be controlled. Along with normal operational info, the load cells can be monitored if they are connected.

8.6.2

Events

Events will be displayed across the bottom of the EasyServe screen (The event can also be viewed by going to View | Events, bringing up the event window). Alarms and warnings can be ack nowledged, after correcting the situation, by clicking on the red X toolbar button. The event message on the bottom will go back to “No Events”.

8.6.3

Calibration

See section Calibration [➙ 20] for feeder calibration instructions.

8.6.4

Service Values

The service values on EasyServe are displayed in pop-up windows. Up to ten windo ws can be opened at one time. To open a service value window go to View – Service Values, and select one. T here is no difference in the ten windows the same inform ation can be accessed from any of them. The values are divided up b y eight tabs across the top to access different information as listed below. 1. MV 1 – Load cell info – Tachometer Hz – Speed set point

BV-H6411GB, 1221 - 54 -



– Belt load info.

2. MV 2 – Software info – Hardware info – Totalizer pulses – Belt motion monitor. 3. AI – Analog input signals. 4. AO – Analog output signals. 5. V103-DI – Digital input status. 6. V103-DO – Digital output status. 7. OP1 – Feedrate info – Totalizers – Belt speed and load – Density. 8. OP2 – Does not contain any values with current DT-9 version.

8.6.5

Trends

Like the service values, ten trend windows can be opened. Within each trend window the following values can be viewed. ▪

Feeder On

▪

Flow Rate

▪

Totalizer 1

▪

Totalizer 2

▪

Belt Load

▪

Belt Speed

▪

Actual Setpoint

▪

Deviation

To open a trend window, add the desired values, and modify the trend, follow these steps. 1. Go to View – Trend – and select one of the ten trends. 2. The trend window will pop up. W hatever the last selected values were, for that trend window number, will be displayed. 3. To change the scaling of the graph or add a name click the third button from the left on the top of the trend window (the modify button). A window will pop up, edit the fields in the top right to the desired values.


BV-H6411GB, 1221 - 55 -


4. While still in the modify window click on value 1 on the left side. 5. Here you can select what you want to appear on the trend. To add this value to the trend make sure the display field is set to yes. Next, click the signal source button. A window will pop up where you can select one of the above mentioned values. Select the one you want and click apply. 6. The name and color can be modified for each value also in the fields below the signal source button. 7. Repeat steps 4 and 5 to add as many values as you want to the trend. 8. Click save and close to apply the settings to the trend. Note: The first two buttons at the top left are for starting record and stopping the trend. The fourth button (red X) deletes the recorded trends.

8.6.6

Setting Time

To adjust the date/time of the DT-9, go to Tools | Commissioning | Adjust Date/Time. Select the date/time in the window that pops up then click OK.

8.6.7

Options

The EasyServe options can be accessed by going to Tools | Options. The options window opens and has 4 tabs. This window lets you change language preferences, communication settings, display settings, print settings and working folder for the parameter set loaded. You can also load the factory default parameters, STOCK DOES NOT RECOMMEND LOADING FACTORY DEFAULTS.

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Testing

9 Testing 9.1

Calibration Weight Test

Calibration weight testing performs the following functions: ▪

Check for mechanical or electrical errors.

▪

Can check system linearity.

Requirements ▪

Calibration weight.

Follow these steps: ▪

Enter effective check weight into Parameter P10.08 Calibration Weight.

▪

Call up the "TW: Weight Check" calibrating function (see Calibration [➙ 20] item).

Deviations of measured value from actual value may be caused by ▪

Platform distortion

▪

Improper alignment

▪

Interferential forces acting on load cell cable.

9.2

Chain Test

Chain testing performs the following functions: ▪

Check for mechanical or electrical errors.

▪

Can check system linearity.

▪

Check for weigh system alignment errors.

Requirements ▪

Calibration chain.

Follow these steps: ▪

Enter chain test weight in Parameter P10.09 Test Chain Weight.

▪

Call up the "TC: Span Calibration" calibrating function (see Calibration [➙ 20] item).

Deviations of measured value from actual value may be caused by ▪

Platform distortion

▪

Improper alignment

▪

Interferential forces acting on load cell cable.

▪

Weight roller mis-alignment.


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Testing

9.3

Material Test

No check or calibration using check weights can perfectly simulate actual conditions. The actual accuracy can only be determined with a material test. The DT-9 allows errors found during this testing to be easily corrected using Parameter P10.05 Range Correction TM.

Requirements ▪

▪

▪

▪

▪

Handling route from weighing platform to material collecting point is totally clean. No material is diverted during the test. If feed screws or air slides are provided between platform and collecting point, run the system with material for approx. 30m minutes before starting the material test. This will allow the normal build-ups to form on feed units. Do not remove dust or clean the equipment during the test. Hoppers or vehicles transporting the material to a legal-for-trade commercial scale have been cleaned and re-weighed before filling (tare weight).

Example: The figure shows the operating principle of a material test.

Within a certain period of time, e.g. 15 min., an actual material amount MW of 4.9 t is fed. The material value MA displayed on DISOCONT is 5.0 t. The new value of P09.01 Limit: Actual Flow Rate MIN is computed using the following formula: Parameter P09.01 (new) = Parameter P09.01 (old) * MW / MA In our example, value is 0.98. Enter new value into Parameter P10.05 Range Correction TM.

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Parameters

10 Parameters This chapter discusses the parameters available with DT -9. Some parameters are not normally used on Stock coal feeders. These parameters are hidden by default and are marked as Norm ally Hidden in the parameter list below. These parameters can be viewed, modified or made visible using the Expert Mode in EasyServe. Use the Edit | Expert Mode menu selection or the F6 key. The default password is 7353.

10.1

General Information

Parameters are variable features or data used to adapt DT-9 to the application. There are two principal types of parameter: ▪

▪

Selection parameters - for selection from multiple Options – Select characteristic values (e.g., display unit, control behavior) – Select event classes (determine reaction on events) – Select hardware configuration (source, unit, channel, level) Numeric parameters - for direct input of numeric values

Parameters can be changed during operation. However, parameters influencing measuring result, e.g., display filters, must not be changed. Default Values:

The DT-9 controller saves two different sets of default parameter value, referred to as Factory Defaults and Custom Defaults. Factory Defaults are set in the controller firmware and cannot be modified. These values provide a common starting point for new systems. Custom Defaults can be modified in the field and can store the custom settings used for a particular installation. Custom Defaults are set during factory testing. All parameters are preset with default values that don’t normally need to be changed. You can recall default values using the "Load Factory Defaults" function and the “Load Custom Defaults” function. Identification:

Parameters are organized by function group and identified as follows: "Group number - parameter number - parameter name", e.g., P01.02 Event: Communication ARM7. Parameters Attributes:

The DT-9 is versatile system that can be user programmed for a variety of application and many of the parameters required for one application are not required for others. To simplify operation, each parameter has a parameter attribute that can be set to hidden (H), read only (R) or read/write (W). Special parameters that are not normally used in Stock feeders are factory set to default values and then hidden. Their current values, default values and hidden status can be changed in EasyServe, using Expert Mode (Menu: Edit | Expert Mode). The default password is 7353. Dependencies :


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Parameters

There are parameters whose availability depends on other parameters setting values. These dependencies are stated in the header of every parameter description. Abbreviations: Hardware Devices

Description

VCU

Main control unit type VCU 201xx

VHM

Operator Panel (control unit)

ARM7

Redundant volumetric control processor in VCU

196NT

Former controller generation

DT-9

DISOCONT Tersus system for coal feeding

Signal Source/Destination

Description

FB

Fieldbus (optional interface required)

OP

Operator Panel (control unit type VHM)

DI

Digital Input

DO

Digital Output

AI

Analog Input

AO

Analog Output

LC

Load Cell

LS

Logical Signal

VCU1

Located on main VCU 20100

VCU2

Located on first extension VCU 20100

VCU3

Located on second extension VCU 20100

V103

Located on VCU20103

V104

Located on VCU20104

FRQ

Frequency Output

R-L

Raise and Lower Contact Input

n/a

Not assigned (signal not used or generated internally

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Parameters

Event Classes

Description

A

Alarm (Stops feeder)

W1

Warning 1 (acknowledgement required)

W2

Warning 2 (no acknowledgement required)

IG

Ignore – No event message but contact outputs

Signals

Description

I

Flow rate

Q

Belt load

VB

Belt speed

TCI

Totalizer Counter Increments

FRI

Remote frequency output

VAP

Delay of control command till point of discharge

PLS

Host plant control

FCB

Function block in mini-PLC

Procedure for Setting Inputs and Outputs Step

Description

1.

Select source or destination of signal DI, DO ...,... "n/a" means "not assigned", i.e. function is not available.

2.

Select unit VCU ... Display only shows units activated in parameter block 1.

3.

Select channelnumber DI 1 ...

4.

Select signal level LOW or HIGH (N/C or N/O contact)

Hardware Configuration

When signal path configuration parameters are set, the source/destination determines whether unit, channel and level must be additionally indicated or not. The following table applies: Possible hardware configurations: Source

Unit

Channel

Level

FB


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Parameters

Source

Unit

Channel

VCU103

AI1 - AI4

VCU104

AI1 - AI3

VCU1

AI1 - AI2

VCU2

AI1 - AI2

VCU3

AI1 - AI2

VCU103

AO1 - AO4

VCU104

AO1 - AO4

VCU1

AO1 - AO3

VCU2

AO1 - AO3

VCU3

AO1 - AO3

Level

OP v n/a AI

AO

LC

VCU103 VCU104 VCU1

LC1 - LC2

VCU2 VCU3 DI

VCU103 VCU104 VCU1 VCU2 VCU3

DO

VCU103 VCU104 VCU1 VCU2 VCU3

DI1 - DI12 DI1 - DI12

HIGH, LOW

DI1 - DI7 DI1 - DI7 DI1 - DI7 DO1 - DO13 DO1 - DO14 DO1 - DO8 DO1 - DO8

HIGH, LOW

DO1 - DO8

Fieldbus (FB), control unit (OP), speed (v), not assigned (n/a) and the low-resolution analog input (DI4) does not require additional specification for unit, channel or level. Analog inputs (AI), outputs (AO) and load cell (LC) require the unit to be specified. Digital inputs (DI) and outputs (DO) require unit, channel and level to be specified.

Example:

Parameter P 16.21 determines the relay output that indicates that a warning (W1 or W2) event is active.

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Parameters

P16.21 DO: W ARNING

Default: DO 13 High

Options:

n/a (not used) DO 1 thru DO 14 - High/Low

The first row shows the parameter description and default values. By default, the output relay is either DO 8 for the VCU 20103, or DO 13 for the VCU 20104. The available digital outputs for the two DT-9 versions are shown in the next two rows.

Event Messages Event messages report abnormal states, e.g. errors or limit value excess.

STRICTLY OBSERVE Always correct the cause of a fault before acknowledging it.

The feeder has the potential to cause injuries or damage if this is not done.

There are four different event classes: Event Class

Code

Display / Effect

Alarm

A

Warning 1

W1

The event is annunciated and remains active until it has been acknowledged. Measuring and control tasks are not affected. This type of event is similar to some type of alarms on the 196NT.

Warning 2

W2

The event is annunciated and remains active until the cause has been corrected. It is not necessary to acknowledge this type of event. Measuring and control tasks are not affected. This type of event is similar to some type of alarms on the 196NT.

Ignore

IG

Event is not annunciated. Measuring and control tasks are not affected.

All measuring and control operations are aborted. System goes to safe state. This type of event is the same as a feeder trip on the 196NT.

Events are classified in the following groups with the priority shown: Event Group

Symbol

System message

SY

Sequence monitoring Electrical system

SC WE

Mechanical system

WM


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Parameters

Event Group

Material flow

Symbol MF

Interlocking

IL

Controllers

CO

Calibration

CA

Maximum

HI

Minimum

LO

Example:

Some parameters specify the response to an error event. Parameter P01.02 determines the response to event SY12, Event: Communication ARM7. P01.02 Event: Communication ARM7 Event Group: SY Options:

Default: A

Number: 12 IG A (Stop feeder) W1 (Warning – Manual reset) W2 (Warning – Automatic reset)

The first row shows the parameter description and default values. By default, an alarm is generated and the feeder is stopped. The second row shows the event group and number (SY12), and the third row shows the available digital outputs for the two DT-9 versions. All of the normal event options are available for this event.

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Parameters

10.2

DT-9 Parameter List

A complete set of DT-9 parameters is listed below with options, default values and descriptions. The factory default values are selected based on either, the requirements of the existing wiring groups or the most commonly used values. Some parameters are shown as “Hidden”. These parameters are not visible from the feeder display and it should not normally be necessary to changed them. If it is necessary to view or modify these parameters set EasyServe to Expert mode (View | Expert Mode). The default password is 7353. This will make the parameters visible in EasyServe and allow the parameter attributes (H-Hidden, R-Read only & W-Read/Write) to be changed.


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Parameters

10.2.1 Parameter Overview VCF20170-008 0643 01 - Hardware Modules

Number:

Name

Default

Customer

Sys ID

P01.01 [➙ 82]

Event: Communication HMI 1

W2

4218

P01.02 [➙ 82]

Event: Communication ARM7

A

5752

P01.03 [➙ 82]

Analog Channel A10

NO

5746

P01.04 [➙ 82]

Analog Channel A11

NO

5747

P01.05 [➙ 82]

Analog Channel A12

NO

5748

P01.06 [➙ 82]

Analog Channel A13

NO

5749

02 - Feeder Definition

Number:

Name

Default

P02.01 [➙ 84]

Language *

ENGLISH

4224

P02.02 [➙ 84]

Units *

English

4225

P02.03 [➙ 84]

Scale Name *

DISOCONT TERSUS CF

6238

P02.04 [➙ 84]

Password *

10000

4292

P02.05 [➙ 84]

Nominal Flow Rate *

50000 lb/h

4226

P02.06 [➙ 84]

Nominal Speed *

3 inch/s

4227

P02.07 [➙ 84]

Display Formats *

SELECTABLE

4228

P02.08 [➙ 84]

Flow Rate Units *

----.- lb/h

4229

P02.09 [➙ 84]

Counter 1 Unit *

------- lb

4230

P02.10 [➙ 84]

Counter 2 Unit *

------- lb

4232

P02.11 [➙ 84]

Counter 3 Unit *

------- lb

4233

P02.12 [➙ 84]

DO: Pulse Counter *

DO

4239

P02.13 [➙ 84]

Totalizer Increment *

100 lb

4254

P02.14 [➙ 84]

Pulse Length Total *

0.1 s

4231

P02.15 [➙ 84]

Event: Remote TCI too small *

W2

5745

P02.16 [➙ 84]

Maintenance Speed *

50 %

5670

BV-H6411GB, 1221 - 66 -

Customer

Sys ID


Parameters

P02.17 [➙ 84]

DO: FRI Frequency *

DO

5753

P02.18 [➙ 84]

Remote FRI Frequency *

10 Hz/(t/h)

5708

P02.20 [➙ 84]

Codepage *

Unicode UTF-8

6242

P02.21 [➙ 84]

DC_Mode *

NO

6243

03 - Control Sources

Number: P03.01 [➙ 91]

Name Feeder Start *

Default DI

Customer

Sys ID 4241

P03.02 [➙ 91]

Feedrate Setpoint *

AI

4242

P03.03 [➙ 91]

Setpoint Range *

20 mA

4243

P03.04 [➙ 91]

Setpoint Offset *

4 mA

4244

P03.05 [➙ 91]

Maximum Feedrate *

50000 lb/h

5686

P03.06 [➙ 91]

Minimum Feedrate *

5000 lb/h

5687

P03.07 [➙ 91]

DI: Raise Setpoint *

n/a

5722

P03.08 [➙ 91]

DI: Lower Setpoint *

n/a

5723

P03.09 [➙ 91]

Raise/Lower Response Time *

30 s

5709

P03.10 [➙ 91]

Source Run Enable *

DI

4245

P03.11 [➙ 91]

Event: Run Disabled *

W2

4246

P03.12 [➙ 91]

Mode Select Enable/Disable *

Keyb.,Remote & Local

5707

P03.13 [➙ 91]

Speed Setpoint *

200 rpm

5682

P03.14 [➙ 91]

Run Mode Select *

Frate Setpoint

5684

P03.15 [➙ 91]

Density Setpoint *

50.955 lb/ft3

5815

Number:

Name

Default

P04.01 [➙ 97]

LC Characteristic Value *

3 mV/V

4257

P04.02 [➙ 97]

LC Rated Capacity *

100 lb

4258

P04.03 [➙ 97]

Effective Platform Length *

18 inch

4259

P04.04 [➙ 97]

Lever Ratio *

1

4260

P04.05 [➙ 97]

Angle *

0 degree

4261

P04.06 [➙ 97]

Speed Measurement *

DI

4262

04 - Rated Data


Customer

Sys ID

BV-H6411GB, 1221 - 67 -

Parameters

P04.07 [➙ 97]

Source Load Cell *

LC

4263

P04.08 [➙ 97]

Source Load Cell 2 *

LC

4269

P04.09 [➙ 97]

Tachometer: Pulses per Rev *

60 P/rev

5690

P04.10 [➙ 97]

Load cross section *

157 inch2

5730

Number: P05.01 [➙ 100]

Name Volum on LC failure

Default YES

P05.02 [➙ 100]

Event: Volum. caused by LC-error

IG

4271

P05.03 [➙ 100]

Afterflow Measurement Time

0s

4274

P05.04 [➙ 100]

Zero Drop-Out Active

NO

4679

P05.05 [➙ 100]

Zero Drop-Out Limit

1%Q

4680

05 - Feeder control

Customer

Sys ID 4270

06 - Feeder Monitoring

Number:

Name

Default

P06.01 [➙ 101]

Event: Stand-By

IG

4289

P06.02 [➙ 101]

Stand-By Limit Value

0 % Io

4290

P06.03 [➙ 101]

Event: Tachometer Input

A

4291

P06.04 [➙ 101]

Event: Error LC Input

IG

4293

P06.05 [➙ 101]

Event: LC Input < MIN

IG

4294

P06.06 [➙ 101]

Event: LC Input > MAX

IG

4295

P06.07 [➙ 101]

Event: Setpoint Limited

IG

4296

P06.08 [➙ 101]

Event: Power Failure

IG

4297

P06.09 [➙ 101]

Time Deviation

20 s

4298

P06.10 [➙ 101]

Threshold Deviation

5%

4299

P06.11 [➙ 101]

Factor Deviation

1

4320

P06.12 [➙ 101]

Event: Deviation

W2

4300

P06.13 [➙ 101]

Event: Controller Limited

IG

4301

P06.14 [➙ 101]

Event: Memory

W1

4302

P06.15 [➙ 101]

Event: Analog Input < Offset

IG

5418

P06.16 [➙ 101]

DO: Dual Tacho active

n/a

4304

BV-H6411GB, 1221 - 68 -

Customer

Sys ID


Parameters

P06.17 [➙ 101]

Event: Primary Tacho Failure

IG

4305

Number:

Name

Default

P07.01 [➙ 108]

DI: Belt Motion Monitor

n/a

5724

P07.02 [➙ 108]


10 s

5698

P07.03 [➙ 108]


IG

5725

P07.04 [➙ 108]

DI: Source Belt Sensor

n/a

4497

P07.05 [➙ 108]

BIC Active

NO

4498

P07.06 [➙ 108]

DI: BIC freeze

n/a

4499

P07.07 [➙ 108]

Slip Value

10 % LB

4507

P07.08 [➙ 108]

Event: Slip

IG

4508

P07.09 [➙ 108]

DO: Belt Slip

n/a

4511

P07.10 [➙ 108]

Sensor Length

3.23 inch

4500

P07.11 [➙ 108]

Sensor W idth

4.73 inch

4501

P07.12 [➙ 108]

Sensor Offset

0 inch

4502

P07.13 [➙ 108]

Belt Drift

1.18 inch

4503

P07.14 [➙ 108]

Event: Belt Drift

W1

4504

P07.15 [➙ 108]

Belt Skew

1.58 inch

4505

P07.16 [➙ 108]

Event: Belt Skew

A

4506

P07.17 [➙ 108]

DO: Belt Drift

n/a

4509

P07.18 [➙ 108]

DO: Belt Skew

n/a

4510

Number:

Name

Default

P08.01 [➙ 113]

LC Filter

3s

4334

P08.02 [➙ 113]

Filter: Actual Flow Rate

1s

4328

P08.03 [➙ 113]

Filter: Actual Flow Rate analog

1s

4329

P08.04 [➙ 113]

Feedback Filter Override Threshold 15 %

5702

P08.05 [➙ 113]

Filter: Belt Load

1s

4331

P08.06 [➙ 113]

Filter: Belt Speed

1s

4332

07 - Belt Monitoring

Customer

Sys ID

08 - Filters


Customer

Sys ID

BV-H6411GB, 1221 - 69 -

Parameters

P08.07 [➙ 113]

Filter: Deviation

1s

4333

Number:

Name

Default

P09.01 [➙ 114]

Limit: Actual Flow Rate MIN

5 % Io

4337

P09.02 [➙ 114]

Event: Actual Flow Rate MIN

IG

4338

P09.03 [➙ 114]

Limit: Actual Flow Rate MAX

120 % Io

4339

P09.04 [➙ 114]

Event: Actual Flow Rate MAX

IG

4340

P09.05 [➙ 114]

Limit: Load MIN

60 % Q

4341

P09.06 [➙ 114]

Event: Load MIN

IG

4342

P09.07 [➙ 114]

Limit: Load MAX

120 % Q

4343

P09.08 [➙ 114]

Event: Load MAX

IG

4344

P09.09 [➙ 114]

Limit: Speed MIN

5%V

4345

P09.10 [➙ 114]

Event: Speed MIN

IG

4346

P09.11 [➙ 114]

Limit: Speed MAX

120 % V

4347

P09.12 [➙ 114]

Event: Speed MAX

IG

4348

P09.13 [➙ 114]

Temperature MAX

80 °C

5518

P09.14 [➙ 114]

Event: Temperature-MAX

IG

5519

09 - Limit Values

Customer

Sys ID

10 - Calibration Data

Number:

Name

Default

P10.01 [➙ 118]


36 inch

5693

P10.02 [➙ 118]

Pulses per length

300 P/inch

4256

P10.03 [➙ 118]

Range Correction TW

1

5731

P10.04 [➙ 118]

Range Correction TC

1

5732

P10.05 [➙ 118]

Range Correction TM

1

5733

P10.06 [➙ 118]

Belt Circuit Time

60 s

4353

P10.07 [➙ 118]

Simulation Travel (Belt Rev.)

2

5703

P10.08 [➙ 118]

Calibration W eight

70 lb

4354

P10.09 [➙ 118]

Test Chain W eight

4.3 lb/inch

5715

P10.10 [➙ 118]

Basic Tare

0 lb/inch

4355

BV-H6411GB, 1221 - 70 -

Customer

Sys ID


Parameters

P10.11 [➙ 118]

Belt Circuit No.

1000000 P/B

4357

Number:

Name

Default

P11.01 [➙ 121]

P-Component KP

0.05 mA/%

4369

P11.02 [➙ 121]

I-Component TN

1s

4370

P11.03 [➙ 121]

AO: Motor Speed Control

AO

4400

P11.04 [➙ 121]

Lower Limit

4 mA

4371

P11.05 [➙ 121]

Upper Limit

20 mA

4372

P11.06 [➙ 121]

Controller Magnitude Offset

4 mA

4373

P11.07 [➙ 121]

Position at STOP

Lower Limit

4374

P11.08 [➙ 121]

KP speed controller

0.07 mA/%

5734

P11.09 [➙ 121]

VAP Active

NO

4480

P11.10 [➙ 121]

Platform Dis.Length

0 % LB

4482

P11.11 [➙ 121]

CC_FC speed controller

0.01 mA/Hz

5920

P11.12 [➙ 121]

Control Offset speed controller

0 mA

5921

P11.13 [➙ 121]

Bypass

0 mA

4375

P11.14 [➙ 121]

Setpoint Filter 1st Ord

0s

4378

P11.15 [➙ 121]

Setpoint Filter 2nd Ord

0s

4379

P11.16 [➙ 121]

Adaptation 1

NO

4382

P11.17 [➙ 121]

Adaptation 2

NO

4383

Number:

Name

Default

P12.01 [➙ 125]

Moisture Active

NO

5386

P12.02 [➙ 125]

Moisture Select

n/a

5399

P12.03 [➙ 125]

AI: Moisture Measurement

n/a

5387

P12.04 [➙ 125]

Nominal Moisture

10 %

5388

P12.05 [➙ 125]

Moisture Offset

4 mA

5389

P12.06 [➙ 125]

Moisture Range

20 mA

5390

P12.07 [➙ 125]

DO: Moisture active

n/a

5400

11 - Rate controller

Customer

Sys ID

12 - M oisture


Customer

Sys ID

BV-H6411GB, 1221 - 71 -

Parameters

P12.08 [➙ 125]

Moisture MAX

20 %

5391

P12.09 [➙ 125]

DO: Moisture MAX

n/a

5392

P12.10 [➙ 125]

Event: Moisture MAX

IG

5393

P12.11 [➙ 125]

AO: Flow Rate corrected

n/a

5394

P12.12 [➙ 125]

AO: Flow Rate Offset

4 mA

5395

P12.13 [➙ 125]

AO: Flow Rate Range

20 mA

5396

P12.14 [➙ 125]

Pulse Counter corrected

NO

5397

13 - Cleanout control

Number:

Name

Default

Customer

Sys ID

P13.01 [➙ 128]

DO: CleanOut Timer

n/a

4277

P13.02 [➙ 128]

CleanOut ON Time

1h

4278

P13.03 [➙ 128]

CleanOut OFF Time

1h

4279

P13.04 [➙ 128]

DI: Chain Motion Monitor

n/a

4404

P13.05 [➙ 128]

Chain Motion Delay

20 s

4405

P13.06 [➙ 128]

Event: Chain Motion Monitor

IG

4406

Number:

Name

Default

P14.01 [➙ 130]

AO: Setpoint

n/a

4385

P14.02 [➙ 130]

Setpoint Offset

4 mA

4386

P14.03 [➙ 130]

Setpoint Range

20 mA

4387

P14.04 [➙ 130]

AO: Actual Flow Rate

AO

4388

P14.05 [➙ 130]

Flow Rate Offset

4 mA

4389

P14.06 [➙ 130]

Flow Rate Range

20 mA

4390

P14.07 [➙ 130]

AO: Belt Load

n/a

4391

P14.08 [➙ 130]

Belt Load Offset

4 mA

4392

P14.09 [➙ 130]

Belt Load Range

20 mA

4393

P14.10 [➙ 130]

AO: Speed

n/a

4394

P14.11 [➙ 130]

Speed Offset

4 mA

4395

P14.12 [➙ 130]

Speed Range

20 mA

4396

14 - Analog Outputs

BV-H6411GB, 1221 - 72 -

Customer

Sys ID


Parameters

P14.13 [➙ 130]

AO: Deviation

n/a

4397

P14.14 [➙ 130]

Deviation Offset

4 mA

4398

P14.15 [➙ 130]

Deviation Range

20 mA

4399

P14.16 [➙ 130]

AO: Actual Flow Rate (2nd)

n/a

4306

P14.17 [➙ 130]

AO: Density

n/a

5924

P14.18 [➙ 130]

Density Offset

4 mA

5925

P14.19 [➙ 130]

Density Range

20 mA

5926

Number:

Name

Default

P15.01 [➙ 134]

DI: Acknowledge Events

n/a

4419

P15.02 [➙ 134]

DI: Local Mode

n/a

4420

P15.03 [➙ 134]

Event: External Event 1

IG

4417

P15.04 [➙ 134]

DI: External Event 1

n/a

4418

P15.05 [➙ 134]

Event: NAMUR Error V103-DI13

IG

5904

P15.06 [➙ 134]


IG

5905

P15.07 [➙ 134]

DI: Reset Totalizer 1

n/a

5414

P15.08 [➙ 134]


n/a

5415

P15.09 [➙ 134]

DI: Discharge Pluggage

DI

5716

P15.10 [➙ 134]

Discharge Pluggage Delay

2s

5697

P15.11 [➙ 134]

Event: Discharge Pluggage

A

5717

P15.12 [➙ 134]

DI: Coal on belt switch

DI

5718

P15.13 [➙ 134]


1s

5704

P15.14 [➙ 134]

Event: Loss of Material

IG

5719

P15.15 [➙ 134]

Event: Coal on Belt

A

5754

P15.16 [➙ 134]

Belt Paddle Feedback Permissive

prop to Rate

5705

P15.17 [➙ 134]

DI: Motor feedback

DI

5720

P15.18 [➙ 134]

Event: Motor Start

A

5721

P15.19 [➙ 134]

DI: Coal Flow Monitor

DI

5726

P15.20 [➙ 134]


100 lb

5699

P15.21 [➙ 134]

Event: Coal Flow

A

5727

15 - Digital Inputs


Customer

Sys ID

BV-H6411GB, 1221 - 73 -

Parameters

P15.23 [➙ 134]

DI: Remote CTRL

n/a

5735

P15.24 [➙ 134]

DI: OFF/Maint CTRL

n/a

5736

P15.25 [➙ 134]

DI: Local Start

n/a

5737

P15.26 [➙ 134]

DI: Jog forward

n/a

5738

P15.27 [➙ 134]

DI: Jog backward

n/a

5739

P15.28 [➙ 134]


IG

4430

P15.29 [➙ 134]


n/a

4431

P15.30 [➙ 134]


IG

4730

P15.31 [➙ 134]


n/a

4731

P15.32 [➙ 134]


IG

4732

P15.33 [➙ 134]


n/a

4733

P15.34 [➙ 134]

DI: Volumetric Mode

n/a

4421

P15.35 [➙ 134]

DI: Mode Switch Lock

n/a

5922

Number:

Name

Default

P16.01 [➙ 143]

DO: Scale Start

DO

4433

P16.02 [➙ 143]

DO: Feeder Started

n/a

4434

P16.03 [➙ 143]

DO: Feeder running (2nd)

n/a

5671

P16.04 [➙ 143]

DO: Feeder Run Forward

DO

5740

P16.05 [➙ 143]

DO: Feeder Run Forward (2nd)

n/a

5672

P16.06 [➙ 143]

DO: Feeder Run Reverse

DO

5741

P16.07 [➙ 143]

DO: Feeder Run Reverse (2nd)

n/a

5673

P16.08 [➙ 143]

DO: Start Prefeeder

n/a

4435

P16.09 [➙ 143]

DO: ALARM

DO

4436

P16.10 [➙ 143]

DO: ALARM (2nd)

n/a

5674

P16.11 [➙ 143]

DO: Deviation

n/a

4437

P16.12 [➙ 143]

DO: Actual Flow Rate MIN

n/a

4438

P16.13 [➙ 143]

DO: Actual Flow Rate MAX

n/a

4439

P16.14 [➙ 143]

DO: Load MIN

n/a

4440

P16.15 [➙ 143]

DO: Load MAX

n/a

4441

16 - Digital Outputs

BV-H6411GB, 1221 - 74 -

Customer

Sys ID


Parameters

P16.16 [➙ 143]

DO: Speed MIN

n/a

4442

P16.17 [➙ 143]

DO: Speed MAX

n/a

4443

P16.18 [➙ 143]

DO: Volumetric Mode

DO

4444

P16.19 [➙ 143]

DO: Volumetric Mode (2nd)

n/a

5675

P16.20 [➙ 143]

DO: Local Mode

n/a

4445

P16.21 [➙ 143]

DO: W ARNING

DO

4759

P16.22 [➙ 143]

DO: W ARNING (2nd)

n/a

5676

P16.23 [➙ 143]

DO: Feeding

DO

5742

P16.24 [➙ 143]

DO: Feeding (2nd)

n/a

5677

P16.25 [➙ 143]

DO: Remote CTRL

DO

5750

P16.26 [➙ 143]

DO: Remote CTRL (2nd)

n/a

5678

17 - Analog calibration

Number:

Name

Default

P17.01 [➙ 150]

Analog Input 1 Min

4 mA

5755

P17.02 [➙ 150]

Analog Input 1 Max

20 mA

5756

P17.03 [➙ 150]

Analog Input 2 Min

4 mA

5757

P17.04 [➙ 150]

Analog Input 2 Max

20 mA

5758

P17.05 [➙ 150]

Analog Input 3 Min

4 mA

5759

P17.06 [➙ 150]

Analog Input 3 Max

20 mA

5760

P17.07 [➙ 150]

Analog Input 4 Min

4 mA

5761

P17.08 [➙ 150]

Analog Input 4 Max

20 mA

5762

P17.09 [➙ 150]

Analog Input 5 Min

4 mA

5763

P17.10 [➙ 150]

Analog Input 5 Max

20 mA

5764

P17.11 [➙ 150]

Analog Output 1 Min

4 mA

5765

P17.12 [➙ 150]

Analog Output 1 Max

20 mA

5766

P17.13 [➙ 150]

Analog Output 2 Min

4 mA

5767

P17.14 [➙ 150]

Analog Output 2 Max

20 mA

5768

P17.15 [➙ 150]

Analog Output 3 Min

4 mA

5769

P17.16 [➙ 150]

Analog Output 3 Max

20 mA

5770

P17.17 [➙ 150]

Analog Output 4 Min

4 mA

5664


Customer

Sys ID

BV-H6411GB, 1221 - 75 -

Parameters

P17.18 [➙ 150]

Analog Output 4 Max

20 mA

5665

P17.19 [➙ 150]

Analog Output 5 Min

4 mA

5666

P17.20 [➙ 150]

Analog Output 5 Max

20 mA

5667

P17.21 [➙ 150]

Analog Output 6 Min

4 mA

5668

P17.22 [➙ 150]

Analog Output 6 Max

20 mA

5669

P17.23 [➙ 150]

Analog Output 1 Test Value

0 mA

5908

P17.24 [➙ 150]


0 mA

5909

P17.25 [➙ 150]


0 mA

5910

P17.26 [➙ 150]


0 mA

5911

P17.27 [➙ 150]


0 mA

5912

P17.28 [➙ 150]


0 mA

5913

Number:

Name

Default

P18.01 [➙ 154]

2-Sensor Slip active

NO

5433

P18.02 [➙ 154]

Source Sensor 1

Speed

5434

P18.03 [➙ 154]

DI: Sensor 1

n/a

5435

P18.04 [➙ 154]

Characteristic Value Sensor 1

100 P/inch

5436

P18.05 [➙ 154]

DI: Sensor 2

n/a

5437

P18.06 [➙ 154]


100 P/inch

5438

P18.07 [➙ 154]

Slip Value 2

2 % LB

5439

P18.08 [➙ 154]

Event: Slip 2

IG

5440

P18.09 [➙ 154]

DO: Slip 2

n/a

5443

18 - 2-Sensor Slip

Customer

Sys ID

19 - Maintenance interval

Number:

Name

Default

P19.01 [➙ 156]

Maintenance Electric

3000 h

Customer

Sys ID 4465

P19.02 [➙ 156]

Event: Maint. Electric

IG

4466

P19.03 [➙ 156]

Maintenance Feeder Run

3000 h

4467

P19.04 [➙ 156]

Event: Maint.Feeder Run

IG

4468

20 - Data Logging

BV-H6411GB, 1221 - 76 -


Parameters

Number:

Name

Default

P20.01 [➙ 157]

Hourly Total Time

0 min

Customer

Sys ID 5743

P20.02 [➙ 157]

Daily Total Time

0 min

5744

P20.03 [➙ 157]

Logger cycle time

1 min

6288

P20.04 [➙ 157]

Data Log Value 1

752

6289

P20.05 [➙ 157]

Data Log Value 2

755

6290

P20.06 [➙ 157]

Data Log Value 3

1872

6291

P20.07 [➙ 157]

Data Log Value 4

1874

6292

P20.08 [➙ 157]

Data Log Value 5

1876

6293

P20.09 [➙ 157]

Data Log Value 6

2316

6294

P20.10 [➙ 157]

Data Log Value 7

1880

6295

P20.11 [➙ 157]

Data Log Value 8

1894

6296

P20.12 [➙ 157]

Data Log Value 9

2230

6297

P20.13 [➙ 157]

Data Log Value 10

2232

6298

21 - Communication EasyServe

Number:

Name

Default

P21.01 [➙ 159]

Customer

Sys ID

Own Address

1

4520

P21.02 [➙ 159]

Baud Rate

38400

4521

P21.03 [➙ 159]

Format Data

8-N-1

6189

22 - Communication Fieldbus

Number:

Name

Default

P22.01 [➙ 160]

Protocol Type

NO

4528

P22.02 [➙ 160]

Timeout Host

5s

4529

P22.03 [➙ 160]

Event: Cyclic Communication

A

4530

P22.04 [➙ 160]

Modbus-Version

compatible Stock

5729

P22.05 [➙ 160]

Word Sequence

I:std/L:std

6246

P22.06 [➙ 160]

Byte Sequence

High - Low

6245

P22.07 [➙ 160]

Configuration

FIXED_8_16

4661

P22.08 [➙ 160]

Address

1

4531

P22.09 [➙ 160]

Resolution

4096

4533


Customer

Sys ID

BV-H6411GB, 1221 - 77 -

Parameters

P22.10 [➙ 160]

Baud rate

19200

4535

P22.11 [➙ 160]

Data Format

8-O-1

4656

P22.12 [➙ 160]

Physics

RS232

6186

P22.13 [➙ 160]

Address

16

4539

P22.14 [➙ 160]

FLOAT-Format

IEEE

4540

P22.15 [➙ 160]

Address

63

4541

P22.16 [➙ 160]

Baud rate

125K

4542

P22.17 [➙ 160]

Parameter

NO

4658

P22.18 [➙ 160]

Preset Count

2

4734

P22.19 [➙ 160]

READ_ID Count

6

4659

P22.20 [➙ 160]

Access Rights Limitation FB

NO

4786

P22.21 [➙ 160]

Remote IP Address FB

192.168.240.250

4787

P22.22 [➙ 160]

Event: Acyclic Communication

W2

5680

P22.23 [➙ 160]

Configuration

PARA_ID_6_15

5923

Number:

Name

Default

P23.01 [➙ 165]

IP Address

192.168.240.1

6235

P23.02 [➙ 165]

Net Mask

255.255.255.0

6236

P23.03 [➙ 165]

Gateway

0.0.0.0

6237

Number:

Name

Default

P24.01 [➙ 166]

DO: PLC 1

n/a

4662

P24.02 [➙ 166]

DO: PLC 2

n/a

4663

P24.03 [➙ 166]

DO: PLC 3

n/a

4664

P24.04 [➙ 166]

DO: PLC 4

n/a

4665

P24.05 [➙ 166]

DO: PLC 5

n/a

4666

P24.06 [➙ 166]

DO: PLC 6

n/a

4667

P24.07 [➙ 166]

DO: PLC 7

n/a

4668

P24.08 [➙ 166]

DO: PLC 8

n/a

4669

23 - Ethernet

Customer

Sys ID

24 - PLC Outputs

BV-H6411GB, 1221 - 78 -

Customer

Sys ID


Parameters

P24.09 [➙ 166]

AO: PLC 1

n/a

4670

P24.10 [➙ 166]

AO: PLC 2

n/a

4671

25 - Fixed mode configuration

Number:

Name

Default

Customer

Sys ID

P25.01 [➙ 168]

ID Preset Value 1

320

6247

P25.02 [➙ 168]

ID Preset Value 2

352

6248

P25.03 [➙ 168]

ID Preset Value 3

384

6249

P25.04 [➙ 168]

ID Preset Value 4

592

6250

P25.05 [➙ 168]

ID Preset Value 5

0

6251

P25.06 [➙ 168]

ID Preset Value 6

0

6252

P25.07 [➙ 168]

ID Preset Value 7

0

6253

P25.08 [➙ 168]

ID Preset Value 8

0

6254

P25.09 [➙ 168]

ID Read Value 1

752

6256

P25.10 [➙ 168]

ID Read Value 2

816

6257

P25.11 [➙ 168]

ID Read Value 3

1552

6258

P25.12 [➙ 168]

ID Read Value 4

1872

6259

P25.13 [➙ 168]

ID Read Value 5

1894

6260

P25.14 [➙ 168]

ID Read Value 6

2230

6261

P25.15 [➙ 168]

ID Read Value 7

2232

6262

P25.16 [➙ 168]

ID Read Value 8

2234

6263

P25.17 [➙ 168]

ID Read Value 9

0

6264

P25.18 [➙ 168]

ID Read Value 10

0

6265

P25.19 [➙ 168]

ID Read Value 11

0

6266

P25.20 [➙ 168]

ID Read Value 12

0

6267

P25.21 [➙ 168]

ID Read Value 13

0

6268

P25.22 [➙ 168]

ID Read Value 14

0

6269

P25.23 [➙ 168]

ID Read Value 15

0

6270

P25.24 [➙ 168]

ID Read Value 16

0

6271

26 - FCB analog outputs


BV-H6411GB, 1221 - 79 -

Parameters

Number:

Name

Default

P26.01 [➙ 172]

FCB_AO 01

n/a

Customer

Sys ID

P26.02 [➙ 172]

Offset FCB_AO 1

4 mA

6272

P26.03 [➙ 172]

Range FCB_AO 1

20 mA

6273

P26.04 [➙ 172]

Reference FCB_AO 1

1000

P26.05 [➙ 172]

FCB_AO 02

n/a

P26.06 [➙ 172]

Offset FCB_AO 2

4 mA

6275

P26.07 [➙ 172]

Range FCB_AO 2

20 mA

6276

P26.08 [➙ 172]

Reference FCB_AO 2

1000

6277

P26.09 [➙ 172]

FCB_AO 03

n/a

P26.10 [➙ 172]

Offset FCB_AO 3

4 mA

6278

P26.11 [➙ 172]

Range FCB_AO 3

20 mA

6279

P26.12 [➙ 172]

Reference FCB_AO 3

10000

6280

P26.13 [➙ 172]

FCB_AO 04

n/a

P26.14 [➙ 172]

Offset FCB_AO 4

4 mA

6281

P26.15 [➙ 172]

Range FCB_AO 4

20 mA

6282

P26.16 [➙ 172]

Reference FCB_AO 4

1000

P26.17 [➙ 172]

FCB_AO 05

n/a

P26.18 [➙ 172]

Offset FCB_AO 5

4 mA

6284

P26.19 [➙ 172]

Range FCB_AO 5

20 mA

6285

P26.20 [➙ 172]

Reference FCB_AO 5

1000

6286

P26.21 [➙ 172]

FCB Variant

Empty

5902

P26.22 [➙ 172]

Event: FCB-Error

A

5903

20481

6274 20482

20483

20484

6283 20485

27 - FCB digital outputs

Number:

Name

Default

P27.01 [➙ 177]

FCB_DO 01

n/a

20529

P27.02 [➙ 177]

FCB_DO 02

n/a

20530

P27.03 [➙ 177]

FCB_DO 03

n/a

20531

P27.04 [➙ 177]

FCB_DO 04

n/a

20532

P27.05 [➙ 177]

FCB_DO 05

n/a

20533

BV-H6411GB, 1221 - 80 -

Customer

Sys ID


Parameters

P27.06 [➙ 177]

FCB_DO 06

n/a

20534

P27.07 [➙ 177]

FCB_DO 07

n/a

20535

P27.08 [➙ 177]

FCB_DO 08

n/a

20536

P27.09 [➙ 177]

FCB_DO 09

n/a

20537

P27.10 [➙ 177]

FCB_DO 10

n/a

20538

P27.11 [➙ 177]

FCB_DO 11

n/a

20539

P27.12 [➙ 177]

FCB_DO 12

n/a

20540

P27.13 [➙ 177]

FCB_DO 13

n/a

20541

P27.14 [➙ 177]

FCB_DO 14

n/a

20542

P27.15 [➙ 177]

FCB_DO 15

n/a

20543

P27.16 [➙ 177]

FCB_DO 16

n/a

20544

P27.17 [➙ 177]

FCB_DO 17

n/a

20545

P27.18 [➙ 177]

FCB_DO 18

n/a

20546

P27.19 [➙ 177]

FCB_DO 19

n/a

20547

P27.20 [➙ 177]

FCB_DO 20

n/a

20548

28 - Configuration HMI Values

Number: P28.01 [➙ 180]

Name HMI Value 01

Default 1884

P28.02 [➙ 180]

HMI Value 02

1880

6300

P28.03 [➙ 180]

HMI Value 03

2276

6301

P28.04 [➙ 180]

HMI Value 04

2292

6302

P28.05 [➙ 180]

HMI Value 05

2236

6303

P28.06 [➙ 180]

HMI Value 06

2234

6304

P28.07 [➙ 180]

HMI Value 07

2224

6305

P28.08 [➙ 180]

HMI Value 08

2226

6306

P28.09 [➙ 180]

HMI Value 09

1904

6307

P28.10 [➙ 180]

HMI Value 10

1960

6308

Customer


Sys ID 6299

BV-H6411GB, 1221 - 81 -

Parameters

10.2.2 Parameter Details 10.2.2.1 Parameter Block 01 - Hardware Modules Parameters in this group are used to select the error conditions that are generated by communication errors and to indicate to the controller which I/O module has been installed in each of the analog I/O slots. The analog I/O channels that are defined here are used in later parameter groups. The VCU 20103 has three built in analog channels and four slots for analog I/O modules. On the VCU 20103 channel A10 is closest to the power supply and channel A13 is farthest from the power supply. P01.01

Event: Communication HMI 1

Event Group: SY

Default: W2

Number: 07

The parameter selects the error condition generated when communications between the DT-9 and the touch screen HMI are lost for m ore then 10 seconds. The touch screen HMI must be connected to the X96 Ethernet port. This connector is located toward the center of the board, is marked in red and is keyed for a special cable. The parameter should be set to W2 (Warning with automatic reset). Actions: - Check operation of touch screen display (see display section). - Check cable connections. - Is correct Ethernet connection used?

P01.02


Event Group: SY

Default: A

Number: 12

The parameter selects the error condition generated when communications between the ARM9 main processor and the ARM7 auxiliary processor are lost. The parameter must always be set to A (Stop feeder) because the controller can not operate when communications are lost. Action: - Check cable connections between boards. - Replace controller.

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Parameters

P01.03

Analog Channel A10

Alternative:

NO AI2 (Analog In 2) AO3 (Analog Out 3)

Default: NO

This parameter specifies the analog I/O card that is installed in position A10. It is connected to terminal blocks X12-1 and X12-2.

This I/O port is not normally used on the VCU 20103 and this parameter is normally set to NO.

P01.04

Analog Channel A11

Alternative:


Default: NO

This parameter specifies the analog input card that is installed in position A11. It is connected to terminal blocks X12-3 and X12-4. This I/O port is not normally used on the VCU 20103 and this parameter is normally set to NO.

P01.05 Alternative:

Analog Channel A12 NO AI4 (Analog In 4) AO5 (Analog Out 5)

Default: NO


P01.06

Analog Channel A13

Alternative:


Default: NO


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Parameters


10.2.2.2 Parameter Block 02 - Feeder Definition This parameter group is used to specify the rating of the components in the weighing system. P02.01

Language

Alternative:

DEUTSCH ENGLISH OTHER

Default: ENGLISH

This parameter selects the language used in DT 9 displays. When it is set to “O THER” the individual display strings can be set using EasyServe.

P02.02

Units

Alternative:

Metric English

Default: English

This parameter selects the units used for displays and parameter inputs. Either SI (metric) or normal American (English) units may be selected.

P02.03

Default: DISOCONT TERSUS CF

Scale Name

This parameter specifies the text string to identify the feeder and is shown on the top line of the touch screen HMI. This parameter is set according to customer preference.

P02.04

Min: 1000

Password

Default: 10000

Max: 9999

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Parameters

This parameter specifies the password used to restrict access to various controller functions.

Note: This parameter can be changed using EasyServe in the event that the password is lost. Note: Some functions may require an alternate password. The default value is 7353.

P02.05

Min: 0 lb/h

Nominal Flow Rate

Default: 50000 lb/h

Max: 220000000 lb/h

This parameter is used to specify the feeder design feedrate. It is similar to 196NT Setup 05 (Maximum Feedrate) and is used for limit alarm s and display outputs. It should always be set to the same value as parameter P03.05 Maximum Feedrate. It is also used to scale the analog I/O channels and to calculate the simulated load when the controller is installed on a volumetric feeder. This parameter is set based on customer requirements and the mechanical design of the feeder. Check the project manual or certified drawings to insure that the proper value is selected.

Note: If both P04.07 Source Load Cell and P04.08 Source Load Cell 2 are set to Not Used, the load cells will be disabled and the system will operate as a volumetric feeder. The DT-9 will calculate an assumed belt load based on P02.05 Nominal Flow Rate and P02.06 Nominal Speed as shown below.

Nominal Belt Load = (P02.05 Nominal Flow Rate) / (3600 X P02.06 Nominal Speed)

P02.06

Nominal Speed

Min: 0.001 inch/s

Default: 3 inch/s

Max: 500 inch/s


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Parameters

This parameter is used to scale the belt speed analog output (i.e., Maximum analog signal = Nominal speed) and serves as the reference value for limit value monitoring. Nominal speed, together with nominal feedrate, is used to calculate the nominal belt load. Nominal speed is calculated as: (P02.05 Nominal Flow Rate ) / (300 X Nom. Density X P04.10 Load cross section)

Note: If both P04.07 Belt LC Left and P04.08 Belt LC Right are set to Not Used, the load cells will be disabled and the system will operate as a volumetric feeder. The DT-9 will calculate an assumed belt load based on P02.05 Nominal Flow Rate and P02.06 Nominal Belt Speed as shown below.

Nominal Belt Load = (P02.05 Nominal Flow Rate) / (3600 X P02.06 Nominal Belt Speed)

P02.07

Display Formats

Alternative:

STANDARD SELECTABLE

Default: SELECTABLE

This parameter allows the operator to either, accept the standard set of display formats (determined by the controller based on the P02.05 Nominal Flow Rate) or to select the display formats individually using parameters P02.08 through P02.11. This parameter should be set according to customer preference. The default value is STANDARD, which is suitable for most applications.

P02.08

Flow Rate Units

Alternative:

------ lb/h ----.- lb/h ---.-- lb/h --.--- lb/h ------ t/h ----.- t/h ---.-- t/h --.--- t/h ----.-- lb/min ------ lb/s

Default: ----.- lb/h

----.- lb/s ---.-- lb/s --.--- lb/s

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Parameters

This parameter selects the format used to display feedrate values. It is only visible when parameter P02.07 Display Formats is set to SELECTABLE and the available options depend on the selection value of parameter P02.02 Units . This parameter should be set according to customer preference.

P02.09

Counter 1 Unit

Alternative:

------- lb -----.- lb ----.-- lb ---.--- lb ------- t -----.- t ----.-- t ---.--- t

Default: ------- lb

This parameter selects the format used to display the total value in Counter 1. It is only visible when parameter P02.07 Display Formats is set to SELECTABLE and the available options depend on the selection value of parameter P02.02 Units . This parameter should be set according to customer preference.

P02.10

Counter 2 Unit

Alternative:

------- lb -----.- lb ----.-- lb ---.--- lb ------- t -----.- t ----.-- t ---.--- t

Default: ------- lb


P02.11

Counter 3 Unit

Default: ------- lb


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Parameters

Alternative:

------- lb -----.- lb ----.-- lb ---.--- lb ------- t -----.- t ----.-- t ---.--- t


P02.12

DO: Pulse Counter

Alternative:

DO n/a

Default: DO V103.DO12 High

This parameter specifies the digital output used for the Total Coal Integrator (TCI). The TCI cycles continuously while the feeder is in operation. To prevent premature failure of the output relay this parameter should always be set to DO 12 (Reed Relays - Terminal blocks X16-3 through X16-6).

P02.13

Min: 0 lb

Totalizer Increment

Default: 100 lb

Max: 100000 lb

This parameter sets the weight associated with each Total Coal Integrator (TCI) pulse. It is the same as 196NT Setup 07 (Remote Totalizer Data Logging Increment). The TCI output frequenc y is based on parameter P02.11, parameter P02.12 and the actual feedrate. If the values selected for these parameters require an output frequency greater then the maximum frequency of the selected device, an error (MF 14 - P02.13) will be generated. See parameter P02.12 for more information. This parameter is normally set to either 100 Lbs or 100 Kg.

P02.14

Min: 0 s

Pulse Length Total

Default: 0.1 s

Max: 10 s

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Parameters

This parameter sets the duration of each Total Coal Integrator (TCI) pulse. It is the same as 196NT Setup 35 (Remote Totalizer Pulse Width). The TCI output frequency is based on this parameter, parameter P02.11 and the actual feedrate. If this combination of values requires an output frequency greater then the maximum frequency of the selected device, an error (MF 14 - P02.13) will be generated. The maximum pulse frequency can be calculated as: Frequency = (P03.05 Maximum Feedrate) / ((3600) x ( P02.11)) When the TCI output is directed to an open collector or reed relay output the maximum possible pulse frequency is 10 Hz (P02.12 set to 0.05 sec). W hen the TCI output is directed to a mechanical relay output the m aximum possible pulse frequency is 1.0 Hz (P02.12 set to 0.5 sec). When the pulse length (P02.12) is increased, these values are reduced. The maximum possible frequency (in Hz) is calculated as: Max. possible freq. = 1 / (2 X P02.12 (in sec)) To insure that the TCI output works correctly the maximum pulse frequency must always be less then the maximum possible frequency.

P02.15

Event: Remote TCI too small Event Group: MF Number: 14

Default: W2

The parameter selects the error condition generated when totalizer pulses for the Total Coal Integrator (TCI) output are generated faster then the TCI output can operate. See parameter P02.14 Pulse Length Total for more information. This parameter shou ld be s et to W 2. Action: Set P02.13 Totalizer Increment and/or P02.14 Pulse Length Total to a smaller value.

P02.16

Min: 0 %

Maintenance Speed

Default: 50 %

Max: 100 %


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Parameters

This parameter determines the Motor Speed Control (MSC) demand signal used during maintenance (local, calibrate, jog) operations. It is similar to 196NT Setup 01 (Speed Setpoint) except that the MSC demand signal is set rather then the actual motor speed (open loop operation). The actual motor RPM is determined by the characteristics of the motor and the MSC. This parameter is normally set to 50% which will produce a motor speed of approximately 900 RPM with a 4 pole, 60 Hz motor.

P02.17

DO: FRI Frequency

Alternative:

DO n/a


This parameter specifies the digital output used for the Feed Rate Indicator (FRI). This parameter output can only be set to DO 13 (terminal block X6-1 and X6-2) which is an isolated, unpowered, transistor output.

P02.18

Min: 0 Hz/(t/h)

Remote FRI Frequency

Default: 10 Hz/(t/h)

Max: 2000000 Hz/(t/h)

The value of this parameter is used to calculate remote Feedrate Indicator (FRI) output frequency. It must be selected so that the FRI output at the minimum feedrate (see P03.06) is greater then 1.0 Hz and the FRI output at the maximum feedrate (see P03.06) is less then 1000 Hz. This parameter is normally set to 10.0 Hz / Ton/hr

Default: Unicode UTF-8

P02.20

Codepage

Alternative:

Standard (8859-1) Latin-2 (8859-2) Cyrillic (1251) Japanese Shift-JIS Chinese 936 (GBK) Chinese EUC-CN Unicode UTF-8 Unicode UTF-16

P02.21

DC_Mode

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Default: NO


Parameters

Alternative:

NO YES

This parameter allows for changing of the type of load cell excitation voltage. When set to NO, the load cell is supplied by a rectangular AC voltage. This mode should be used in case the load cell is connected straight to the load cell interface of the controller. This mode provides best suppression of thermal effects in the load cell cable and term inals. When set to YES, the load cell is supplied by a DC voltage. This mode requires the installation of an external load cell amplifier close to the load cell with a transmission of the DC output signal on a higher voltage and current level to suppress thermal effects in the load cell cable and terminals.

10.2.2.3 Parameter Block 03 - Control Sources This parameter group is used to select the control sources for use during Remote mode operation. P03.01

Feeder Start

Alternative:

DI OP FB

Default: DI V103.DI2 High

This parameter selects the digital input used as the feeder start command. Caution: This is a static input! Switching to remote control mode with the start input activated will start the feeder.

This parameter is normally set to DI 2 – High (terminal block X1-4) and is connected to wire 112.

P03.02

Feedrate Setpoint

Alternative:

AI OP FB R-L

Default: AI V103.AI1


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Parameters

This parameter selects the source for the feedrate demand signal and can be set to the following values: AI 3 for use with an analog (usually 4-20mA) input signal on SIG+ and SIGR-L for use with the Raise/Lower input signals (See P03.07 and P03.08). The demand signal is set to its lower limit in case the feeder is switched off. OP for use with EasyServe FB or remote control using a Field Bus This parameter is normally set to AI 3. Check the certified drawings to insure that the proper value is selected.

P03.03

Min: 0 mA

Setpoint Range

Default: 20 mA

Max: 1000 mA

This parameter determines the nominal 100% signal level for the analog input channel. It should be set to 20.0 for a 0-20mA, 4-20mA or 0-10V input. This parameter is norm ally set to 20.00 mA and is only active when P03.02 is set to an analog input signal. Note: When an analog input card is used, the input jumper must be set toward the outside of the card for a voltage input signal and toward the middle of the card for a current input

signal.

P03.04

Setpoint Offset

Min: -200 mA

Max: 200 mA

Default: 4 mA

This parameter determines the nominal 0% signal level for the analog input channel. This parameter is norm ally set to 4.00 mA and is only active when P03.02 is set to an analog input signal. If a zero based signal (0-20mA or 0-10V) is used it must be set to 0.00 mA. Note: When an analog input card is used, the input jumper must be set toward the outside of the card for a voltage input signal and toward the middle of the card for a current input signal.

P03.05 Min: 0 lb/h

Maximum Feedrate Max: 220000000 lb/h

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Default: 50000 lb/h


Parameters

This is the maximum feedrate clamp. The feeder will not operate above this rate regardless of the feedrate demand signal. This is similar to the 196NT parameter 05 (Maximum Feedrate). It should alwa ys be set to the same values as parameter P02.05 Nominal Flow Rate. This parameter is set based on custom er requirements and the mechanical design of the feeder. Check the project specifications or certified drawings to insure that the proper value is selected.

P03.06

Min: 0 lb/h

Minimum Feedrate

Default: 5000 lb/h

Max: 220000000 lb/h

This is the minimum feedrate clamp. The feeder will not operate below this rate regardless of the feedrate demand signal. This is similar to the 196NT parameter 06 (Minimum Feedrate). This parameter is set based on customer requirements and the minimum motor speed. Check the project specifications or certified drawings to insure that the proper value is selected.

P03.07

DI: Raise Setpoint

Alternative:

n/a DI

Default: n/a

This parameter selects the digital input signal used as the raise feedrate setpoint command. This parameter is only active if P03.02 is set to R-L. This parameter is normally set to DI 3 – High (terminal block X1-2), or Not Used, and is connected to wire 113.

P03.08

DI: Lower Setpoint

Alternative:

n/a DI

Default: n/a


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Parameters

This parameter selects the digital input signal used as the lower feedrate setpoint command. This parameter is only active if P03.02 is set to R-L. This parameter is normally set to DI 11 – High (terminal block X4-5), or Not Used, and is connected to wire 114.

P03.09

Min: 5 s

Raise/Lower Response Time

Default: 30 s

Max: 300 s

This parameter determ ines the speed at which the feedrate setpoint changes when the raise or lower input is active. The value represents the approximate time, in seconds, for the setpoint to go from 0% to 100%. This is similar to the 196NT parameter 28 (Raise/Lower Response Time). This parameter is only active if P03.02 is set to R-L.

P03.10

Source Run Enable

Alternative:

DI n/a FB


This parameter selects the digital input signal used as the belt motor start permissive. When it is enabled, (set to a digital input) an active signal on the designated input is required to start the belt drive motor. When it is set to n/a, this feature is disabled. This parameter is normally set to DI 8 - High (terminal block X3-4) and is connected to (wire 111). Caution: Setting this parameter to n/a will disable the Run Enable feature and create an unsafe operating condition. The Run Enable input m ust ALWAYS be enabled and connected to a user accessible stop switch.

P03.11

Event: Run Disabled

Event Group: IL

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Default: W2

Number: 01


Parameters

The parameter selects the method used to annunciate the error condition when the Run Enable input is not active. Setting the parameter to IG does not disable the Run Enable feature but it does prevent an error from being generated. The parameter is normally set to W2 so that there is an indication on the display when the feeder is disabled. Cause of event: - When a touch screen HMI is used, parameter P03.10 Source Run Enable must be set to DI 8, which is connected to the stop switch mounted under the HMI. This switch is used to stop the feeder in the event that the HMI is disabled or disconnected. Action: - Check the position of the Run Enable switch. - Check the wiring to the Run Enable switch. Note: The Run Enable switch is not normally used with the Stock 196NT displa y and in this case P03.10 Source Run Enable must be set to n/a to allow motor operation.

P03.12

Mode Select Enable/Disable

Alternative:

Keyboard only Keyboard & Local Keyb.,Remote & Local

Default: Keyb.,Remote & Local


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Parameters

This parameter is used to enable the Remote (P15.23 DI: Remote CTRL) and Local (P15.25 DI: Local Start) digital inputs. The Remote and Local digital inputs are edge triggered, meaning that their function is initiated by the transition from OFF to ON or, ON to OFF rather then by their state. This type of operation allows the feeder to be stopped due to an error condition or a keyboard input, even when the digital input is active. The operation of the Remote and Local digital inputs is described below.

Keyboard Only - Both the Remote and Local digital inputs are ignored at all times. Keyboard & Local - The Remote input is ignored but the Local input is active. If the feeder

is in OFF/Maint mode and stopped, energizing the Local input will cause the feeder to run in Local mode. If the feeder is in OFF/Maint mode and running, de-energizing the Local input will cause the feeder to stop. Keyboard, Remote & Local - Both the Remote and Local input are active. If the feeder is in OFF/Maint mode and stopped, energizing the Local input will start the feeder in Local mode and energizing the Remote input will force the feeder into Remote mode. If the feeder is in OFF/Maint mode and running, the Remote input will be ignored and de-energizing the Local input will stop the feeder. If the feeder is in Remote mode, the Local input is ignored and deenergizing the Remote input will force the feeder into OFF/Maint mode.

The keyboard is always enabled regardless of the value selected for this parameter. This parameter is norm ally set to Keyboard Only.

P03.13

Min: 10 rpm

Speed Setpoint

Default: 200 rpm

Max: 30000 rpm

This parameter is used to set motor RPM when P03.14 Run Mode Select is set to Speed Setpoint.

P03.14

Run Mode Select

Alternative:

Frate Setpoint Speed Setpoint

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Default: Frate Setpoint


Parameters

This parameter allows the feeder to operate in remote at a fixed motor speed. It is normally set to Frate Setpoint for normal control and when in this mode the controller responds to the Analog input or Raise/Lower contacts. When Speed Setpoint is selected the motor speed is fixed at the value specified in P03.13 Speed Setpoint and the controller does not respond to either the analog input or the Raise/Lower contacts. Selecting Speed Setpoint is similar to setting 196NT Setup 03 (Run Mode Select) to 5 (RPM Setpoint). This parameter MUST be set to Frate Setpoint

P03.15

Min: 1 lb/ft3

Density Setpoint

Default: 50.955 lb/ft3

Max: 100000 lb/ft3

This parameter specifies the bulk material density in weight per volume. The value is relevant during the very first startup of the feeder and in c ase the feeder doesn't have load cells to deternine the belt load.

10.2.2.4 Parameter Block 04 - Rated Data The parameters of this group describe important characteristic values of the scales' mechanics. P04.01

LC Characteristic Value

Min: 0.01 mV/V

Default: 3 mV/V

Max: 10 mV/V

This parameter specifies the Load cell rated output. Both load cells must have the same output value. Our normally use 3.000 mV/V load cells.

P04.02

Min: 0.5 lb

LC Rated Capacity

Default: 100 lb

Max: 220000000 lb

This parameter specifies the rated capacity of each load cell. Both load cells must have the same capacity. Our normally use 100.0 Lbs (50 kg) load cells but smaller load cells may be used for low capacity feeders or feeders with a short weigh span. This parameter is normally set to 100.0 Lbs (50 kg). Check the project manual or certified drawings to insure that the proper value is selected.

P04.03

Effective Platform Length

Min: 0.1 inch

Max: 50 inch

Default: 18 inch


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Parameters

This parameter specifies the length of belt that is supported by the load cells. Our use a three roller weighing system with one weighing roller, supported by the load cells, and two fixed weigh span rollers. In this configuration, one half of the weight between the weigh span rollers is supported by the load cells and this parameter must be set to one half of the distance between the weigh span rollers. This parameter must be set to ½ the value of 196NT Setup 10 Weigh Span Length, normally 18 inches (45.7cm) on new feeder installations and 19.146 (48,6 cm) on mechanical feeder conversions.

P04.04

Min: 0.01

Lever Ratio

Default: 1

Max: 2

This parameter is used to specify the ratio of weigh on the load cell and total platform weigh on multi weigh roller systems. This parameter MUST be set to 1.000.

P04.05

Min: 0 degree

Angle

Default: 0 degree

Max: 60 degree

This parameter is used to specify the feeder inclination and is used to adjust the weight signal when the load cell is mounted perpendicular to the belt on an inclined feeder. The load cells in our are always mounted vertically, to eliminate weighing errors, and this adjustment is not necessary. The parameter must be set to 0.00 degrees.

P04.06

Speed Measurement

Alternative:

DI n/a


This parameter selects the digital input used for the tachometer input signal. This parameter is normally set to DI 15 (terminal block X5-1 & X5-2) and is connected to (wires 145 & 146).

Note: If DI 14 is selected, a NAMUR type sensor must be used, and connected to X5-3 & X5-4.

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Parameters

P04.07

Source Load Cell

Alternative:

LC n/a

Default: LC V103.LC1

This parameter specifies the input channel connected to the load cell on the left side of the feeder (viewed in the direction of belt travel). This parameter should always be set to LC 1. Note: Setting both P04.07 Source Load Cell and P04.08 Source Load Cell 2 to Not Used, will disable the load cells and force the system to operate as a volumetric feeder. The DT-9 will calculate an assumed density and belt load based on P02.05 Nominal Flow Rate and P02.06 Nominal Speed.

P04.08

Source Load Cell 2

Alternative:

LC n/a

Default: LC V103.LC2

This parameter specifies the input channel connected to the load cell on the right side of the feeder (viewed in the direction of belt travel). This parameter should always be set to LC 2. Note: Setting both P04.07 Source Load Cell and P04.08 Source Load Cell 2 to Not Used, will disable the load cells and force the system to operate as a volumetric feeder. The DT-9 will calculate an assumed density and belt load based on P02.05 Nominal Flow Rate and P02.06 Nominal Speed.

P04.09

Min: 1 P/rev

Tachometer: Pulses per Rev

Default: 60 P/rev

Max: 1000 P/rev

This parameter specifies the number of pulses generated by the tachometer for each revolution of the motor. It is similar to 196NT Setup 09 tachometer type. This parameter is set based on the type or tachometer that is installed. In most (but not all) cases, feeders that use a VFD control use a tachometer that produces 60 pulses per revolution and feeders that use an Edd y Current Clutch use a tachometer that produces 12 pulses per revolution. Check the project specifications or certified drawings to insure that the proper value is selected.

P04.10

Load cross section

Default: 157 inch2


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Parameters

Min: 0.1 inch2

Max: 100000 inch2

This parameter specifies the area under the inlet leveling bar. This parameter is norm ally set to 157.0 square inches (1013 square cm). Check the project specifications or certified drawings to insure that the proper value is selected.

10.2.2.5 Parameter Block 05 - Feeder control This parameter group specifies the actions to be taken when error conditions are detected. P05.01

Volum on LC failure

Alternative:

NO YES

Default: YES

This parameter allows the DT-9 to force the feeder into volumetric mode in the event of a weighing system failure. Volumetric mode is independent of the event generated in P05.02 Event: Volum. caused by LC-error. This parameter should always be set to YES.

P05.02


Event Group: CO

Default: IG

Number: 05

The parameter is used to specify the type of error that is generated in the event of a weighing system failure. This event is independent of volumetric mode. This parameter should be set to IG (Ignore). Cause of event: - Indicates that the system is in volumetric mode due to failure in the weighing system. Action to be taken: - Check for load cell wiring errors or imbalanced load cell inputs.

P05.03

Min: 0 s

Afterflow Measurement Time

Default: 0 s

Max: 2000 s

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Parameters

This parameter specifies the amount of time that the feeder continues to totalize after the belt has stopped. This parameter should always be set to 0.0 sec.

P05.04

Zero Drop-Out Active

Alternative:

NO YES

Default: NO

This parameter is used to specify that the DT-9 should stop totalizing and set the weight signal to zero when the load on the belt reaches a low limit specified by P05.05 Zero DropOut Limit This parameter must be set to NO.

P05.05

Min: 0 % Q

Zero Drop-Out Limit

Default: 1 % Q

Max: 10 % Q

This parameter specifies the limit at which the weight signal will be set to zero and the DT-9 will stop totalizing if P05.04 Zero Drop-Out Active is set to YES. This parameter should be set to 1.00%.

10.2.2.6 Parameter Block 06 - Feeder Monitoring This parameter group can be used to cause various feeder operating conditions either to produce an alarm (A) and trip the feeder or to produce a warning (W1 or W2). P06.01

Event: Stand-By

Event Group: SC

Default: IG

Number: 02


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Parameters

The parameter selects the error condition generated when the belt drive motor is stopped because the motor demand signal is less than the limit specified in P06.02 Stand-By Limit Value. The parameter should be set to IG (Ignore). Cause of event: - Scale is in standby mode, i.e. setpoint is smaller than set standby limit (Parameter P06.02 Stand-By Limit Value ). Material pre-feeder cuts off.

P06.02

Min: 0 % Io

Stand-By Limit Value

Default: 0 % Io

Max: 100 % Io

If the motor speed control (MSC) demand signal goes below the limit specified by this parameter, the required motor speed is set to zero and the motor start contact is deenergized. There is a 3 second delay before the motor is stopped and no delay before it is restarted. Setting this parameter to 0% deactivates this function. This parameter should normally be set to 5%.

P06.03

Event: Tachometer Input Event Group: CA Number: 02

Default: A

The parameter selects the error condition generated when the tachometer signal is lost or is greater than 3600 Hz. The parameter should be set to A (Stop Feeder). Cause of event: - Input frequency is zero or exceeds 3600 Hz. Action: - Insure that the motor is turning. - Insure that parameter P04.06 Speed Measurement is set to the correct input. - Check the tachometer wiring. - Check the tachometer signal using a frequency counter or oscilloscope.

P06.04


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Default: IG


Parameters

Event Group: CA

Number: 01

The parameter selects the error condition generated when the load cell signal is invalid. If P05.01 Volum on LC failure is set to YES, this condition will force the feeder into volumetric mode, regardless of the value selected here. The parameter should be set to IG (Ignore).

Cause of event: - Load cell cable wrong. - Measuring amplifier A/D converter is in saturated state. - Supply voltage is below 19V. - Error must be available for minimum 3s. Action: - Check cabling. - If cabling is OK, load cell amplifier could be defective. - Check for either possibility. If scale cannot be restarted after remedy of fault, turn device off and restart.

P06.05


Event Group: LO

Default: IG

Number: 01

The parameter selects the error condition generated when either of the load cell signals is less than 3% of the full scale value. If P05.01 Volum on LC failure is set to YES, this condition will force the feeder into volumetric mode regardless of the value selected here. The parameter should be set to IG (Ignore).

P06.06

Event: LC Input > M AX

Event Group: HI

Default: IG

Number: 01


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Parameters

The parameter selects the error condition generated when either of the load cell signals is greater than the maximum allowable value. If P05.01 Volum on LC failure is set to YES, this condition will force the feeder into volumetric mode regardless of the value selected here. This parameter should be set to IG (Ignore). Cause of event: - Load cell load is higher than 110% of load cells rated capacities. Full scale value: 125% with 2.85mV/V load cells 175% with 2mV/V load cells Action: - Check material infeed.

P06.07


Event Group: SC

Default: IG

Number: 01

The parameter selects the error condition generated when the feedrate demand signal is greater than the feedrate limit as determined by the operating mode. In gravimetric mode, the limit is the lesser of P02.05 Nominal Flow Rate or P03.05 Maximum Feedrate. In volumetric mode, the limit is 3 times P02.05 Nominal Flow Rate. The parameter should be set to IG (Ignore). Depending on selected mode: a) In gravimetric mode, setpoint is limited to nominal feed rate. b) In volumetric mode, limitation starts from values exceeding 3 times the nominal value. c) Emergency setpoint is active.

P06.08


Event Group: W E

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Default: IG

Number: 01


Parameters

The parameter selects the error condition generated when the controller restarts after a loss of power. If it is set to A, the feeder will not restart after power is lost during normal remote mode operation. This parameter should be set to IG (Ignore). Cause of event: - Power failure. Power supply failed or cut off. During power failure, no totalization takes place. Scale does not start automatically, independent of event class.

P06.09

Min: 0 s

Time Deviation

Default: 20 s

Max: 600 s

This parameter specifies the maximum time that the actual feedrate can differ from the feedrate setpoint by an amount greater than P06.10 Threshold Deviation before an error is generated. This parameter is normally set to 20 sec.

P06.10

Min: 0 %

Threshold Deviation

Default: 5 %

Max: 100 %

This parameter specifies the minimum amount that the actual feedrate can differ from the feedrate setpoint without generating an error. The error is generated after a delay specified by P06.09 Time Deviation . This parameter is normally set to 5.0 %.

P06.11

Min: 0

Factor Deviation

Default: 1

Max: 1


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Parameters

This parameter allows P06.10 Threshold Deviation to be adjusted based on the feedrate setpoint. This allows the effective threshold to be reduced as the feedrate setpoint is reduced. When P06.11 is set to 1.0 there is no adjustment and the effective threshold is always equal to P06.10 Threshold Deviation. When P06.11 is set to 0.0 the effective deviation is calculated by multiplying P06.10 Threshold Deviation by a factor equal to the (feedrate setpoint) / (P02.05 (Nominal Flow Rate ). This parameter should be set to 1.0.

P06.12

Event: Deviation

Event Group: HI

Default: W2

Number: 05

The parameter specifies the event that is generated when the actual feedrate can differ from the feedrate setpoint by an amount greater than P06.10 Threshold Deviation for a time greater than P06.09 Time Deviation. The parameter is similar to the 196NT Feedrate Error and should be set to W2. Action: - Check for loss or material on belt.

P06.13


Event Group: CO

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Default: IG

Number: 01


Parameters

The parameter selects the error condition generated when the motor speed control demand signal reaches its upper limit. The parameter should be set to IG (Ignore). Cause of event: - Feed rate controller control magnitude has reached upper response threshold. After some time, message HI-5 (Deviation) is additionally output.

1. Material flow missing or irregular. 2. External feed rate controller wrongly set.

Action: - Check material discharge and control magnitude (service value Y). At nominal feed rate, Y should be 10 to 14mA.

P06.14

Event: Memory

Event Group: SY

Default: W1

Number: 01

The parameter selects the error condition generated when the controller detects an error in the internal non-volatile memory. Reload the non-volatile memory by using the "Load Default Parameters" function to correct this error. If the problem persists, the controller must be replaced. The parameter should be set to A (Stop feeder). Note: The Load Default Parameters function will reset all of the controller's internal parameters, including Calibration and Trim. After this operation is performed, all parameters must be reset, the feeder must be recalibrated and the analog I/O channels must be retrimmed.

P06.15


Event Group: W E

Default: IG

Number: 08


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Parameters

The parameter selects the error condition generated when the analog feedrate demand signal is more then 0.4 mA below the minimum value (P03.04 Setpoint Offset). The parameter should be set to IG (Ignore). Cause of event: - The signal available across an analog input is smaller than the offset. A tolerance space of 0.4 mA is built in for ensuring that events are not constantly set and deleted with noisy input signals around the offset. Action: - Check analog input (Sig+ & Sig-) wiring.

P06.16

DO: Dual Tacho active

Alternative:

n/a DO

Default: n/a

This parameter selects the digital output used to switch to the secondar y tachometer in a dual tachometer system. The output is reset when the feeder is switched off. This parameter should be set to n/a in a single tachometer system and DO 3 in a dual tachometer system. DO 3 is norm ally used by P16.07 DO: Feeder Run Reverse (2nd) which must be set to not used.

P06.17


Event Group: CA

Default: IG

Number: 09

Event is detected in case the primary tachometer doesn't deliver pulses during normal operation.

10.2.2.7 Parameter Block 07 - Belt Monitoring The parameters in this group control the Belt Motion Monitor (BMM). P07.01

DI: Belt Motion Monitor

Alternative:

n/a

Default: n/a

DI

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Parameters

This parameter selects the digital input used for the Belt Motion Monitor (BMM). This parameter is normally set to DI 12 - High (terminal block X4-2) and is connected to wire 115.

P07.02

Min: 0 s


Default: 10 s

Max: 50 s

This parameter sets the maximum delay between Belt Motion Monitor (BMM) pulses before a BMM error (P07.03 Event: Belt Motion Monitor) is generated. It is the same as 196NT Setup 17 (Belt Motion Monitor Delay). The interval is determined when the feeder is operating at its minimum design feed rate and is equal to the time necessary for the pulley or roller which inputs the sensor to make one complete revolution, divided by two, plus ten percent. Therefore, time intervals for motion monitors mounted to the tension roll or belt take-up pulley will be considerably longer than those for sensors mounted to the weigh span roller. Example: If the motion monitor is mounted to the weigh span roller which make revolution every 20 seconds at minimum feed rate, the time interval between pulses before the belt is certain not to be moving is: 20 / 2 = 10 + 10% = 11. Note: To disable this function if a belt motion monitor is not installed set P07.03 Event: Belt Motion Monitor to IG.

P07.03


Event Group: W M

Default: IG

Number: 10

The parameter selects the error condition generated when the belt motion monitor (BMM) pulse delay is exceeded. The parameter is normally set to A (Stop Feeder) if a BMM is installed. Setting it to IG (Ignore) will disable the BMM feature. Cause of event: - The Belt Motion Monitor (BMM) pulse delay (P07.02) has been exceeded.

P07.04

DI: Source Belt Sensor

Alternative:

n/a DI

Default: n/a


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Parameters

The digital input for the belt sensor. This function can be checked with the corresponding service value. DI: Sensor input DI13 or DI14 should be used. n/a: BIC and the belt monitoring functions are inactive. This is used if a belt with V-guide and without mark in the belt is installed.

P07.05

BIC Active

Alternative:

NO YES

Default: NO

This parameter is used to activate the Belt Influence Compensation (BIC) system. The BIC system is used in batching feeders to tare individual sections of the belt separately so that batches that are less then a full belt length are weighted accurately. The BIC feature is not used in continuous feeding systems and this parameter should always be set to NO.

P07.06

DI: BIC freeze

Alternative:

n/a DI

Default: n/a

This parameter is used to specify a digital input that is used to freeze the tare value while the BIC feature is active. This parameter is normally set to n/a.

P07.07

Min: 0 % LB

Slip Value

Default: 10 % LB

Max: 20 % LB

This parameter specifies the maximum amount that the belt speed measured by the belt slip input can differ from belt speed measured by the tachometer input, without generating an error. This parameter is normally set to 10.0 % LB.

P07.08 Event: Slip Event Group: W M Number: 02

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Default: IG


Parameters

The parameter selects the error condition generated when the belt slip exceeds the limit specified in parameter P07.07 Slip Value. The parameter is normally set to IG.

P07.09

DO: Belt Slip

Alternative:

n/a DO

Default: n/a

This parameter selects the digital output that is energized when the Belt Slip event is active. This parameter is normally set to IG.

P07.10

Min: 0.01 inch

Sensor Length

Default: 3.23 inch

Max: 400 inch

Length of the metallic markings worked into the belt in the direction of belt travel.

P07.11

Min: 0.01 inch

Sensor Width

Default: 4.73 inch

Max: 400 inch

Width of the metallic markings worked into the belt at right angles to the direction of belt travel.

P07.12

Min: -400 inch

Sensor Offset

Default: 0 inch

Max: 400 inch

The zero point of recording the belt drift can be corrected with the offset. Unfortunately, this restricts the maximum display zone. This is why greater differences should be calibrated by mechanically shifting the sensor. The new display = the old display - the offset

P07.13

Min: 0.01 inch

Belt Drift

Default: 1.18 inch

Max: 400 inch

Threshold value for belt misalignment identification to generate an event message Event: Belt Drift .


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Parameters

P07.14

Event: Belt Drift

Event Group: W M

Default: W1

Number: 04

The belt has exceeded the tolerance levels set. Steps: 1. Remove any soiling to the tail and drive pulleys 2. Align the belt Monitoring may also be subject to error. Therefore: keep an eye on the service value for the belt motion sensor and correct any errors that may arise. Related threshold value: Belt Drift

P07.15

Min: 0.01 inch

Belt Skew

Default: 1.58 inch

Max: 400 inch

Threshold of the belt drift for detection of event Event: Belt Skew.

P07.16

Event: Belt Skew

Event Group: W M

Default: A

Number: 03

Belt has run off-center. Feeder is no longer operable. Action: See Event: Belt Drift Related threshold: Belt Skew

P07.17

DO: Belt Drift

Alternative:

n/a DO

Default: n/a

Digital output to show the 'off-track running' event. Also refer to: P07.13 Belt Drift and P07.14 Event: Belt Drift The output operates independently of the event class of the corresponding event.

P07.18

DO: Belt Skew

Alternative:

n/a DO

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Default: n/a


Parameters

Digital output to show the belt drift event. Also refer to: P07.15 Belt Skew and P07.16 Event: Belt Skew The output operates independently of the event class of the corresponding event.

10.2.2.8 Parameter Block 08 - Filters The parameters of this group define the time constants of the filters for measurement and display. All filters are of the 1st order (exponentially), i.e. approximately 2/3 of the final value is reached after the time set if there is an abrupt change in the signal. Long times result in a smooth, slowly-updating display. P08.01

LC Filter

Min: 0.25 s

Default: 3 s

Max: 300 s

This parameter sets the amount of digital filtering used on the load cell signals. It is similar to the 196NT Setup 19 Weight Signal Filter.

P08.02

Min: 0 s

Filter: Actual Flow Rate

Default: 1 s

Max: 600 s

This parameter sets the amount of digital filtering used on the feedrate value displayed on the display, EasyServe and field bus interface. It is similar to the 196NT Setup 20 Feedback Signal Filter.

P08.03

Min: 0 s

Filter: Actual Flow Rate analog

Default: 1 s

Max: 600 s

This parameter sets the amount of digital filtering used on the feedrate signal sent to the analog output channel. It is similar to the 196NT Setup 20 Feedback Signal Filter.

P08.04

Min: 0 %

Feedback Filter Override Threshold

Default: 15 %

Max: 200 %

This parameter specifies point at which the point at which the feedback filter is overridden and the actual feedrate is displayed. This is used so that large changes are displayed quickly. This parameter is the same as 196NT Setup 21 (Feedback filter override threshold).


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Parameters

P08.05

Min: 0 s

Filter: Belt Load

Default: 1 s

Max: 600 s

This parameter sets the amount of digital filtering used on the belt load signal sent to the analog output channel.

P08.06

Min: 0 s

Filter: Belt Speed

Default: 1 s

Max: 600 s

This parameter sets the amount of digital filtering used on the belt speed signal sent to the analog output channel.

P08.07

Min: 0 s

Filter: Deviation

Default: 1 s

Max: 600 s

This parameter sets the amount of digital filtering used on the deviation signal sent to the analog output channel.

10.2.2.9 Parameter Block 09 - Limit Values The parameters in this group are used to set the limit points at which various events are generated as well as selecting the type of event that are generated when the limit points are reached. Note: Limit values are only checked after the feeder has been running for 10 seconds. P09.01

Limit: Actual Flow Rate MIN

Min: -10 % Io

Max: 200 % Io

Default: 5 % Io

This parameter sets the point at which a minimum feedrate event is generated. This parameter is normally set to 5 % of the nominal flow rate (P02.06).

P09.02


Event Group: LO

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Default: IG

Number: 02


Parameters

The parameter determines the type of event that is generated when the feedrate is less than the value specified in P09.01 Limit: Actual Flow Rate MIN . The parameter is normally set to IG (Ignore)

P09.03

Limit: Actual Flow Rate MAX

Min: -10 % Io

Max: 200 % Io

Default: 120 % Io

This parameter sets the point at which a maximum feedrate event is generated. This parameter is normally set to 120 % of the nominal flow rate (P02.06).

P09.04


Event Group: HI

Default: IG

Number: 02

The parameter determines the type of event that is generated when the feedrate exceeds the value specified in P09.03 Limit: Actual Flow Rate MAX . This parameter is normally set to IG (Ignore) Cause of event: - Flow rate exceeds set maximum value.

P09.05

Limit: Load MIN

Min: -10 % Q

Max: 200 % Q

Default: 60 % Q

This parameter sets the point at which a minimum belt load event is generated. This parameter is normally set to 60 % of the nominal belt load (calculated from the nominal flow rate and the nominal belt speed).

P09.06

Event: Load MIN

Event Group: LO

Default: IG

Number: 03


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Parameters

The parameter determines the type of event that is generated when the feedrate is less than the value specified in P09.05 Limit: Load MIN. Set this value to W2 to simulate the 196NT low density alarm. The parameter is normally set to IG (Ignore) Cause of event: - Belt load smaller than set minimum value.

P09.07

Limit: Load MAX

Min: -10 % Q

Max: 200 % Q

Default: 120 % Q

This parameter sets the point at which a maximum belt load event is generated. This parameter is normally set to 120 % of the nominal belt load (calculated from the nominal flow rate and the nominal belt speed).

P09.08

Event: Load MAX

Event Group: HI

Default: IG

Number: 03

The parameter determines the type of event that is generated when the feedrate exceeds the value specified in P09.07 Limit: Load MAX. The parameter is normally set to IG (Ignore) Cause of event: - Belt load exceeds set maximum value.

P09.09

Limit: Speed MIN

Min: -10 % V

Max: 200 % V

Default: 5 % V

This parameter sets the point at which a minimum belt speed event is generated. This parameter is normally set to 5 % of the nominal belt speed (P02.06).

P09.10

Event: Speed MIN

Event Group: LO

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Default: IG

Number: 04


Parameters

The parameter determines the type of event that is generated when the feedrate is less than the value specified in P09.09 Limit: Speed MIN . The parameter is normally set to IG (Ignore) Cause of event: - Belt speed is smaller than set minimum value.

P09.11

Limit: Speed MAX

Min: -10 % V

Max: 200 % V

Default: 120 % V

This parameter sets the point at which a maximum belt speed event is generated. This parameter is normally set to 120 % of the nominal belt speed (P02.06).

P09.12

Event: Speed MAX

Event Group: HI

Default: IG

Number: 04

The parameter determines the type of event that is generated when the feedrate exceeds the value specified in P09.01 Limit: Actual Flow Rate MIN . The parameter is normally set to IG (Ignore) Cause of event: - Belt speed exceeds set maximum value.

P09.13

Min: 30 °C

Temperature MAX

Default: 80 °C

Max: 90 °C

Maximum allowed temperatur inside the VCU. W hen the actual temperature exceeds the threshold event Event: Temperature-MAX is generated. See also: P09.14 Event: Temperature-MAX

P09.14


Event Group: MF

Default: IG

Number: 13


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Parameters

The event will be detected in case the actual temperature is above the threshold (P09.13 Temperature MAX). The controller might fail to function. Countermeasures: - Check temperatur of environment - Install cooler close to the controller

10.2.2.10

Parameter Block 10 - Calibration Data

The parameters of this group contain the setpoints for setup programs and their outputs. Adjustment values that have been lost can be completely reconstructed by entering earlier values. If replacements are made it is sufficient to load the previously set parameters into the new unit. No readjustment is necessary. P10.01


Min: 0.01 inch

Default: 36 inch

Max: 500 inch

This parameter specifies the distance between the two calibration probe bosses. It is the same as the 196NT Setup 12 Calibration Probe Span This parameter must match the physical characteristics of the feeder but in most cases, it is set to 36 inches (91,5 cm) for new feeder installations or 38.7 inches (98,3 cm) on mechanical weighing feeder conversions.

P10.02

Pulses per length

Min: 1 P/inch

Max: 1000000 P/inch

Default: 300 P/inch

This parameter indicates the number of tachometer pulses per lenght unit of belt travel. It is calculated by the DT-9 during the calibration process based on the time it takes for a calibration tape to travel between the two calibration probes. This parameter should not normally be changed by the operator.

P10.03

Min: 0.5

Range Correction TW

Default: 1

Max: 2

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Parameters

This parameter indicates the correction factor applied to the load cell reading based on a dead weight calibration (TW: Span Calibration). It is calculated by the DT-9 during the calibration process based on the weigh s ystem characteristics specified in Parameter Group 4, and on the calibration weight specified in P10.08 Calibration Weight. This parameter should not normally be changed by the operator. Note: The gross weight on the load cells is calculated based on the load cell characteristics

specified in Parameter Group 4 and the product of the three correction factors specified in P10.03 thru P10.05.

P10.04

Min: 0.5

Range Correction TC

Default: 1

Max: 2

This parameter indicates the correction factor applied to the load cell reading based on a chain calibration (TC: Span Calibration). It is calculated by the DT-9 during the calibration process based on the weigh system characteristics specified in Parameter Block 4, and on the test chain weight specified in P10.09 Test Chain Weight. This parameter should not normally be changed by the operator. Note: The gross weight on the load cells is calculated based on the load cell characteristics specified in Parameter Block 4 and the product of the three correction factors specified in

P10.03 thru P10.05.

P10.05

Min: 0.5

Range Correction TM

Default: 1

Max: 2

This parameter specifies the correction factor applied to the load cell reading based on a material test. It is calculated by the operator based on the difference between the totalized value, indicated by the DT-9, and the actual value, determ ined by an external static scale. Note: The gross weight on the load cells is calculated based on the load cell characteristics specified in Parameter Block 4 and the product of the three correction factors specified in P10.03 thru P10.05.

P10.06

Min: 1 s

Belt Circuit Time

Default: 60 s

Max: 9999 s


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Parameters

This parameter specifies the duration of the LB: Pulse/Belt calibration process. This process counts the number of tachom eter pulses received during the specified time and place the result in P10.11 Belt Circuit No..

P10.07

Min: 0.5

Simulation Travel (Belt Rev.)

Default: 2

Max: 5000

This parameter specifies the duration, in belt revolutions, of the TC: Span Calibration process. This process performs a span calibration using P10.09 Test Chain Weight as the calibration weight, and places the result in P10.04 Range Correction TC. This parameter should be set to 2.0 belt revolutions.

P10.08

Calibration Weight

Min: 0.001 lb

Max: 22000 lb

Default: 70 lb

This parameter specifies the value of the calibration weight used during the span portion of a feeder calibration (TW: Span Calibration). It is the same as the 196NT Setup 13 Calibration W eight The correct value is normally stamped on the calibration weight.

P10.09

Test Chain Weight

Min: 0 lb/inch

Max: 22000 lb/inch

Default: 4.3 lb/inch

This parameter specifies the value of the calibration chain used when a chain calibration (TC: Span Calibration) is preformed. It is similar to the 196NT Setup 36 Test Chain Weight

P10.10

Basic Tare

Min: 0 lb/inch

Max: 10000 lb/inch

Default: 0 lb/inch

This parameter indicates the weight of the empty belt. It is calculated by the DT-9 during the tare portion of the calibration process (BS: Tare/Belt Speed). This parameter should not normally be changed by the operator.

P10.11

Min: 0 P/B

Belt Circuit No.

Default: 1000000 P/B

Max: 9000000 P/B

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Parameters

This parameter indicates the total number of tachometer pulses in one complete belt revolution. It is calculated by the DT-9 during the tare portion of the calibration process (BS: Tare/Belt Speed). This parameter should not normally be changed by the operator.

10.2.2.11

Parameter Block 11 - Rate controller

The parameters in this group are used to control the operation of the Motor Speed Control (MSC). P11.01

P-Component KP

Min: 0 mA/%

Max: 1000 mA/%

Default: 0.05 mA/%

This parameter specifies the proportional gain of the speed control loop. Increasing this value produces a faster response but my produce oscillation or unstable operation. Reducing this value increases stability but produces a slower response. Note: The DT-9 uses a PI control loop (Proportional & Integral terms, no Derivative term). The proportional term is specified by P11.01 P-Component KP and the Integral term is specified by P11.02 I-Component TN.

P11.02

I-Compone nt T N

Default: 1 s

Min: 0 s Max: 60000 s This parameter specifies the integral gain of the speed control loop. The value specified here is the reciprocal of the actual gain value. Decreasing this parameter produces a faster response but my produce oscillation or unstable operation and increasing it increases stability but produces a slower response. Note: The DT-9 uses a PI control loop (Proportional & Integral terms, no Derivative term). The proportional term is specified by P11.01 P-Component KP and the Integral term is specified by P11.02 I-Component TN.

P11.03

AO: Motor Speed Control

Alternative:

AO n/a

Default: AO V103.AO1


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Parameters

This parameter specifies the analog output channel used to control the Motor Speed Control (MSC). This parameter is normally set to AO 1 (terminal blocks X6-7 and X6-6) and is connected to wires 142 through 144.

P11.04

Min: 0 mA

Lower Limit

Default: 4 mA

Max: 20 mA

This parameter determines the lower limit of the Motor Speed Control (MSC) demand signal. It should always be set to the same value as P11.06 Controller Magnitude Offset. This parameter is normally set to 4.00 mA. If a zero based signal (0-20mA or 0-10V) is used it must be set to 0.00 mA.

P11.05

Min: 0 mA

Upper Limit

Default: 20 mA

Max: 20 mA

This parameter determines the nominal 100% signal level for the analog input channel. It should be set to 20.0 for a 0-20mA, 4-20mA and 0-10V input.

P11.06

Min: 0 mA

Controller Magnitude Offset

Default: 4 mA

Max: 20 mA

This parameter determines the nominal 0% signal level for the analog input channel. It should always be set to the sam e value as P11.04 Lower Limit. This parameter is normally set to 4.00 mA. If a zero based signal (0-20mA or 0-10V) is used it must be set to 0.00 mA.

P11.07

Position at STOP

Alternative:

0 Lower Limit

Default: Lower Limit

This parameter specifies the value of the Motor Speed Control (MSC) demand signal (see P11.03 Controller Magnitude Y) when the belt drive motor is not running. This parameter should always be set to Lower Limit.

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Parameters

P11.08

KP speed controller

Min: 0 mA/%

Max: 1000 mA/%

Default: 0.07 mA/%

This parameter specifies the speed control gain used during the volumetric startup period.

P11.09

VAP Active

Alternative:

NO YES

Default: NO

When this parameter is set to YES the feedrate and total calculations are time shifted to adjust for the delay between the time that the material is weighed and the time that it is discharged. This feature is useful when small batches are being delivered but is not used on Stock feeders. It should always be set to NO.

P11.10

Min: 0 % LB

Platform Dis.Length

Default: 0 % LB

Max: 50 % LB

This parameter specifies the distance between the center of the weigh platform and the material discharge point in percentage of total belt length.

This parameter is only used when P11.09 VAP Active is set to YES. It should always be set to 0.0% Lb.

P11.11

CC_FC speed controller

Min: 0 mA/Hz

Max: 1000 mA/Hz

Default: 0.01 mA/Hz

Relation of control output to resulting frequency of the tachometer. This value is determined by the adjustment programm Basic (Cal1). The value takes effect during the volumetic startup phase of the controller after power recovery only.

P11.12

Min: -1000 mA

Control Offset speed controller

Default: 0 mA

Max: 1000 mA

Control output resulting in a tachometer frequency of 0 Hz.This value is determined by the adjustment programm Basic (Cal1). The value takes effect during the volumetic startup phase of the controller after power recovery only.


BV-H6411GB, 1221 - 123 -

Parameters

P11.13

Min: 0 mA

Bypass

Default: 0 mA

Max: 20 mA

The constant for the setpoint bypass (also refer to the controller figure in the appendix). The bypass instantaneously passes on a portion of the flow rate setpoint to the controller magnitude to the feed drive. This parameter contains the current at which the prefeeder just supplies the nominal flow rate (P02.05 Nominal Flow Rate).

Setting: operate the feeder volumetrically and set the bypass so that actual flow rate = setpoint. This value should be approximately 10 ... 15 mA. Otherwise the external flow rate controller should be adjusted.

P11.14

Min: 0 s

Setpoint Filter 1st Ord

Default: 0 s

Max: 6000 s

The time constant for a 1st-order filter in the setpoint branch. Does not function for the bypass. To prevent overshoot, the setpoint is decoupled from the actual controller through a reconstruction of the controlled member. The setpoint filters P11.14 and P11.15 delay the controller while the bypass comes to the controller magnitude output without a delay. The filter is switched off with P11.14 = 0. Also refer to: the controller figure in the appendix

P11.15

Min: 0 s

Setpoint Filter 2nd Ord

Default: 0 s

Max: 6000 s

The time constant for a second filter in the setpoint branch. Does not function for the b ypass. To prevent overshoot, the setpoint is decoupled from the actual controller through a reconstruction of the controlled member. The setpoint filters P11.14 Setpoint Filter 1st Ord and P11.15 delay the controller while the bypass comes to the controller magnitude output without a delay. The filter is switched off with P11.15 = 0. Also refer to: the controller figure in the appendix

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Parameters

P11.16

Adaptation 1

Alternative:

NO V 1/Q 1/W

Default: NO

Controlled adaption of the controller input.

The adaption means that the controller can be adapted to variable route reinforcements or the guidance behavior can be improved.

P11.17

Adaptation 2

Alternative:

NO W

Default: NO

Regulated adaptation of the controller output. Alternatives: NO, W

10.2.2.12

Parameter Block 12 - Moisture

Parameters in this group supply the information required when material moisture compensation is used. We do not currently supply moisture measurement equipment and these parameters should always be disabled. P12.01

Moisture Active

Alternative:

NO YES

Default: NO

This parameter is used to activate the moisture compensation system. At present Stock does not supply moisture measurement equipment and these parameters should always be disabled. This parameter should always be set to NO.

P12.02

Moisture Select

Alternative:

n/a DI FB

Default: n/a

With factory default value "n/a" , the correction is not active.


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Parameters

P12.03

AI: Moisture Measurement

Alternative:

n/a AI

Default: n/a

Defines the input signal for the measuring signal of the error effects, e.g. the moisture content. Also refer to: P12.04 Nominal Moisture P12.05 Moisture Offset P12.06 Moisture Range

P12.04

Min: 0 %

Nominal Moisture

Default: 10 %

Max: 100 %

Maximum value of additives (moisture) content as a percentage of weight. Also refer to: P12.03 AI: Moisture Measurement P12.05 Moisture Offset P12.06 Moisture Range

P12.05 Min: -200 mA

Moisture Offset Max: 200 mA

Default: 4 mA

Current for a correction value of 0% Reference value: P12.04 Nominal Moisture Also refer to: P12.03 AI: Moisture Measurement , P12.06 Moisture Range

P12.06

Min: 0 mA

Moisture Range

Default: 20 mA

Max: 1000 mA

Current for a correction value of 100% Reference value: P12.04 Nominal Moisture Also refer to: P12.03 AI: Moisture Measurement , P12.05 Moisture Offset

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Parameters

P12.07

DO: Moisture active

Alternative:

n/a DO

Default: n/a

Definition of the output channel for signal 'Correction active'. Also refer to: P12.02 Moisture Select

P12.08

Min: 0 %

Moisture MAX

Default: 20 %

Max: 100 %

Threshold for monitoring the moisture as a portion of the moisture content of the overall weight. Also refer to: P12.09 DO: Moisture MAX, P12.10 Event: Moisture MAX

P12.09

DO: Moisture MAX

Alternative:

n/a DO

Default: n/a

Defines the output channel for the signal that indicates that the moisture content has exceeded its threshold. The output is independent of the class of the related event. Also refer to: P12.08 Moisture MAX, P12.10 Event: Moisture MAX

P12.10

Event: Moisture MAX

Event Group: MF

Default: IG

Number: 05

Cause of event: - The value of the moisture input signal is greater than the maximum signal set by P12.08 Moisture MAX.

P12.11

AO: Flow Rate corrected

Alternative:

n/a AO

Default: n/a


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Parameters

Defines the output channel for the feed rate corrected for the disturbance value (moisture). Also refer to: P12.12 AO: Flow Rate Offset , P12.13 AO: Flow Rate Range

P12.12

AO: Flow Rate Offset

Min: -200 mA

Max: 200 mA

Default: 4 mA

Output current for an output of 0 %. Reference value: P02.05 Nominal Flow Rate

P12.13

Min: 0 mA

AO: Flow Rate Range

Default: 20 mA

Max: 1000 mA

Output current for an output of 100 %. Reference value: P02.05 Nominal Flow Rate

P12.14

Pulse Counter corrected

Alternative:

NO YES

Default: NO

Defines the output signal for connecting an external impulse counter. NO: The impulse output supplies the uncorrected material quantity YES: The impulse output supplies the bulk material quantity corrected by the correction factor, e.g. moisture.

10.2.2.13

Parameter Block 13 - Cleanout control

The parameters in this group control the cleanout conveyor timer and Chain Motion Monitor (CMM). P13.01

DO: CleanOut Timer

Alternative:

n/a DO

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Default: n/a


Parameters

This parameter specifies the digital output used to energize the cleanout conveyor motor starter when the cleanout timer feature is enabled. Note: The cleanout timer output relay is only energized when the feeder is operating in remote mode.

P13.02

CleanOut ON Time

Min: 0.01 h

Default: 1 h

Max: 1000 h

This parameter specifies the cleanout conveyor ON time when the cleanout timer feature is enabled. Note: The cleanout timer output relay is only energized when the feeder is operating in

remote mode.

P13.03

Min: 0 h

CleanOut OFF Time

Default: 1 h

Max: 1001 h

This parameter specifies the cleanout conveyor OFF time when the cleanout timer feature is enabled. Note: The cleanout timer output relay is only energized when the feeder is operating in

remote mode.

P13.04

DI: Chain M otion Monitor

Alternative:

n/a DI

Default: n/a

This parameter specifies the digital input used for the Chain Motion Monitor (CMM)

P13.05

Min: 1 s

Chain Motion Delay

Default: 20 s

Max: 1000 s

This parameter sets the maximum delay between Chain Motion Monitor (CMM) pulses before a CMM error (P13.06 Event: Chain Motion Monitor ) is generated.

This parameter is normally set to 20 sec. To disable this function if a CMM is not installed set P13.06 Event: Chain Motion Monitor to IG.


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Parameters

P13.06


Event Group: W M

Default: IG

Number: 06

The parameter selects the error condition generated when the Chain Motion Monitor (CMM) pulse delay is exceeded. The parameter is normally set to A (Stop Feeder) if a CMM is installed and IG (Ignore) if not. Cause of event: - The Chain Motion Monitor (CMM) pulse delay (P13.05) has been exceeded.

10.2.2.14

Parameter Block 14 - Analog Outputs

The parameters in this group select the control source for the analog output channels. P14.01

AO: Setpoint

Alternative:

n/a AO

Default: n/a

This parameter selects the analog output channel used for the indicated signal. Setpoint: The Setpoint value is the feedrate that the feeder is currently attempting to meet. The source of the setpoint signal is determined by P03.02 Feedrate Setpoint. The analog output is scaled to P02.05 Nominal Flow Rate.

P14.02

Setpoint Offset

Min: -200 mA

Max: 200 mA

Default: 4 mA

This parameter selects the actual analog output when the control signal is zero.

P14.03

Min: 0 mA

Setpoint Range

Default: 20 mA

Max: 1000 mA

This parameter selects the actual analog output when the control signal is maximum.

P14.04

AO: Actual Flow Rate

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Default: AO V103.AO2


Parameters

Alternative:

AO n/a

This parameter selects the analog output channel used for the indicated signal. Actual Flow Rate: The Actual Flow Rate value is the feedrate that the feeder is currently delivering. This is the default signal source for Analog Output 2 (Set by P01.04 Analog Channel A11). The analog output is scaled to P02.05 Nominal Flow Rate

P14.05

Flow Rate Offset

Min: -200 mA

Max: 200 mA

Default: 4 mA


P14.06

Min: 0 mA

Flow Rate Range

Default: 20 mA

Max: 1000 mA


P14.07

AO: Belt Load

Alternative:

n/a

Default: n/a

AO This parameter selects the analog output channel used for the indicated signal. Belt Load: The Belt Load value is the current weight of material on the belt per unit length. The analog output is scaled to the nominal belt load, which is calculated using P02.05 Nominal Flow Rate and P02.06 Nominal Speed.

P14.08

Belt Load Offset

Min: -200 mA

Max: 200 mA

Default: 4 mA


P14.09

Belt Load Range

Default: 20 mA

Min: 0 mA Max: 1000 mA This parameter selects the actual analog output when the control signal is maximum.


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Parameters

P14.10

AO: Speed

Alternative:

n/a AO

Default: n/a

This parameter selects the analog output channel used for the indicated signal. Speed: The Speed value is the current belt speed. The analog output is scaled to P02.06 Nominal Speed.

P14.11

Speed Offset

Min: -200 mA

Max: 200 mA

Default: 4 mA


P14.12

Min: 0 mA

Speed Range

Default: 20 mA

Max: 1000 mA


P14.13

AO: Deviation

Alternative:

n/a AO

Default: n/a

This parameter selects the analog output channel used for the indicated signal. Deviation: The Setpoint value indicates the amount that the actual feedrate deviates from the feedrate setpoint.

P14.14

Deviation Offset

Min: -200 mA

Max: 200 mA

Default: 4 mA

See P14.15 Deviation Range.

P14.15

Min: 0 mA

Deviation Range

Default: 20 mA

Max: 1000 mA

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Parameters

The output signal is generated as follows: Current = 10 mA + (P14.14/ 2) + (P14.16 - P14.15) X (Deviation / 100) Note: Deviation can have either a positive or a negative value.

P14.16

AO: Actual Flow Rate (2nd)

Alternative:

n/a AO

Default: n/a

This parameter is used when a second analog output proportional to feedrate is required. A second analog output card is required and is normally installed in position A10. In this case both parameter P01.03 Analog Channel A10 and P14.16 AO: Actual Flow Rate (2nd) must be set to AO 3. Actual Flow Rate: The Actual Flow Rate value is the feedrate that the feeder is currently delivering. This is the default signal source for Analog Output 2 (Set by P01.04 Analog Channel A11). The analog output is scaled to P02.05 Nominal Flow Rate.

P14.17

AO: Density

Alternative:

n/a AO

Default: n/a

Definition of the output channel for the measured density of the bulk material. For the adjustment of the signal see P14.18 Density Offset and P14.18 Density Offset.

P14.18

Density Offset

Min: -200 mA

Max: 200 mA

Default: 4 mA

Output signal for an empty belt (= density zero). See also: P14.17 AO: Density P14.19 Density Range

P14.19

Min: 0 mA

Density Range

Default: 20 mA

Max: 1000 mA


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Parameters

Output signal for measured density = rated density. Not to physically limit the output at the rated density, P14.17 should be set below 20 mA. See also: P14.17 AO: Density Service value Nominal Density

10.2.2.15

Parameter Block 15 - Digital Inputs

The parameters in this group are used to associate various controller functions with specific digital input channels and to associate events with those functions. Most of the functions specified in this group are hard wired on the controller and cannot be changed. P15.01

DI: Acknowledge Events

Alternative:

n/a DI

Default: n/a

This parameter specifies the digital input used to remotely acknowledge error conditions. This function is not normally used and this parameter should be set to n/a (not used).

P15.02

DI: Local Mode

Alternative:

n/a DI

Default: n/a

This parameter specifies the digital input used to indicate that the VMO is in local mode. This function is not used and this parameter should always be set to n/a (not used).

P15.03


Event Group: SC

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Default: IG

Number: 05


Parameters

The parameter specifies the event that is generated when the input specified in P15.04 DI: External Event 1 is active. The function is not used and the parameter should be set to IG (Ignore). Cause of event: - External event 1 (see P15.04) is enabled, and external event 1 input (see P15.03 ) is active.

P15.04


Alternative:

n/a DI

Default: n/a

This parameter specifies the digital input used to remotely generate External Event 1. This function is not used and this parameter should be set to n/a (not used).

P15.05


Event Group: W E

P15.06

Number: 15


Event Group: W E

Default: IG

Default: IG

Number: 16

P15.07


Alternative:

n/a DI

Default: n/a

This parameter specifies the digital input used to remotely reset totalizer 1. The totalizer is reset on the rising edge of the signal. This function is not used and this parameter should be set to n/a (not used).

P15.08


Default: n/a


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Parameters

Alternative:

n/a DI

This parameter specifies the digital input used to remotely reset totalizer 2. The totalizer is reset on the rising edge of the signal. This function is not used and this parameter should be set to n/a (not used).

P15.09

DI: Discharge Pluggage

Alternative:

DI n/a


This parameter specifies the digital input used for the discharge pluggage switch (LSFD). It is internally programmed as a failsafe input. When the parameter is set to HIGH, open contact (low signal) on the input will produce an event. This parameter is normally set to DI 5 – High (terminal block X2-4) and is connected to wire 109.

P15.10

Min: 0 s

Discharge Pluggage Delay

Default: 2 s

Max: 50 s

This parameter specifies the delay between the time that a discharge pluggage is detected and the time that the discharge pluggage event is generated. It is the same as Setup 16 (Discharge Pluggage Delay) on the 196NT.

P15.11


Event Group: W M

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Default: A

Number: 07


Parameters

The parameter specifies the event that is generated when a discharge pluggage is detected. The parameter is normally set to A (Stop feeder). It can be set to IG (Ignore) to disable the discharge pluggage event. Cause of event: - The discharge pluggage switch (LSFD) detected a build up of coal at the feeder discharge. This is a fail safe input. The event is generated when the LSFD signal is lost. Action: - Insure that discharge is clear. - Check LSFD wiring.

P15.12

DI: Coal on belt switch

Alternative:

DI n/a


This parameter specifies the digital input used for the Coal on belt switch (LSFB), This parameter is normally set to DI 7 – High (terminal block X3-6) and is connected to wire 108 if a coal on belt switch is installed on the feeder. It can be set to n/a (not use) to disable the coal on belt input.

P15.13

Min: 0 s


Default: 1 s

Max: 50 s

This parameter specifies the delay between the time that a loss of material on the belt is detected (coal on belt switch is inactive) and the time that the Loss of material event is generated. It is the same as Setup 39 (Loss of Flow Delay) on the 196NT. Note: The loss of flow event can be disabled by setting P15.14 Event: Loss of Material to IG (Ignore).

P15.14


Event Group: W M

Default: IG

Number: 08


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Parameters

The parameter specifies the event that is generated when a loss of material is detected (coal on belt switch is inactive). The parameter is normally set to A (Stop feeder). It can be set to IG (Ignore) to disable the Loss of material event. Cause of event: - The coal on belt switch (LSFB) has indicated a loss of material on the belt while running in Remote.

P15.15

Event: Coal on Belt

Event Group: W M

Default: A

Number: 12

The parameter specifies the event that is generated when the feeder attempts to run in Local mode with material on the belt (coal on belt switch is active). The parameter should always be set to A (Stop feeder). Cause of event: - Coal was detected by the coal on belt switch (LSFB) when the feeder was running in local or calibrate mode.

P15.16

Belt Paddle Feedback Permissive

Alternative:

prop to Rate Low. Lim. if empty

Default: prop to Rate

This parameter specifies the source for the feedback signal when a loss of material (coal on belt switch is inactive) on the belt is detected. If it is set to Prop to Rate, the feedback signal always follows the actual feedrate value; if it is set to Low Lim if Empty, the feedback signal is set to zero when a loss of material is detected (coal on belt switch is inactive). It is similar to Setup 24 – (Belt Paddle Feedback Permissive) on the 196NT. Note: This parameter should always be set to Low Lim. If Empty when the DT-9 is used on a volumetric feeder.

P15.17

DI: Motor feedback

Alternative:

DI n/a

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Parameters

This parameter specifies the digital input used to indicate that the motor speed control has been energized. This parameter is normally set to DI 4 – High (terminal block X2-6) and is connected to wire 110.

P15.18

Event: Motor Start

Event Group: W M

Default: A

Number: 09

The parameter specifies the type of event that is generated when the motor feedback signal (P15.17) does not follow the motor start signal (P16.04 through P16.07). The parameter should always be set to A (Stop Feeder) Cause of event: - The motor starter of VFD has failed to start the feeder when instructed to by the controller.

P15.19

DI: Coal Flow M onitor

Alternative:

DI n/a


This parameter specifies the digital input used to indicate that the coal flow monitor has detected a loss of flow. This parameter is normally set to DI 10 – High (terminal block X4-7) and is connected to wire 116.

P15.20

Min: 0 lb


Default: 100 lb

Max: 10000000 lb

This parameter specifies the delay between the time that a loss of material flow is indicated by the coal flow monitor (P15.19) and the time that the Coal Flow Error event is generated. It is specified in units of weight so that a head seal can be maintained regardless of the feedrate. It is similar to Setup 18 (Level/Temperature Sensor Delay) on the 196NT. This parameter is normally set to 100 lbs (50 kg) to provide a quick response without nuisance trips.


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Parameters

P15.21

Event: Coal Flow

Event Group: W M

Default: A

Number: 11

The parameter specifies the type of event that is generated when a loss of material flow is detected. The parameter should be set to A (Stop Feeder) when a coal flow monitor is installed and IG (ignore) when one is not. Cause of event: - The (optional) coal flow monitor has indicated a loss of material in the downspout above the feeder.

P15.23

DI: Remote CTRL

Alternative:

n/a DI

Default: n/a

This parameter specifies the digital input used to force the feeder into Remote mode. This parameter is normally set to DI 1 – High (terminal block X1-6) and is connected to wire 118. Note: This input is only active when parameter P03.12 Mode Select Enable/Disable is set to Keyboard, Remote & Local.

P15.24

DI: OFF/Maint CTRL

Alternative:

n/a DI

Default: n/a

This parameter specifies the digital input used to force the feeder into Off mode. This function is not used and this parameter should be set to n/a (not used).

P15.25

DI: Local Start

Alternative:

n/a DI

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Default: n/a


Parameters

This parameter specifies the digital input used to force the feeder into Local mode. Attention: This input start the belt drive! This parameter is normally set to DI 9 – High (terminal block X3-2) and is connected to wire 119. Note: This input is only active when parameter P03.12 Mode Select Enable/Disable is set

to Keyboard & Local or Keyboard, Remote & Local.

P15.26

DI: Jog forward

Alternative:

n/a DI

Default: n/a

This parameter specifies the digital input used to jog the feeder forward. This function is not used and this parameter should be set to n/a (not used).

P15.27

DI: Jog backward

Alternative:

n/a DI

Default: n/a

This parameter specifies the digital input used to jog the feeder in reverse. This function is not used and this parameter should be set to n/a (not used).

P15.28


Event Group: SC

Default: IG

Number: 06


P15.29


Default: n/a


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Parameters

Alternative:

n/a DI


P15.30


Event Group: SC

Default: IG

Number: 11


P15.31


Alternative:

n/a

Default: n/a

DI This parameter specifies the digital input used to remotely generate External Event 3. This function is not used and this parameter should be set to n/a (not used).

P15.32


Event Group: SC

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Default: IG

Number: 12


Parameters


P15.33


Alternative:

n/a DI

Default: n/a


P15.34

DI: Volumetric Mode

Alternative:

n/a DI

Default: n/a

This parameter defines the digital input to force the feed rate control into volumetric mode. The beltspeed is not influenced by the beltload in volumetric control operation.

P15.35

DI: Mode Switch Lock

Alternative:

n/a DI

Default: n/a

Definition of the input signal that prevents modem switching (Remote <-> Off/Service) using the VHM keyboard. The signal can be given by i.e. a key switch.

10.2.2.16

Parameter Block 16 - Digital Outputs

The parameters in this group are used to associate various controller functions with specific digital output channels. Most of the functions specified in this group are hard wired at assembly. P16.01

DO: Scale Start

Alternative:

DO n/a



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Parameters

This parameter specifies the digital output used to start the feeder. This parameter is normally set to DO 11 – High and is connected to wires 7 and 8.

P16.02

DO: Feeder Started

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output used to indicate that the feeder is running. This function is not used and this parameter should be set to n/a (Not used).

P16.03

DO: Feeder running (2nd)

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output used to indicate that the feeder is running. This output is a duplicate of P16.02 DO: Feeder Started. This function is not used and this parameter should be set to n/a (not used).

P16.04

DO: Feeder Run Forward

Alternative:

DO n/a


This parameter specifies the digital output used to start the feeder running forward. This output is similar to the K6 relay on the 196 NT. This parameter must be set to DO 7 – High and is connected to wires 177-179.

P16.05

DO: Feeder Run Forward (2nd)

Alternative:

n/a DO

Default: n/a

This parameter specifies the second digital output used to start the feeder running forward. This output is a duplicate of P16.04 DO: Feeder Run Forward. This function is not used and this parameter should be set to n/a (not used).

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Parameters

P16.06

DO: Feeder Run Reverse

Alternative:

DO n/a


This parameter specifies the digital output used to start the feeder in reverse. This output is similar to the K2 relay on the 196 NT. This parameter must be set to DO 2 – High and is connected to wires 156-158.

P16.07

DO: Feeder Run Reverse (2nd)

Alternative:

n/a DO

Default: n/a

This parameter specifies the second digital output used to start the feeder in reverse. This output is a duplicate of P16.06 DO: Feeder Run Reverse . This parameter must be set to DO 3 – High and is connected to wires 159-161.

P16.08

DO: Start Prefeeder

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output used to start the pre-feeder. This function is not used and this parameter should be set to n/a (not used).

P16.09

DO: ALARM

Alternative:

DO n/a


This parameter specifies the digital output used to annunciate an alarm condition (Event type A feeder Stopped). This output is similar to the K1 relay on the 196 NT. This parameter must be set to DO 1 – High and is connected to wires 150-152. Note: Set this parameter to DO 1 – Low to simulate the K1 failsafe function of the 196NT.

P16.10

DO: ALARM (2nd)

Default: n/a


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Parameters

Alternative:

n/a DO

This parameter specifies the digital output used to annunciate an alarm condition (Event type A feeder Stopped). This output is a duplicate of P16.09 DO: ALARM . This function is not used and this parameter should be set to n/a (not used).

P16.11

DO: Deviation

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output used to indicate that a deviation event is active. This function is not used and this parameter should be set to n/a (not used).

P16.12

DO: Actual Flow Rate MIN

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output used to indicate that a low flow rate event is active. This function is not used and this parameter should be set to n/a (not used).

P16.13

DO: Actual Flow Rate MAX

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output used to indicate that a high flow rate event is active. This function is not used and this parameter should be set to n/a (not used).

P16.14

DO: Load MIN

Alternative:

n/a

Default: n/a

DO

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Parameters

This parameter specifies the digital output used to indicate that a low belt load event is active. This function is not used and this parameter should be set to n/a (not used).

P16.15

DO: Load MAX

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output used to indicate that a high belt load event is active. This function is not used and this parameter should be set to n/a (not used).

P16.16

DO: Speed MIN

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output used to indicate that a low belt speed event is active. This function is not used and this parameter should be set to n/a (not used).

P16.17

DO: Speed MAX

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output used to indicate that a high belt speed event is active. This function is not used and this parameter should be set to n/a (not used).

P16.18

DO: Volumetric Mode

Alternative:

DO n/a



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Parameters

This parameter specifies the digital output used to indicate that the feeder is in volumetric mode. This output is similar to the K4 relay on the 196 NT. This parameter must be set to DO 5 – High and is connected to wires 165-167.

P16.19

DO: Volumetric Mode (2nd)

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output used to indicate that the feeder is in volumetric mode. This output is a duplicate of P16.18 DO: Volumetric Mode. This function is not used and this parameter should be set to n/a (not used).

P16.20

DO: Local Mode

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output used to indicate that the feeder is in VMO Mode. This function is not used and this parameter should be set to n/a (not used).

P16.21

DO: WARNING

Alternative:

DO n/a


This parameter specifies the digital output used to annunciate a warning condition (Event type W1 or W 2). This output is similar to the K7 relay on the 196 NT. This parameter must be set to DO 8 – High and is connected to wires 183-185. Note: Set this parameter to DO 8 – Low to simulate the K7 failsafe function of the 196NT.

P16.22

DO: WARNING (2nd)

Alternative:

n/a DO

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Default: n/a


Parameters

This parameter specifies the digital output used to annunciate a warning condition (Event type W1 or W2). This output is a duplicate of P16.21 DO: WARNING . This function is not used and this parameter should be set to n/a (not used).

P16.23

DO: Feeding

Alternative:

DO n/a


This parameter specifies the digital output used to indicate that the belt drive motor is running and there is material on the belt. This output is similar to the K5 relay on the 196 NT. This parameter must be set to DO 6 – High and is connected to wires 171-173.

P16.24

DO: Feeding (2nd)

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output used to indicate that the belt drive motor is running and there is material on the belt. This output is a duplicate of P16.23 DO: Feeding. This function is not used and this parameter should be set to n/a (not used).

P16.25

DO: Remote CTRL

Alternative:

DO n/a


This parameter specifies the digital output used to indicate that the feeder is in remote mode. This output is similar to the Kx relay on the 196 NT. This parameter must be set to DO 4 – High and is connected to wires 162-164.

P16.26

DO: Remote CTRL (2nd)

Alternative:

n/a DO

Default: n/a


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Parameters

This parameter specifies the digital output used to indicate that the feeder is in remote mode. This output is a duplicate of P16.25 DO: Remote CTRL. This function is not used and this parameter should be set to n/a (not used).

10.2.2.17

Parameter Block 17 - Analog calibration

The parameters in this group are used to trim the analog output values. They can be set manually but they are normally set using the Analog Trim Function. P17.01

Min: 1 mA

Analog Input 1 Min

Default: 4 mA

Max: 7 mA

See section Analog Trim Function.

P17.02

Min: 17 mA

Analog Input 1 Max

Default: 20 mA

Max: 23 mA


P17.03

Analog Input 2 Min

Default: 4 mA

Min: 1 mA Max: 7 mA See section Analog Trim Function.

P17.04

Min: 17 mA

Analog Input 2 Max

Default: 20 mA

Max: 23 mA


P17.05

Min: 1 mA

Analog Input 3 Min

Default: 4 mA

Max: 7 mA


P17.06

Min: 17 mA

Analog Input 3 Max

Default: 20 mA

Max: 23 mA

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Parameters


P17.07

Min: 1 mA

Analog Input 4 Min

Default: 4 mA

Max: 7 mA


P17.08

Min: 17 mA

Analog Input 4 Max

Default: 20 mA

Max: 23 mA


P17.09

Min: 1 mA

Analog Input 5 Min

Default: 4 mA

Max: 7 mA


P17.10

Min: 17 mA

Analog Input 5 Max

Default: 20 mA

Max: 23 mA


P17.11

Min: 1 mA

Analog Output 1 Min

Default: 4 mA

Max: 7 mA


P17.12

Min: 17 mA

Analog Output 1 Max

Default: 20 mA

Max: 23 mA


P17.13

Min: 1 mA

Analog Output 2 Min

Default: 4 mA

Max: 7 mA


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Parameters


P17.14

Min: 17 mA

Analog Output 2 Max

Default: 20 mA

Max: 23 mA


P17.15

Min: 1 mA

Analog Output 3 Min

Default: 4 mA

Max: 7 mA


P17.16

Min: 17 mA

Analog Output 3 Max

Default: 20 mA

Max: 23 mA


P17.17

Min: 1 mA

Analog Output 4 Min

Default: 4 mA

Max: 7 mA


P17.18

Min: 17 mA

Analog Output 4 Max

Default: 20 mA

Max: 23 mA


P17.19

Min: 1 mA

Analog Output 5 Min

Default: 4 mA

Max: 7 mA


P17.20

Min: 17 mA

Analog Output 5 Max

Default: 20 mA

Max: 23 mA

BV-H6411GB, 1221 - 152 -


Parameters


P17.21

Min: 1 mA

Analog Output 6 Min

Default: 4 mA

Max: 7 mA


P17.22

Min: 17 mA

Analog Output 6 Max

Default: 20 mA

Max: 23 mA


P17.23

Min: 0 mA


Default: 0 mA

Max: 23 mA

This parameter specifies the value written to the output when adjustment program AO Test is called. This allows for simple test of the analog interface to the plant control. After termination of the adjustment program the output jumps back the normal process value.

P17.24

Min: 0 mA


Default: 0 mA

Max: 23 mA


P17.25

Min: 0 mA


Default: 0 mA

Max: 23 mA


P17.26

Min: 0 mA


Default: 0 mA

Max: 23 mA


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Parameters


P17.27

Min: 0 mA


Default: 0 mA

Max: 23 mA


P17.28

Min: 0 mA


Default: 0 mA

Max: 23 mA


10.2.2.18

Parameter Block 18 - 2-Sensor Slip

The parameters in this group control the DT-9 belt slip sensor system. P18.01

2-Sensor Slip active

Alternative:

NO YES

Default: NO

This parameter is used to enable the DT-9 slip sensor system.

P18.02

Source Sensor 1

Alternative:

Speed DI

Default: Speed

This parameter specifies the type of input used for the first of the two sensors used in slip detection.

P18.03

DI: Sensor 1

Alternative:

n/a DI

BV-H6411GB, 1221 - 154 -

Default: n/a


Parameters

This parameter specifies the digital input used for the first slip sensor. It is only active if P18.02 Source Sensor 1 is set to DI.

P18.04


Min: 0.01 P/inch

Default: 100 P/inch

Max: 1000000 P/inch

This parameter specifies the number of pulses that the first slip sensor generates in one inch (or cm) of belt travel.

P18.05

DI: Sensor 2

Alternative:

n/a DI

Default: n/a

This parameter specifies the digital input used for the second slip sensor.

P18.06


Min: 0.01 P/inch

Default: 100 P/inch

Max: 1000000 P/inch

This parameter specifies the number of pulses that the second slip sensor generates in one inch (cm) of belt travel.

P18.07

Min: 0 % LB

Slip Value 2

Default: 2 % LB

Max: 10 % LB

This parameter specifies the minimum difference between the two sensors (in percent of total belt length, LB) required to generate a belt slip event.

P18.08

Event: Slip 2

Event Group: W M

Default: IG

Number: 05

The parameter specifies the type of event that is generated when belt slippage is detected. Cause of event: - The difference between the belt speed calculated using sensor 1 (P18.02) and sensor 2 (P18.05) has exceeded the limit specified by P18.07 Slip Value 2.


BV-H6411GB, 1221 - 155 -

Parameters

P18.09

DO: Slip 2

Alternative:

n/a DO

Default: n/a

This parameter specifies the digital output that is activated when a belt slippage event is generated.

10.2.2.19

Parameter Block 19 - Maintenance interval

The parameters in this group allow an event to be generated to indicate that periodic maintenance is required. P19.01

Min: 1 h

Maintenance Electric

Default: 3000 h

Max: 10000 h

This parameter specifies the time intervals between maintenance events based on the total amount of time the DT-9 is powered.

P19.02


Event Group: SC

Default: IG

Number: 04

The parameter specifies the type of event that is generated when the time interval specified in P19.01 Maintenance Electric has expired. This parameter is normally set to IG to disable the maintenance event.

P19.03

Min: 1 h

Maintenance Feeder Run

Default: 3000 h

Max: 10000 h

This parameter specifies the time intervals between maintenance events based on the total amount of time the belt drive motor is energized.

P19.04


Event Group: SC

BV-H6411GB, 1221 - 156 -

Default: IG

Number: 03


Parameters

The parameter specifies the type of event that is generated when the time interval specified in P19.03 Maintenance Feeder Run has expired. The parameter is normally set to IG to disable the maintenance event. Cause of event: - Total of scale run times exceeds "Scale ON-Time". After every time interval elapsed, a message is output. This message simply informs you that service work is required.

10.2.2.20

Parameter Block 20 - Data Logging

The parameters in this group configure the recording of process data. The recorded data are available at the operating panel and can be easily accessed via Ethernet on the controller homepage. P20.01

Min: 0 min

Hourly Total Time

Default: 0 min

Max: 59 min

This parameter specifies the time that the hourly total is saved to the total data logging system. It is the same as Setup 37 (Hourly total time) on the 196NT. This parameter is set according to customer preference.

P20.02

Min: 0 min

Daily Total Time

Default: 0 min

Max: 1439 min

This parameter specifies the time that the daily total is saved to the total data logging system. It is the same as Setup 38 (Daily total time) on the 196NT. This parameter is set according to customer preference.

P20.03

Min: 1 min

Logger cycle time

Default: 1 min

Max: 1439 min

Logging cycle time for the Data Log Values selected by P20.04 ... P20.13.

P20.04

Data Log Value 1

Default: 752


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Parameters

Select the process value for recording. You can find the identification number of a value in the 'data communication' manual. Also refer to: P20.03 Logger cycle time These manuals: DISOCONT Tersus: BV-H2448 INTECONT Tersus: BV-H2474 DISOCONT Tersus Software VCF2017x: BV-H2468

P20.05

Data Log Value 2

Default: 755

Similar to P20.04 Data Log Value 1

P20.06

Data Log Value 3

Default: 1872


P20.07

Data Log Value 4

Default: 1874


P20.08

Data Log Value 5

Default: 1876


P20.09

Data Log Value 6

Default: 2316


P20.10

Data Log Value 7

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Default: 1880


Parameters


P20.11

Data Log Value 8

Default: 1894


P20.12

Data Log Value 9

Default: 2230


P20.13

Data Log Value 10

Default: 2232


10.2.2.21

Parameter Block 21 - Communication EasyServe

The parameters in this group control serial communication between EasyServe and the DT-9. Note: EasyServe is normally connected using Ethernet and these param eters are not used. P21.01

Min: 1

Own Address

Default: 1

Max: 1

This parameter specifies the serial loop address of the DT-9. This address and baud rates (see below) much match the address specified in EasyServe. Note: The station address is designed for systems with Service bus. If Service bus is not

used, select address 1.

P21.02

Baud Rate

Alternative:

38400

Default: 38400

This parameter specifies the baud rate used for serial communication with EasyServe.

P21.03

Format Data

Default: 8-N-1


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Parameters

Alternative:

8-N-1

This parameter specifies the communications protocol used for serial communication between EasyServe and the DT-9.

10.2.2.22

Parameter Block 22 - Communication Fieldbus

The parameters in this group are used to control the various types of fieldbus communications that are supported by the DT-9. Contact us for a detailed description of Fieldbus communications. Note: Fieldbus communications are disabled and hidden by default. P22.01

Protocol Type

Alternative:

NO Modbus-RTU PROFIBUS DP DeviceNet Modbus-TCP PROFINET IO Ethernet/IP

Default: NO

Type of communication protocol. Some types of fieldbus need their respective fieldbus card. Further details on card installation can be found in the system manual BV-H2406. The manual 'DISOCONT Tersus Data Communication' (BV-H2468) contains further information on the data structures. NO: MODBUS/TCP can be used to read but write-accesses will not be processed. MODBUS: Modbus RTU protocol; RS232-, RS422- or RS485 interface; fieldbus interface card VSS 28020 must be installed.

P22.02

Min: 1 s

Timeout Host

Default: 5 s

Max: 600 s

Monitors the interface A telegram from the host system will be expected within the time set if the tim eout value in P22.02 is greater than zero.

P22.03


Event Group: SY

BV-H6411GB, 1221 - 160 -

Default: A

Number: 08


Parameters

Cyclical serial communication with the higher-order plant control system has been interrupted for longer than the timeout-period in P22.02. To rectify: check cable connections.

P22.04

Modbus-Version

Alternative:

compatible Stock STANDARD

P22.05

Word Sequence

Alternative:

I:std/L:std I:swp/L:std I:std/L:swp I:swp/L:swp

Default: compatible Stock

Default: I:std/L:std

The parameter determines the word sequence within a double word. I L

→

→

std swp

denotes IEEE 754 values (floating -point values) denotes LONG values (4 byte integer values)

→

will not swap the word order will swap the word order

→

P22.06

Byte Sequence

Alternative:

High - Low Low - High

Default: High - Low

Determines the byte sequence in a data word.

P22.07

Configuration

Default: FIXED_8_16


BV-H6411GB, 1221 - 161 -

Parameters

Alternative:

NO_PARA_ID_3_6 NO_PARA_ID_4_12 PARA_ID_6_15 FIXED_8_16 FIXED_8_8 FIXED_4_4 VARIABLE COMPATIBLE FIXED COMPATIBLE

The configuration of the content of the data of the fieldbus telegrams. You can find a detailed description in the manuals for data communication: DISOCONT Tersus: BV-H2448 INTECONT Tersus: BV-H2474 DISOCONT Tersus Software VCF2017x: BV-H2468 The contents of the data have to be set on the scale and opposite point in a way that is compatible to one another!

P22.08

Min: 1

Address

Default: 1

Max: 254

Address of the device as a slave at the modbus. Each address may be used at a bus once only.

P22.09

Min: 1

Resolution

Default: 4096

Max: 32767

The maximum resolution in analog format or integer format of the measured value transferred. The resolution is related to the nominal value of the respective process value.

P22.10

Baud rate

Alternative:

9600 4800 2400 19200 38400

Default: 19200

Data transfer rate at Modbus-RTU.

BV-H6411GB, 1221 - 162 -


Parameters

P22.11

Data Format

Alternative:

8-O-1 8-E-1 8-N-1

Default: 8-O-1

Modbus-RTU always uses an 11-bit character frame. Example: 8-O-1 means:

1 start bit, 8 data bit, odd parity, 1 stop bit N = No parity O = Odd parity E = Even parity

P22.12

Physics

Alternative:

RS485-2-wire RS485-4-wire RS232

Default: RS232

Selects the electrical interface type (Modbus RTU)

P22.13

Min: 0

Address

Default: 16

Max: 126

Address of the slave at the PROFIBUS

P22.14

FLOAT-Format

Alternative:

IEEE SIEMENS-KG

Default: IEEE

Information on the formats for all setpoints, measuring values and floating point parameters.

P22.15

Min: 0

Address

Default: 63

Max: 63

The address of the weighing electronics on DeviceNet

P22.16

Baud rate

Default: 125K


BV-H6411GB, 1221 - 163 -

Parameters

Alternative:

125K 250K 500K

Data transfer rate of the DeviceNet.

P22.17

Parameter

Alternative:

NO YES

Default: NO

Select whether the user data package has a parameter block or not.

P22.18

Min: 2

Preset Count

Default: 2

Max: 4

The number of specified values that can be specified in a telegram by the higher-order plant control system.

P22.19

Min: 0

READ_ID Count

Default: 6

Max: 12

The number of freely selectable measuring and status values (scales queried in a telegram.

P22.20

Access Rights Limitation FB

Alternative:

NO FIRST WRITE REMOTE IP

BV-H6411GB, 1221 - 164 -

→

master) that are

Default: NO


Parameters

Determines for network protocol Modbus-TCP which master system may intervene as a controller: NO: No restrictions FIRST WRITE: The subscriber that transmits the first write access gets the control rights. The other subscribers may read only.

REMOTE IP: Control commands from the subscriber with the IP address given in P22.21 Remote IP Address FB only will be carried out.

P22.21

Remote IP Address FB

Default: 192.168.240.250

IP address of the subscriber with control rights for Modbus-TCP. Also refer to: P22.20 Access Rights Limitation FB

P22.22

Event: Acyclic Communicat ion

Event Group: SY

Default: W2

Number: 10

Incorrect data in the noncyclical communication from the host computer. Possible cause: poor programming of the host computer

P22.23

Configuration

Alternative:

PARA_ID_6_15 FIXED_8_16

Default: PARA_ID_6_15

Selection of the data structure used in fieldbus interface PROFINET. See also: Communication manual of DISOCONT TERSUS

10.2.2.23

Parameter Block 23 - Ethernet

The parameters in this group control the DT-9 Ethernet ports. P23.01

IP Address

Default: 192.168.240.1


BV-H6411GB, 1221 - 165 -

Parameters

This parameter specifies the DT-9 IP address. This parameter should be set to the default value of 192.168.240.1 for normal communication with EasyServe and the (optional) touch screen display.

P23.02

Default: 255.255.255.0

Net Mask

This parameter specifies the DT-9 subnet mask.

P23.03

Default: 0.0.0.0

Gateway

This parameter specifies the network gate way used to connect the DT-9.

10.2.2.24

Parameter Block 24 - PLC Outputs

This parameter group is used to specify analog and digital output channels that are under Fieldbus control. Contact us for a detailed description of Fieldbus communications. Note: Fieldbus communications are disabled and hidden by default. P24.01

DO: PLC 1

Alternative:

n/a DO

Default: n/a

Definition of the binary output channel controlled by PCS command 1.

P24.02

DO: PLC 2

Alternative:

n/a DO

Default: n/a

Corresponds to P24.01 DO: PLC 1

P24.03

DO: PLC 3

Alternative:

n/a DO

BV-H6411GB, 1221 - 166 -

Default: n/a


Parameters


P24.04

DO: PLC 4

Alternative:

n/a DO

Default: n/a


P24.05

DO: PLC 5

Alternative:

n/a DO

Default: n/a


P24.06

DO: PLC 6

Alternative:

n/a DO

Default: n/a


P24.07

DO: PLC 7

Alternative:

n/a DO

Default: n/a


P24.08

DO: PLC 8

Alternative:

n/a DO

Default: n/a


P24.09

AO: PLC 1

Alternative:

n/a AO

Default: n/a


BV-H6411GB, 1221 - 167 -

Parameters

Definition of the analog output channel controlled by PCS analog command word 1.

P24.10

AO: PLC 2

Alternative:

n/a AO

Default: n/a

Corresponds to P24.09 AO: PLC 1

10.2.2.25

Parameter Block 25 - Fixed mode configuration

This parameter group is used to specify fixed data points that are used with Fieldbus communication. Contact us for a detailed description of Fieldbus communications. Note: Fieldbus communications are disabled and hidden by default. P25.01

ID Preset Value 1

Default: 320

Selecting the first control command with ID 320 (decimal) in the Fieldbus telegram. It cannot be changed in this parameter. The following values in the telegram can be configured as per the ID list in the 'data communication' manual: DISOCONT Tersus: BV-H2448 INTECONT Tersus: BV-H2474 DISOCONT Tersus Software VCF2017x: BV-H2468

P25.02

ID Preset Value 2

Default: 352

Corresponds to P25.01 ID Preset Value 1

P25.03

ID Preset Value 3

Default: 384


P25.04

ID Preset Value 4

BV-H6411GB, 1221 - 168 -

Default: 592


Parameters


P25.05

ID Preset Value 5

Default: 0


P25.06

ID Preset Value 6

Default: 0


P25.07

ID Preset Value 7

Default: 0


P25.08

ID Preset Value 8

Default: 0


P25.09

ID Read Value 1

Default: 752

Selecting the first value to be read from weighing electronics in the fieldbus telegram. The number of the value (ID) can be found in the Data Communication manual: DISOCONT Tersus: BV-H2448 INTECONT Tersus: BV-H2474 DISOCONT Tersus Software VCF2017x: BV-H2468

P25.10

ID Read Value 2

Default: 816


BV-H6411GB, 1221 - 169 -

Parameters

As P25.09 ID Read Value 1

P25.11

ID Read Value 3

Default: 1552


P25.12

ID Read Value 4

Default: 1872


P25.13

ID Read Value 5

Default: 1894


P25.14

ID Read Value 6

Default: 2230


P25.15

ID Read Value 7

Default: 2232


P25.16

ID Read Value 8

Default: 2234


P25.17

ID Read Value 9

BV-H6411GB, 1221 - 170 -

Default: 0


Parameters


P25.18

ID Read Value 10

Default: 0


P25.19

ID Read Value 11

Default: 0


P25.20

ID Read Value 12

Default: 0


P25.21

ID Read Value 13

Default: 0


P25.22

ID Read Value 14

Default: 0


P25.23

ID Read Value 15

Default: 0


P25.24

ID Read Value 16

Default: 0


BV-H6411GB, 1221 - 171 -

Parameters


10.2.2.26

Parameter Block 26 - FCB analog outputs

This parameter group is used to associate Function Block analog outputs with physical I/O points. Contact us for a detailed description of Function Control Blocks.

Note: Function Control Block parameters are disabled and hidden by default. P26.01

FCB_AO 01

Alternative:

n/a AO

Default: n/a

Assigning the physical output signal for analog output 1 of the PLC.

P26.02

Offset FCB_AO 1

Min: -200 mA

Max: 200 mA

Default: 4 mA

Output current for a PLC signal of 0.

P26.03

Range FCB_AO 1

Default: 20 mA

Min: 0 mA Max: 1000 mA Output current for a PLC signal of 100% Reference value: P26.04 Reference FCB_AO 1 See also: P26.01 FCB_AO 01

P26.04

Min: 1

Reference FCB_AO 1

Default: 1000

Max: 1000000

Maximum value of the signal at the PLC analog output. Also refer to: P26.01 FCB_AO 01, P26.03 Range FCB_AO 1

P26.05

FCB_AO 02

Alternative:

n/a AO

BV-H6411GB, 1221 - 172 -

Default: n/a


Parameters

Corresponds to P26.01 FCB_AO 01

P26.06

Offset FCB_AO 2

Min: -200 mA

Max: 200 mA

Default: 4 mA

Description see: P26.01 FCB_AO 01 P26.02 Offset FCB_AO 1 P26.03 Range FCB_AO 1 P26.04 Reference FCB_AO 1

P26.07

Range FCB_AO 2

Min: 0 mA

Default: 20 mA

Max: 1000 mA


P26.08

Min: 1

Reference FCB_AO 2

Default: 1000

Max: 1000000


P26.09

FCB_AO 03

Alternative:

n/a AO

Default: n/a


P26.10

Offset FCB_AO 3

Min: -200 mA

Max: 200 mA

Default: 4 mA


BV-H6411GB, 1221 - 173 -

Parameters


P26.11

Range FCB_AO 3

Min: 0 mA

Default: 20 mA

Max: 1000 mA


P26.12

Min: 1

Reference FCB_AO 3

Default: 10000

Max: 1000000


P26.13

FCB_AO 04

Alternative:

n/a AO

Default: n/a


P26.14

Offset FCB_AO 4

Min: -200 mA

Max: 200 mA

Default: 4 mA


BV-H6411GB, 1221 - 174 -


Parameters

P26.15

Range FCB_AO 4

Min: 0 mA

Default: 20 mA

Max: 1000 mA


P26.16

Min: 1

Reference FCB_AO 4

Default: 1000

Max: 1000000


P26.17

FCB_AO 05

Alternative:

n/a AO

Default: n/a


P26.18

Offset FCB_AO 5

Min: -200 mA

Max: 200 mA

Default: 4 mA


P26.19

Min: 0 mA

Range FCB_AO 5

Default: 20 mA

Max: 1000 mA


BV-H6411GB, 1221 - 175 -

Parameters


P26.20

Min: 1

Reference FCB_AO 5

Default: 1000

Max: 1000000


P26.21

Default: Empty

FCB Variant

Name of the required function block link. This name is automatically transferred to the parameter when a new link is loaded. When the system is started after turning on the voltage, it checks to see whether the name of the function block link loaded is the same as the name entered in the parameter. Event P26.22 Event: FCB-Error is identified if the names are different. This check serves as a control if a replacement part is used. Also refer to: P26.22 Event: FCB-Error

P26.22

Event: FCB-Error

Default: A

Event Group: IL Number: 10

BV-H6411GB, 1221 - 176 -


Parameters

This event is identified if the function block link loaded does not correspond to the link stored in the parameter. Caution: It probably does not have the full functionality. Unreliable operating states may arise.

Possible causes: - it forgot to load the correct link after exchanging the VCU. - the name in the parameter was changed manually. Steps to be taken: Load the function block link to the correct name given in P26.21 FCB Variant. No further links can be loaded as long as this event is identified. If in this error state a link with a different name should be loaded, the new name must first be entered into P26.21.

10.2.2.27

Parameter Block 27 - FCB digital outputs

This parameter group is used to associate Function Block digital outputs with physical I/O points. Contact us for a detailed description of Function Control Blocks. Note: Function Control Block parameters are disabled and hidden by default. P27.01

FCB_DO 01

Alternative:

n/a DO

Default: n/a

Allocation of the physical output channel to the binary output signal of the internal PLC.

P27.02

FCB_DO 02

Alternative:

n/a DO

Default: n/a


P27.03

FCB_DO 03

Alternative:

n/a DO

Default: n/a



BV-H6411GB, 1221 - 177 -

Parameters

P27.04

FCB_DO 04

Alternative:

n/a DO

Default: n/a


P27.05

FCB_DO 05

Alternative:

n/a DO

Default: n/a


P27.06

FCB_DO 06

Alternative:

n/a DO

Default: n/a


P27.07

FCB_DO 07

Alternative:

n/a DO

Default: n/a


P27.08

FCB_DO 08

Alternative:

n/a DO

Default: n/a


P27.09

FCB_DO 09

Alternative:

n/a DO

Default: n/a


P27.10

FCB_DO 10

BV-H6411GB, 1221 - 178 -

Default: n/a


Parameters

Alternative:

n/a DO


P27.11

FCB_DO 11

Alternative:

n/a

Default: n/a

DO Allocation of the physical output channel to the binary output signal of the internal PLC.

P27.12

FCB_DO 12

Alternative:

n/a DO

Default: n/a


P27.13

FCB_DO 13

Alternative:

n/a DO

Default: n/a


P27.14

FCB_DO 14

Alternative:

n/a DO

Default: n/a


P27.15

FCB_DO 15

Alternative:

n/a DO

Default: n/a


P27.16

FCB_DO 16

Alternative:

n/a DO

Default: n/a


BV-H6411GB, 1221 - 179 -

Parameters


P27.17

FCB_DO 17

Alternative:

n/a DO

Default: n/a


P27.18

FCB_DO 18

Alternative:

n/a DO

Default: n/a


P27.19

FCB_DO 19

Alternative:

n/a DO

Default: n/a


P27.20

FCB_DO 20

Alternative:

n/a DO

Default: n/a


10.2.2.28

Parameter Block 28 - Configuration HMI Values

The parameters in this group define the process variables to be displayed on the 'Values' page of the operating panel (HMI, OP) for a DISOCONT Tersus. On an INTECONT Tersus these values can be called up with the '9' key. EasyServe can be used for easy configuration or the settings can be m ade with the help of the allocation map in the data description of the serial interface in the operating panel.

You can find the characteristic values (ID) belonging to the process variables in the manual on data communication: DISOCONT Tersus: BV-H2448

BV-H6411GB, 1221 - 180 -


Parameters

INTECONT Tersus: BV-H2474 DISOCONT Tersus Software VCF2017x: BV-H2468 P28.01

HMI Value 01

Default: 1884

Identification number (ID) of the desired process variable.

P28.02

HMI Value 02

Default: 1880


P28.03

HMI Value 03

Default: 2276


P28.04

HMI Value 04

Default: 2292


P28.05

HMI Value 05

Default: 2236


P28.06

HMI Value 06

Default: 2234


P28.07

HMI Value 07

Default: 2224



BV-H6411GB, 1221 - 181 -

Parameters

P28.08

Default: 2226

HMI Value 08


P28.09

Default: 1904

HMI Value 09


P28.10

Default: 1960

HMI Value 10


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Event (Error) Messages

11 Event (Error) Messages Event messages report abnormal states, e.g. errors or limit value excess.

STRICTLY OBSERVE Always correct the cause of a fault before acknowledging it.

The feeder has the potential to cause injuries or damage if this is not done.

There are four different event classes: Event Class

Code

Display / Effect

Alarm

A

All measuring and control operations are aborted. System goes to safe state. This type of event is the same as a feeder trip on the 196NT.

Warning 1

W1

The event is annunciated and remains active until it has been acknowledged. Measuring and control tasks are not affected. This type of event is similar to some type of alarms on the 196NT.

Warning 2

W2

The event is annunciated and remains active until the cause has been corrected. It is not necessary to acknowledge this type of event. Measuring and control tasks are not affected. This type of event is similar to some type of alarms on the 196NT.

Ignore

IG

Event is not annunciated. Measuring and control tasks are not affected.

Events are classified in the following groups with the priority shown: Event Group

Symbol

System message

SY

Sequence monitoring

SC

Electrical system

WE

Mechanical system

WM

Material flow

MF

Interlocking

IL

Controllers

CO

Calibration

CA

Maximum

HI

Minimum

LO


BV-H6411GB, 1221 - 183 -


Note: In the following list, parameters related to the indicated event are shown in parentheses.

11.1

Events Details

11.1.1 Event Group: Calibration CA01


(P06.04)

The parameter selects the error condition generated when the load cell signal is invalid. If P05.01 Volum on LC failure is set to YES, this condition will force the feeder into volumetric mode, regardless of the value selected here. The parameter should be set to IG (Ignore). Cause of event: - Load cell cable wrong. - Measuring amplifier A/D converter is in saturated state. - Supply voltage is below 19V. - Error must be available for minimum 3s. Action: - Check cabling. - If cabling is OK, load cell amplifier could be defective. - Check for either possibility. If scale cannot be restarted after remedy of fault, turn device off and restart.

CA02

Event: Tachometer Input

(P06.03)

The parameter selects the error condition generated when the tachometer signal is lost or is greater than 3600 Hz. The parameter should be set to A (Stop Feeder). Cause of event: - Input frequency is zero or exceeds 3600 Hz. Action: - Insure that the motor is turning. - Insure that parameter P04.06 Speed Measurement is set to the correct input. - Check the tachometer wiring. - Check the tachometer signal using a frequency counter or oscilloscope.

CA09


BV-H6411GB, 1221 - 184 -

(P06.17)



Event is detected in case the primary tachometer doesn't deliver pulses during normal operation.

11.1.2 Event Group: Controller CO01


(P06.13)

The parameter selects the error condition generated when the motor speed control demand signal reaches its upper limit. The parameter should be set to IG (Ignore). Cause of event: - Feed rate controller control magnitude has reached upper response threshold. After some time, message HI-5 (Deviation) is additionally output. 1. Material flow missing or irregular. 2. External feed rate controller wrongly set.

Action: - Check material discharge and control magnitude (service value Y). At nominal feed rate, Y should be 10 to 14mA.

CO05


(P05.02)

The parameter is used to specify the type of error that is generated in the event of a weighing system failure. This event is independent of volumetric mode. This parameter should be set to IG (Ignore). Cause of event: - Indicates that the system is in volumetric mode due to failure in the weighing system. Action to be taken: - Check for load cell wiring errors or imbalanced load cell inputs.

11.1.3 Event Group: Electrical System WE01


(P06.08)


BV-H6411GB, 1221 - 185 -


The parameter selects the error condition generated when the controller restarts after a loss of power. If it is set to A, the feeder will not restart after power is lost during normal remote m ode operation. This parameter should be set to IG (Ignore). Cause of event: - Power failure. Power supply failed or cut off. During power failure, no totalization takes place. Scale does not start automatically, independent of event class.

WE08


(P06.15)

The parameter selects the error condition generated when the analog feedrate demand signal is more then 0.4 mA below the minimum value (P03.04 Setpoint Offset). The parameter should be set to IG (Ignore). Cause of event: - The signal available across an analog input is smaller than the offset. A tolerance space of 0.4 mA is built in for ensuring that events are not constantly set and deleted with noisy input signals around the offset. Action: - Check analog input (Sig+ & Sig-) wiring.

WE15


(P15.05)

WE16


(P15.06)

11.1.4 Event Group: Interlock IL01

Event: Run Disabled

BV-H6411GB, 1221 - 186 -

(P03.11)



The parameter selects the m ethod used to annunciate the error condition when the Run Enable input is not active. Setting the parameter to IG does not disable the Run Enable feature but it does prevent an error from being generated. The parameter is normally set to W2 so that there is an indication on the display when the feeder is disabled. Cause of event: - When a touch screen HMI is used, parameter P03.10 Source Run Enable must be set to DI 8, which is connected to the stop switch mounted under the HMI. This switch is used to stop the feeder in the event that the HMI is disabled or disconnected. Action: - Check the position of the Run Enable switch. - Check the wiring to the Run Enable switch. Note: The Run Enable switch is not normally used with the Stock 196NT displa y and in this case P03.10 Source Run Enable must be set to n/a to allow motor operation.

IL10

Event: FCB-Error

(P26.22)

This event is identified if the function block link loaded does not correspond to the link stored in the parameter. Caution: It probably does not have the full functionality. Unreliable operating states may arise.

Possible causes: - it forgot to load the correct link after exchanging the VCU. - the name in the parameter was changed manually. Steps to be taken: Load the function block link to the correct name given in P26.21 FCB Variant. No further links can be loaded as long as this event is identified. If in this error state a link with a different name should be loaded, the new name must first be entered into P26.21.

11.1.5 Event Group: Material Flow MF05

Event: Moisture MAX

(P12.10)


BV-H6411GB, 1221 - 187 -


Cause of event: - The value of the moisture input signal is greater than the maximum signal set by P12.08 Moisture MAX.

MF13


(P09.14)

The event will be detected in case the actual temperature is above the threshold (P09.13 Temperature MAX). The controller might fail to function. Countermeasures: - Check temperatur of environment - Install cooler close to the controller

MF14

Event: Remote TCI too small

(P02.15)

The parameter selects the error condition generated when totalizer pulses for the Total Coal Integrator (TCI) output are generated faster then the TCI output can operate. See parameter P02.14 Pulse Length Total for more information. This parameter shou ld be s et to W 2. Action: Set P02.13 Totalizer Increment and/or P02.14 Pulse Length Total to a smaller value.

11.1.6 Event Group: MAX HI01

Event: LC Input > MAX

BV-H6411GB, 1221 - 188 -

(P06.06)



The parameter selects the error condition generated when either of the load cell signals is greater than the maximum allowable value. If P05.01 Volum on LC failure is set to YES, this condition will force the feeder into volumetric mode regardless of the value selected here. This parameter should be set to IG (Ignore). Cause of event: - Load cell load is higher than 110% of load cells rated capacities. Full scale value: 125% with 2.85mV/V load cells 175% with 2mV/V load cells Action: - Check material infeed.

HI02


(P09.04)

The parameter determines the type of event that is generated when the feedrate exceeds the value specified in P09.03 Limit: Actual Flow Rate MAX . This parameter is normally set to IG (Ignore) Cause of event: - Flow rate exceeds set maximum value.

HI03

Event: Load MAX

(P09.08)

The parameter determines the type of event that is generated when the feedrate exceeds the value specified in P09.07 Limit: Load MAX. The parameter is normally set to IG (Ignore) Cause of event: - Belt load exceeds set maximum value.

HI04

Event: Speed M AX

(P09.12)


BV-H6411GB, 1221 - 189 -


The parameter determines the type of event that is generated when the feedrate exceeds the value specified in P09.01 Limit: Actual Flow Rate MIN . The parameter is normally set to IG (Ignore) Cause of event: - Belt speed exceeds set maximum value.

HI05

Event: Deviation

(P06.12)

The parameter specifies the event that is generated when the actual feedrate can differ from the feedrate setpoint by an amount greater than P06.10 Threshold Deviation for a time greater than P06.09 Time Deviation. The parameter is similar to the 196NT Feedrate Error and should be set to W2. Action: - Check for loss or material on belt.

11.1.7 Event Group: Mechanic WM02

Event: Slip

(P07.08)

The parameter selects the error condition generated when the belt slip exceeds the limit specified in parameter P07.07 Slip Value. The parameter is normally set to IG.

WM03

Event: Belt Skew

(P07.16)

Belt has run off-center. Feeder is no longer operable. Action: See Event: Belt Drift Related threshold: Belt Skew

WM04

Event: Belt Drift

BV-H6411GB, 1221 - 190 -

(P07.14)



The belt has exceeded the tolerance levels set. Steps: 1. Remove any soiling to the tail and drive pulleys 2. Align the belt Monitoring may also be subject to error. Therefore: keep an eye on the service value for the belt motion sensor and correct any errors that may arise. Related threshold value: Belt Drift

WM05

Event: Slip 2

(P18.08)

The parameter specifies the type of event that is generated when belt slippage is detected. Cause of event: - The difference between the belt speed calculated using sensor 1 (P18.02) and sensor 2 (P18.05) has exceeded the limit specified by P18.07 Slip Value 2.

WM06


(P13.06)

The parameter selects the error condition generated when the Chain Motion Monitor (CMM) pulse delay is exceeded. The parameter is normally set to A (Stop Feeder) if a CMM is installed and IG (Ignore) if not. Cause of event: - The Chain Motion Monitor (CMM) pulse delay (P13.05) has been exceeded.

WM07


(P15.11)


BV-H6411GB, 1221 - 191 -


The parameter specifies the event that is generated when a discharge pluggage is detected. The parameter is normally set to A (Stop feeder). It can be set to IG (Ignore) to disable the discharge pluggage event. Cause of event: - The discharge pluggage switch (LSFD) detected a build up of coal at the f eeder discharge. This is a fail safe input. The event is generated when the LSFD signal is lost. Action: - Insure that discharge is clear. - Check LSFD wiring.

WM08


(P15.14)

The parameter specifies the event that is generated when a loss of material is detected (coal on belt switch is inactive). The parameter is normally set to A (Stop feeder). It can be set to IG (Ignore) to disable the Loss of material event. Cause of event: - The coal on belt switch (LSFB) has indicated a loss of material on the belt while running in Remote.

WM09

Event: Motor Start

(P15.18)

The parameter specifies the type of event that is generated when the motor feedback signal (P15.17) does not follow the motor start signal (P16.04 through P16.07). The parameter should always be set to A (Stop Feeder) Cause of event: - The motor starter of VFD has failed to start the feeder when instructed to by the controller.

WM10


BV-H6411GB, 1221 - 192 -

(P07.03)



The parameter selects the error condition generated when the belt motion monitor (BMM) pulse delay is exceeded. The parameter is normally set to A (Stop Feeder) if a BMM is installed. Setting it to IG (Ignore) will disable the BMM feature. Cause of event: - The Belt Motion Monitor (BMM) pulse delay (P07.02) has been exceeded.

WM11

Event: Coal Flow

(P15.21)

The parameter specifies the type of event that is generated when a loss of material flow is detected. The parameter should be set to A (Stop Feeder) when a coal flow monitor is installed and IG (ignore) when one is not. Cause of event: - The (optional) coal flow monitor has indicated a loss of material in the downspout above the feeder.

WM12

Event: Coal on Belt

(P15.15)

The parameter specifies the event that is generated when the feeder attempts to run in Local mode with material on the belt (coal on belt switch is active). The parameter should always be set to A (Stop feeder). Cause of event: - Coal was detected by the coal on belt switch (LSFB) when the feeder was running in local or calibrate mode.

11.1.8 Event Group: MIN LO01


(P06.05)


BV-H6411GB, 1221 - 193 -


The parameter selects the error condition generated when either of the load cell signals is less than 3% of the full scale value. If P05.01 Volum on LC failure is set to YES, this condition will force the feeder into volumetric mode regardless of the value selected here. The parameter should be set to IG (Ignore).

LO02


(P09.02)

The parameter determines the type of event that is generated when the feedrate is less than the value specified in P09.01 Limit: Actual Flow Rate MIN . The parameter is normally set to IG (Ignore)

LO03

Event: Load MIN

(P09.06)

The parameter determines the type of event that is generated when the feedrate is less than the value specified in P09.05 Limit: Load MIN. Set this value to W2 to simulate the 196NT low density alarm. The parameter is normally set to IG (Ignore) Cause of event: - Belt load smaller than set minimum value.

LO04

Event: Speed MIN

(P09.10)

The parameter determines the type of event that is generated when the feedrate is less than the value specified in P09.09 Limit: Speed MIN. The parameter is normally set to IG (Ignore) Cause of event: - Belt speed is smaller than set minimum value.

11.1.9 Event Group: Sequence Monitoring SC01


BV-H6411GB, 1221 - 194 -

(P06.07)



The parameter selects the error condition generated when the feedrate demand signal is greater than the feedrate limit as determined by the operating mode. In gravimetric mode, the limit is the lesser of P02.05 Nominal Flow Rate or P03.05 Maximum Feedrate . In volumetric mode, the limit is 3 times P02.05 Nominal Flow Rate. The parameter should be set to IG (Ignore). Depending on selected mode: a) In gravimetric mode, setpoint is limited to nominal feed rate. b) In volumetric mode, limitation starts from values exceeding 3 times the nominal value. c) Emergency setpoint is active.

SC02

Event: Stand-By

(P06.01)

The parameter selects the error condition generated when the belt drive motor is stopped because the motor demand signal is less than the limit specified in P06.02 Stand-By Limit Value. The parameter should be set to IG (Ignore). Cause of event: - Scale is in standby mode, i.e. setpoint is smaller than set standby limit (Parameter P06.02 Stand-By Limit Value ). Material pre-feeder cuts off.

SC03


(P19.04)

The parameter specifies the type of event that is generated when the time interval specified in P19.03 Maintenance Feeder Run has expired. The parameter is normally set to IG to disable the maintenance event. Cause of event: - Total of scale run times exceeds "Scale ON-Time". After every time interval elapsed, a message is output. This m essage simply informs you that service work is required.

SC04


(P19.02)


BV-H6411GB, 1221 - 195 -


The parameter specifies the type of event that is generated when the time interval specified in P19.01 Maintenance Electric has expired. This parameter is normally set to IG to disable the maintenance event.

SC05


(P15.03)


SC06


(P15.28)


SC11


(P15.30)


SC12


BV-H6411GB, 1221 - 196 -

(P15.32)




11.1.10 Event Group: System Message SY01

Event: Memory

(P06.14)

The parameter selects the error condition generated when the controller detects an error in the internal non-volatile memory. Reload the non-volatile memory by using the "Load Default Parameters" function to correct this error. If the problem persists, the controller must be replaced. The parameter should be set to A (Stop feeder). Note: The Load Default Parameters function will reset all of the controller's internal parameters, including Calibration and Trim. After this operation is performed, all parameters must be reset, the feeder must be recalibrated and the analog I/O channels must be re-trimmed.

SY07

Event: Communication VHM serial

(P01.01)

The parameter selects the error condition generated when communications between the DT-9 and the touch screen HMI are lost for more then 10 seconds. The touch screen HMI must be connected to the X96 Ethernet port. This connector is located toward the center of the board, is marked in red and is keyed for a special cable. The parameter should be set to W2 (Warning with automatic reset). Actions: - Check operation of touch screen display (see display section). - Check cable connections. - Is correct Ethernet connection used?

SY08


(P22.03)


BV-H6411GB, 1221 - 197 -


Cyclical serial communication with the higher-order plant control system has been interrupted for longer than the timeout-period in P22.02. To rectify: check cable connections.

SY10

Event: Acyclic Communication

(P22.22)

Incorrect data in the noncyclical communication from the host computer. Possible cause: poor programming of the host computer

SY12


(P01.02)

The parameter selects the error condition generated when communications between the ARM9 main processor and the ARM7 auxiliary processor are lost. The parameter must always be set to A (Stop feeder) because the controller can not operate when communications are lost. Action: - Check cable connections between boards. - Replace controller.

BV-H6411GB, 1221 - 198 -


Default I/O Points

12 Default I/O Points 12.1

Default Digital Inputs

Note: The default parameter must be set to n/a if the digital input is reallocated.

Input Terminal Number Block

Wire Default Number Parameter

Comments:

DI 1

X1-6

118

P15.23 DI: Remote CTRL

Not normally used. P03.12 must be set to Keyboard Only or Keyboard & Local if this point is reallocated.

DI 2

X1-4

112

P03.01 Feeder Start

Start contact from customer DCS

DI 3

X1-2

113

P03.07 DI: Raise Setpoint

Not Normally used. Must be enabled when P03.02 Feedrate Setpoint is set to R-L.

DI 4

X2-6

110

P15.17 DI: Motor feedback

Running contact from motor speed control

DI 5

X2-4

109

P15.09 DI: Discharge Pluggage Limit Switch Feeder Discharge (LSFD)

DI 6

X2-2

117

P15.22 DI: Configuration Lock

Keyboard lock

DI 7

X3-6

108

P15.12 DI: Coal on belt switch

Limit Switch Feeder Belt (LSFB)

DI 8

X3-4

111

P03.10 Source Run Enable

Must be enabled when (optional) touch screen HMI is used.

DI 9

X3-2

119

P15.25 DI: Local Start

Not normally used. P03.12 must be set to Keyboard Only if this point is reallocated.

DI 10

X4-7

116

P15.19 DI: Coal Flow Monitor

Set P15.21 Event: Coal Flow to A, W1 or W2 to enable the coal flow monitor or IG to disable it.

DI 11

X4-5

114

P03.08 DI: Lower Setpoint

Not Normally used. Must be enabled when P03.02 Feedrate Setpoint is set to R-L.

DI 12

X4-2

115

P07.01 DI: Belt Motion Monitor

Set P07.03 Event: Belt Motion Monitor to A, W1 or W2 to enable the belt motion monitor or IG to disable it.

DI 13

X5-5

n/a


NAMUR BMM input

n/a

P04.06 Speed Measurement

NAMUR Tachometer input

X5-6 DI 14

X5-3 X5-4


BV-H6411GB, 1221 - 199 -

Default I/O Points

Input Terminal Number Block


DI 15

X5-1

145

X5-2

146

12.2


Comments:

Can only be used for tachometer input.

Default Digital Outputs

Note: The default parameter must be set to n/a if the digital output is reallocated.

Each output is a single form C contact (NO, C, NC).

Output Terminal Number Block

DO 1


X10-1 thru 150-152

P16.09 DO: ALARM

Comments:

Feeder has tripped.

X10-3 DO 2

X10-4 thru 156-158 X10-6

DO 3

DO 4

P16.06 DO: Feeder Run Reverse

X11-3

P16.07 DO: Feeder Run Reverse (2nd)

X11-4 thru 162-164

P16.25 DO: Remote CTRL

X11-1 thru 159-161

Feeder is ready for normal (remote) operation.

X11-6 DO 5

X13-1 thru 165-167

P16.18 DO: Volumetric Mode Weigh system error. Feeding in volumetric

X13-3 DO 6

mode.

X13-4 thru 171-173

P16.23 DO: Feeding

Running in Remote with coal on the belt.

X13-6 DO 7

DO 8

X14-3

P16.04 DO: Feeder Run Forward

X14-4 thru 180-182

P16.21 DO: WARNING

Minor error condition.

n/a

Spare Contact

X14-1 thru 177-179

X14-6 DO 9

X15-1 thru 194-196 X15-3

DO 10

X15-4 thru 197-198

P13.01 DO: CleanOut Timer

X15-6 DO 11

X16-1

7, 8

P16.01 DO: Scale Start

X16-2 DO 12

X16-3 thru 186-189 X16-6

BV-H6411GB, 1221 - 200 -

P02.12 DO: Pulse Counter

Pulsed based on amount of coal delivered.


Default I/O Points

Output Terminal Number Block


Comments:

DO 13

134, 135 P02.17 DO: FRI Frequency

Frequency signal proportional to feedrate.

X6-1 X6-2

12.3 I/O

Default Analog I/O Wire

Default

Number Block

Terminal

Number

Parameter

AI 1

Sig +, Sig- P03.02 Feedrate Setpoint

X6-3

Comments:

Customer Demand Signal

X6-4 AO 1

X6-8

142-144

P11.03 AO: Motor Speed Control

139-141

P14.04 AO: Actual Flow Rate

Customer Feedback Signal

n/a

P01.03 Analog Channel A10

Not used

n/a


Not used

n/a


Not used

n/a


Not used

X6-9 AO 2

X6-7 X6-8

A 10

X12-1 X12-2

A 11

X12-3 X12-4

A 12

X12-5 X12-6

A 13

X12-7 X12-8


BV-H6411GB, 1221 - 201 -

Trending Data

13 Trending Data This item lists the most important data addresses available with the trending display.

Data Address:

Data Value:

Unit Comments:

Feedrate

1872 1874

Totalizer 1

lb/h lb

1876

Totalizer 2

lb

1878

Totalizer 3

lb

1880

Belt Load

lb/f

1884

Belt Speed

f/s

1894

Setpoint

lb/h

1904

Deviation

%

1906

Moisture

%

1908

Corrected Feedrate

lb/h

1910

Totalizer 1 corrected

lb

1912


lb

1914


lb

1920

Analog Output 1

mA

1938

Belt Slip

%

1942

Relative Feedrate

%

1944

Relative Belt Load

%

1946

External Setpoint

lb/h

1950

Tachometer 1

Hz

1952

Utilization LC

%

1954

Loadcell VAP

mV/ V

1956

Loadcell BIC

mV/ V

1958

Loadcell

mv/ V

1960

Controller Magnitude

mA

1996

Nominal Belt Load

lb/f


BV-H6411GB, 1221 - 203 -

Trending Data

Data Address:

Data Value:

Unit Comments:

2008

Actual Tare

lb/f

2042

Relative Setpoint

%

2078

Corr. Rel. Feedrate

%

2082

2-Sensor Slip

%

2212

Analog Output 2

mA

2214

Analog Input 1

mA

2224

Loadcell 1

mV/ V

2226

Loadcell 2

mV/ V

2228

Utilization LC 2

%

2230

Gravimetric Total

lb

2232

Volumetric Total

lb

2234

Material Total

lb

2236

Rate

lb/h

2238

Analog Input 2

mA

2240

Analog Input 3

mA

2242 2244

Analog Input 4 Analog Input 5

mA mA

2246

Analog Input 1 (A10)

mA

2248


mA

2250


mA

2252

Analog Input 4 cor.

mA

2254

Analog Input 5 cor.

mA

2256

Analog Output 3

mA

2258

Analog Output 4

mA

2260

Analog Output 5

mA

2262

Analog Output 6

mA

2264

Analog Output 1 (A10)

mA

2266 2268

Analog Output 2 (A11) Analog Output 3 (A12)

mA mA

2270

Analog Output 4 cor.

mA

BV-H6411GB, 1221 - 204 -


Trending Data

Data Address:

Data Value:

Unit Comments:

2272

Analog Output 5 cor.

mA

2274

Analog Output 6 cor

mA

2276

Speed

rpm

2278

Belt Speed

inch/ s

2280

Nominal Belt Load

lb/in ch

2282

Actual Tare

lb/in ch

2284

Belt Load

lb/in ch

2286

Speed Setpoint

rpm

2288

FRI output

Hz

2290

Nominal Density

lb/ft

2292

Density

lb/ft

2294

Gravimetric Total corr.

lb

2296

Volumetric Total corr.

lb

2298

Material Total corr.

lb

2300

Belt Load (average)

lb/in ch

2310

Belt Motion Counter

s

2312

Digital Mode output

Hz

2316

Belt Speed

%

3 3


BV-H6411GB, 1221 - 205 -

Appendix

14 Appendix 14.1

Calculating the setpoint

The setpoint for use in the regulator (refer to Section CTRL) in the Remote operating mode is calculated according to the following scheme:

Fig. 3: Block diagram for calculating the setpoint

INT Integrator

P02.05 Nominal Flow Rate

LIM Limit

P03.02 Feedrate Setpoint

Qo Rated charge. For details see Chapter CTRL AI Analog input

FB Fieldbus P Feed rate setpoint

P03.03 Setpoint Range

P03.04 Setpoint Offset P03.05 Maximum Feedrate P03.06 Minimum Feedrate P03.07 DI: Raise Setpoint P03.08 DI: Lower Setpoint P03.09 Raise/Lower Response Time


BV-H6411GB, 1221 - 207 -

Appendix

P03.13 Speed Setpoint P03.14 Run Mode Select P04.09 Tachometer: Pulses per Rev P10.02 Pulses per length

The controller magnitude is specified to the controller in the OFF/Maint operating mode by P02.16 in percent of the range that is defined by P11.06 and P11.05.

14.2

Switch-on logic

The Remote in operating mode is calculated according to the following scheme:

Fig. 4: Switch-on logic

P03.01 Feeder Start

DI Digital Input Fieldbus

FB

P03.10

OP The keyboard for the VHM or EasyServe operator panel

Source Run Enable

P06.02 Stand-By Limit Value

ERR Any ALARM LOCK Release signal from the downstream process STB Automatically turning off the main drive at low controller magnitude

BV-H6411GB, 1221 - 208


Appendix

RUN-D The switch-on command for the external power unit for starting the feeder R-AD The switch-on command for the external power unit for starting optional auxiliaries R-FB The Feeding is Running report on the plant control system

Belt operation is started in the OFF/Maint operating mode from the operator panel or EasyServe by pressing the RUN <<, RUN >>, STOP, JOG << and JOG << buttons or with the set-up program. In addition, P15.26 and P15.27 can be used to configure input signals for connecting buttons to have the belt run forwards and backwards. The locking signal from the downstream process is ignored. ALARM switches the drive off. The R-FB report (Feeder is Running) is not set.


BV-H6411GB, 1221 - 209 -

Appendix

14.3

Measuring the feed rate (MEASURE)

BV-H6411GB, 1221 - 210


Appendix

UBALI

+

P11.10

I

tp

--------4

P04.02 X P04.04 P04.01 X P04.03 X cos(P04.05)

P09.11

P10.03

HI04

L004 P1o.os-. P10.10

P08.06

P09.09

+

---- )

P08.05

ro +---()9.-+----1

P09.07 HI03 L003

P09.05 P12.xx Q

P09.03 P08.02 HI02 L002

BV-H6411GB, 1221 Schenck Process Group

- 211 -

Appendix

Fig. 5: Measuring the feed rate (MEASURE) F1 Load on load cell 1

P02.21 DC_Mode

F2 Load on load cell 2

P04.01 LC Characteristic Value

f Tachometer 1

P04.02 LC Rated Capacity

RAW1 Loadcell 1

P04.03 Effective Platform Length

RAW2 Loadcell 2

P04.04 Lever Ratio

n Speed

P04.05 Angle

v Belt Speed


I Rate

P04.07 Source Load Cell

UBAL! Event: Significantly uneven load on load cells 1 and 2 (refer to controller operating modes for instructions). Q Belt Load

P04.08 Source Load Cell 2

P04.09 Tachometer: Pulses per Rev P04.10 Load cross section

TA Basic (Cal1) or TW: Tare adjustment program

P08.01 LC Filter

P08.02 Filter: Actual Flow Rate

LP filter Low-pass filter BIC Belt Influence Compensation:

P08.03 Filter: Actual Flow Rate analog

Belt Influence Compensation P08.04 Feedback Filter Override Threshold

ZDO Zero Drop Out: Suppressing tare errors when operating without bulk solids

P08.05 Filter: Belt Load

ro Bulk solids density

P08.06 Filter: Belt Speed

MOIST Moisture correction Refer to separate chapter

P09.01 Limit: Actual Flow Rate MIN

CTRL Feed rate controller Refer to separate chapter HI02 Event: Actual Flow Rate MAX

P09.03 Limit: Actual Flow Rate MAX

HI03 Event: Load MAX

P09.05 Limit: Load MIN

HI04 Event: Speed MAX

P09.07 Limit: Load MAX

LO02 Event: Actual Flow Rate MIN

BV-H6411GB, 1221 - 212 -

P09.09 Limit: Speed MIN


Appendix

LO03 Event: Load MIN

P09.11 Limit: Speed MAX

LO04 Event: Speed MIN

P10.02 Pulses per length

S1G Gravimetric Total

P10.03 Range Correction TW

S1V Volumetric Total

P10.04 Range Correction TC

S1T Material Total

P10.05 Range Correction TM

S1 Totalizer 1 S2 Totalizer 2 S3 Totalizer 3 TW Span (Cal2) set-up program TC CW: Span Calibration set-up program (TC: weight control) TM Manual adjustment with bulk solids weighed on an external scale VAP Feeding with reference to the feeder's discharge point


P10.10 Basic Tare P11.10 Platform Dis.Length

Appendix

14.4

Feed rate controller (CTRL)

Fig. 6: Feed rate control (CTRL) P Feedrate Setpoint

P02.05 P02.05

I Rate

P11.01 P-Component KP

f Tachometer 1

P11.02 I-Component TN

xd Deviation

P11.03 AO: Motor Speed Control

Y Controller Magnitude

P11.04 Lower Limit

Q Belt Load

P11.05 Upper Limit

v Belt Speed

P11.06 Controller Magnitude Offset

BV-H6411GB, 1221 - 214 -


Appendix

MEASURE Measuring the feed rate

P11.07 Position at STOP

Refer to separate chapter Proportional PI integral controller

P11.08

KP speed controller

LIM Limit IDENT Identifying the system behavior to determine system parameters VFD Drive feed rate controller (external)

vol-S Volumetric operating mode grav Gravimetric operating mode Speed Qs Belt load measured in gravimetric operation in units of weight per length for use in volumetric operation Q0 Refer to explanation below

Normal Gravimetrically controlled normal operation S-UP Volumetric operation over approximately 30 s after turning on the supply voltage Stop Stopping the controller when the limit is reached

The Q0 rated belt load in units of weight per length is calculated according to the following regulation: ▪

If the load is measured (P04.07 and P04.08 unequal n/a):

Q0 = P02.05 / P02.06 ▪

If the load is not measured (P04.07 and P04.08 equal n/a):

Q0 = P03.15 / P04.10

General Diagram

The PI controller is of the model

Only P controllers and I controllers are possible as a special case. The controller is stopped when the controller magnitude in the LIM block is run up to its limits. Controller parameters


Appendix

The relationship between the controller parameters and the actuating variable is shown schematically in the following diagram.

Fig. 7: Effect of the controller parameters on the controller output with a discontinuous control deviation on t=0

The abbreviations are as follows: Controller parameters

Meaning

KP

P-portion of the feed rate controller related to the nominal feed rate as a % / % or a dimensionless P-portion of the speed controller.

TN

Reset time in seconds.

Tab. 6 : Controller parameters

Parameter value

Special case

KP = 0

I-controller: KI = 1/TN in % / (mA/s)

TN = 0

P-controller: I-portion will be deleted

KP=TN=0

Controller output = controller increase

Tab. 7 : Special cases of controller parameter setting

Types of operation Mode of operation Specified condition

Characteristics

Gravimetric

The actual feed rate is controlled to the setpoint and paying attention to the values measured for belt load and speed.

The feeder is switched on and at least 40 s of voltage switched on. No condition for volumetric operating modes P03.14 = Frate

Volumetric Synchronous

▪

▪

▪

The No Coal on the Belt transmitter has responded or the volumetric control command is specified from outside P03.14 = Frate

▪

▪

▪

▪

Display: gravimetric operation Volumetric output is not activated The actual feed rate is calculated from the speed and the belt load value ascertained just before the event occurs and then controlled Issuing the gravimetric feed rate and calculating the integration of the totalized amount of material as in gravimetric operation

BV-H6411GB, 1221 - 216 -


Appendix

Mode of operation Specified condition

Volumetric through errors

The difference in measuring results for the load cells on the right-hand and left-hand side of the feeder is greater than 25% or the load cells are underloaded or overloaded

Characteristics ▪

▪

▪

P03.14 = Frate ▪

Display: volumetric operation Volumetric output is activated The actual feed rate is calculated from the speed and belt load value ascertained over the last hour before the error occurred and then controlled The totalized amount of material is added up in the meter for the volumetric totalized amount of material, not in the meter for the gravimetric totalized amount of material.

▪

Feeding at the speed as set in P03.13

Fixed speed

P03.14 = Speed Setpoint

Speed controlled

P04.07 and P04.08 equal to n/a

Target belt speed

P03.14 = Frate

= target feed rate / Q0 with: Q0 = P03.15 / P04.10

Mode of operation Specified condition

Characteristics

Standby

The controller magnitude is below the limit set by P06.02 Stand-By Limit Value

The external drive is turned off to protect the motor and feed rate controller and starts automatically when the controller magnitude is in excess of the limit. It continues to report that the Feeder is Running to the plant control system.

The belt load drops below the limit set by P05.05

The load is set to zero to ensure that small tare

Zero Drop-Out Limit.

errors do not cause the integration of the totalized amount of material to continue with longer running.

Zero drop out

Tab. 8 : Special modes of operation

The upper limit of the controller magnitude can be reduced to prevent excess feeding of hazardous substances at a low target feed rate.


Appendix

Fig. 8: Upper controller magnitude limit

. MX

The value of the P11.05 Upper Limit parameter

P%

The target feed rate in % of P02.05 Nominal Flow Rate

Y-MAX

The limit for the controller magnitude

This figure shows an example of the correlation for three selected settings of the MX parameter.

Behavior with a power failure and return in regular feeding operation

The controller below the line is only in operation for T_Start = approximately 30 s after adding voltage. The weigh feeder runs volumetrically during these 30 s. The constants needed for volumetric operation are determined regularly during gravimetric operation in the IDENT block. Feeding is not possible during T_Start if the feeder was not yet in operation gravimetrically before adding voltage.

14.5

Belt slip identification

14.5.1 Motion monitoring (BMM) A sensor is mounted on a roll that rotates when the belt moves. That might be an idler or the tail pulleys that are not driven. After turning on the scale, it monitors to make sure that the signal of the sensor changes within the time set in P07.02. Then the assumption is made that the belt is moving.

14.5.2 2-sensor slip monitoring Belt slip on the head pulley can be ascertained and monitored with a second sensor on a carrying idler driven by the belt.

BV-H6411GB, 1221 - 218 -


Appendix

Fig. 9: 2-sensor slip identification

S1 Sensor 1, for instance on the head pulley S2 Sensor 2, for instance on the tail pulley M The drive motor of the belt T Impulse tachometer on the drive motor

P:S1 Selecting the source of signal 1. Relevant parameters: P18.02 Source Sensor 1 If P18.02 = speed: P04.06 Speed Measurement If P18.02 = DI: P18.03 DI: Sensor 1, vs or S1C is selected depending upon the signal source selected P:S2 Selecting the source of signals 2: P18.05 DI: Sensor 2 S1C Impulses per length of sensor 1: P18.04 S2C Impulses per length of sensor 2: P18.06 vs Impulses per length on the main tachometer: P10.02 P_U Impulses per belt circuit: P10.11 SLP Slip service display 2-Sensor Slip WM05 Event: Slip 2


Appendix

MAX P18.07 Slip Value 2

The smallest measurable slip S_MIN is the larger of the values A and B: A = 2 * 100 * vs /(P_U *S1C) B = 2 * 100 * vs /(P_U *S2C)

Example

vs = 10000 P_U = 30000 S1C = S2C = 100 S_MIN = 0.667% If P18.07 < S_MIN: S_MIN has an effect

Note

The impulses and pauses between impulses to S1 and S2 have to be at least 1.2 s long. If digital inputs are used on the first VCU of a scale, the impulse and pause have to be at least 0.2 s long.

14.6

Belt drift and slip identification via mark in the belt

Prerequisite: A belt is used with an integrated mark (triangle). The parameters in the Belt Monitoring block should be adjusted.

BV-H6411GB, 1221 - 220 -


Appendix

Fig. 10: Belt drift and slip measurement TThe mark (triangle) in the belt

Le The length of the triangle (P07.10 )

V Proximity sensor

W The width of the triangle (P07.11 )

L The belt drift to the left

N Normal belt position

R The belt drift to the right Sig Sensor signal

SLP Belt slip SP Belt splicing point

Belt drift identification

If the belt runs in the middle of the idlers, the sensor is mechanically set so that a Belt Drift service value is shown to be approximately equal to zero if P07.12 = 0.


Appendix

The length (T) of the signal (-t1 or +t2) changes if the belt drifts to one side. Event: Belt Drift is first identified at low drainage and Event: Belt Skew is identified at greater drainage depending upon the size of the triangle. P07.12 can be used to finely adjust the position of the sensor in relation to the triangle according to the mechanical setting so that a Belt Drift service value is shown that is equal to zero if the belt is in the middle position.

Belt slip identification Event: Slip is identified if the duration T_rev measured for a complete belt revolution is in excess of the limit in %

set in P07.07 of a complete belt revolution. Note

Monitoring needs two complete belt revolutions after starting feeding for synchronisation. Events are not identified during this period.

14.7

Monitoring the mechanism

The following signals can be connected for m onitoring the mechanism of the feeder and bulk solid flow.

Fig. 11: The VCF monitoring mechanism FL OW- Monitoring the flow of bulk solids in the feed M area

P15.19 DI: Coal Flow Monitor

LSFB The sensor for bulk solids on the belt

P15.12 DI: Coal on belt switch

BMM Belt run monitoring


LSFD Monitoring an obstruction on the discharge

P15.09 DI: Discharge Pluggage

BV-H6411GB, 1221 - 222 -


Appendix

Other monitoring signale can be activated for electrical and mechanical malfunctions with the Digital Inputs parameter block.

14.8

Moist correction (MOIST)

You can use the Moisture parameter group to activate a correction in the actual value used for regulating the feed rate. The proportion of foreign matter (such as water) in the bulk solids fed is ascertained externally and communicated to the weighing system. The system uses this as a basis for recalculating the weight ascertained including foreign matter to the net value of the proportion relevant to the downstream step in the process by subtracting the quantity of foreign matter. The mass flow rate is gravimetrically controlled based upon the net value. In other words, the quantity corresponding to the weight of the foreign matter is also fed. The integration of totalized amount of material of the gross or corrected net value can be selected as a signal source for the impulse output.

Fig. 12: A block diagram of moisture correction

14.9

The procedure for adjusting the frequency output

DISOCONT Tersus has a frequency output (FRI, P02.17 DO: FRI Frequency) where the frequency is proportional to the current feed rate. The frequency output is already precisely adjusted by entering the ratio of output frequency to the feed rate in P17.0 4. Sometimes it is necessary to adjust the receiving opposite point. This calls for switching defined frequencies to the output. They are set without bulk solids. Start off by setting P17.04. Then call up the Simulation Mode operating mode with the operator panel or EasyServe (Simulation Mode [➙ 44]). It is advisable to store the current parameters. The parameters for current error reports with the ALARM event class should now be changed so that they can


Appendix

operate without an alarm. The P04.07 and P04.08 parameters should be set to n/a. P03.01 and P03.02 should be set to OP. Switch on the feeder. It runs at the target feed rate set on the operator panel or via EasyServe. Simulation simulates an actual feed rate that is equal to the target feed rate after running for a while. The setpoint is now set to the lowest value (refer to P03.06). The first opposite point is adjusted. Now the maximum setpoint is set (P02.05 and P03.05). The second frequency parameter can be adjusted externally. Then the parameters previously stored should be activated again.

14.10 PLC Functionality (Optional) As with a PLC, the functionality for simple additional tasks can be expanded using signal links and function blocks. The function block links can only be configured using EasyServe. A configuration can be loaded into or read out of the control using EasyServe. The link becomes active immediately after being loaded. All signals available in the fieldbus are available as input signals for the function blocks. The output signals are integrated into the DISOCONT Tersus' standard signal processing via the parameters of the groups ' FCB analog outputs' and 'FCB digital outputs '. A loaded and active link is displayed on the operating panel above the 'Help' button next to the information on the program. The 'Empty' link signifies the factory settings with no additional links.

Fig. 13: Example of a function block link

In the example, a binary input signal, e.g. a DISOCONT Tersus input contact, is read in through the input block 'GP-Din 1' output to the AND gate 'And 1-4' through the delay 'Delay 1' and an inverter. The other inputs are connected to the constant '1' and a frequency generator 'Cycle 1'. This provides the output with a cyclical signal when the waiting period has elapsed after the input has been set. The output of the AND gate is connected to an

BV-H6411GB, 1221 - 224 -


Appendix

output of the DISOCONT Tersus standard control. The signal must be connected to a digital output via P27.01 'FCB_DO 01' to enable physical output. Note: The Schenck Process software DISOPLAN must be installed on the PC to allow working with function blocks.

14.10.1 Handling the Function Blocks Function blocks can be processed and linked using EasyServe in expert mode only. The detailed description of the function block editor is contained in a separate manual. CAUTION: Links may be created and altered by Schenck Process personnel only.

Configurations can be read out of and into the control. They can be stored on PCs and be called up from there. Links must be given a name. The 'empty link' as a factory default has the name 'Empty' and should not be used for other links.

WARNING Possible loss of functions after replacing the VCU. Function blocks are not automatically stored with the parameters in EasyServe. If a function block link is loaded it will be necessary to store it separately in EasyServe. If the VCU is replaced then both the parameters and the function block links must be loaded separately in order to restore full functionality. Alternatively the additional tool DISOPLAN, that contains both the parameters and the function block links, can be used to make a complete backup. However, this backup can then no longer be used with an updated version of

the scales program. It is not necessary in a system with the 'Empty' link (see Cleaning the Screen and Information) to reload the link after a VCU replacement as no functions are expanded using function blocks. Loading the function software or loading factory settings or the locking set of the parameters does not have any impact on the function blocks loaded. In other words, any link that is already loaded is maintained. Any loaded link cannot be deleted; it can only be overwritten. If you want to make a link ineffective, it can be overwritten with a new link that has to contain at least one block. A loaded link does not have any effect on scale operation as long as the outputs for the link are not coupled to the scale software with the corresponding P26.01 to P27.20 parameters.

14.10.2 Function Blocks for Binary Signals The following function blocks are available.


Appendix

Fig. 14: Binary function blocks

No.

1

Type

Binary inputs

quantity Parameters

20

'GP-DIn' 2

Binary output

Function

Process variable as per the descrip- Connection between the function block tion of the fieldbus data interface

20

-

'GP-Dout'

3

Clock generator

2

Periodic time

logic and the function of the standard program Makes output signals available. Connect using the parameter in the ' FCB digital outputs' block. All outputs are available as status information in the fieldbus interface. Signal generator for a periodic signal

'Cycle'

4

5

Bin 0

1

Bin 1

1

-

Pulse generator

1

Time for the pulse

6

-

'Time' 6

AND

Generator for the binary constants 1 = True and 0 = False The timer has three outputs that supply an pulse of 0.1 seconds duration at the time set. And-link of two input signals

'And'

BV-H6411GB, 1221 - 226 -


Appendix

No.

Type

AND

quantity Parameters

Function

4

-

And-link of four input signals

6

-

Or-link of two input signals

8

-

Or-link of four input signals

10

-

Invert the signal

'And 4' 7

OR 'Or' OR 'Or 4'

8

Negation 'Not'

9

Delay

8

Delay time in seconds

'Delay' Tab. 9 : Blocks available for processing binary signals

14.10.3 Function Blocks for Analog Signals Analog signals can be processed with the following function blocks

Fig. 15: Analog function blocks


Delays the input signal by the specified time

Appendix

No. Type

1

Analog input

quantity Parameter

20

'GP-Ain' 2

Analog output

20

3

Comparator

6

Function

Process variable as per the description of the fieldbus data interface -

Input for a continuous variable.

Makes output signals available. Connect using the parameter in the ' FCB analog outputs' block. Only 5 FKB outputs can be configured to physical outputs. All outputs are available as measured values in the fieldbus interface.

Upper and lower comparative value

Supplies the value 'True' if the input signal lies outside of the threshold values.

10

Upper and lower threshold value

Limits the input signal and becomes 'True' if limitation arises.

5

-

Supplies the product of the input values at the output

2

-

The input value at 'MemInp' is tied to 'Acquire' with the increasing slope. It is available at the output. At the same time the 'Hold' output indicates that a value was stored. The memory can be cleared with 'Reset'.

5

-

Makes the sum of the input values available at the output.

5

-

Makes the difference of the input values available at

'Comparator' 4

'Limit'

5

Multiplicator 'Multiplicator'

6

Memory 'Memory'

7

Addition 'Add'

8

Subtraction 'Subtract'

9

Counter

the output 6

Start value

Supplies the numbered input pulses at the output

1

-

Switches one of the three inputs to the output

20

Dividend

Multiplies or divides by a fixed factor

'Counter' 10

Switch 'Analog switch'

11

Multiplication 'Factor'

12

Constant

Divisor 5

Value of the constants

10

Dividend

Supplies the numerical value to the output

'Constant' 13

Offset 'Offset'

BV-H6411GB, 1221 - 228 -

Divisor


Appendix

14.11 Serial Networks The individual components of the DISOCONT Tersus communicate with each other serially using one cable, usually a fieldbus. Few wires are used to transmit the data serially. The advantages of this method are that less complex cabling must be done to allow the exchange of a lot of signals, that it is resistant to interference, it is reliable and guarantees that the signals are transmitted accurately. Different fieldbus systems are used in the DISOCONT Tersus system because of the varying specifications of the communications behavior. As all of these systems are based on open standards, we wish to refer you to the standards in question for a complete technical description. This section will explain only a few of the more commonly needed technical details of the bus systems in question. In order to structure clearly the tasks of the communication system it has been separated into layers that are based on each other, some of which are subject to different standards. The following table lists a selection of terms from different layers.

Model

Use in DISOCONT Tersus, Comments

Relevant Standards

Ethernet

Link to the host computer

IEEE standard 802.3

Link to the VHM operating panel Link between basic unit VCUs and the service tool EasyServe Standard for the hardware layer. The basic unit VCU has 4 ethernet ports as standard. MODBUS/TCP Ethernet/IP

Widely-used protocol layer on an ethernet bus Protocol layer on the ethernet. Often used in Rockwell systems.

http

Protocol layer for the VHM operating panel and for an alternative web browser

RS-485

Alternative link to the operating panel Link to expansion units Link to the DISOCONT VHM operating panel Hardware specification. The basic unit VCU has 2 serial RS485 interfaces as standard.

MODBUS RTU

Link to the host computer Protocol layer on differing pieces of hardware, e.g. RS-485 or ethernet

PROFIBUS-DP

Link to the host computer Extensive standardization of hardware and protocol layer. Often used in Siemens systems. Implemented in the DISOCONT Tersus by means of a plugin card.


EIA-485 (RS-485)

Appendix

Model

Use in DISOCONT Tersus, Comments

DeviceNet

Link to the host computer

Relevant Standards

Extensive standardization of hardware and protocol layer. Often used in Rockwell systems. Implemented in the DISOCONT Tersus by means of a plugin card. USB

Connection for a bluetooth adapter The basic unit VCU has one USB interface as standard.

Bluetooth

Wireless connection for the VHM service operating panel or for a notebook on which the operating software is installed. Implemented in the DISOCONT Tersus by means of a USB bluetooth adapter.

RS-232

For loading the program in special situations Alternative link to the DISOCONT VHM operating panel Connection between exactly two subscribers.

14.11.1 Ethernet Hardware Ethernet networks are today implemented in a star topology with a switch as the node. The DISOCONT Tersus basic unit VCU has its own switch with 5 ports, so that each VCU can be considered to be a node. One of the ports is connected to the weighing processor and the other four are available for external connections.

Fig. 16: Alternative 'series connection' link between basic units and the on-site ethernet

BV-H6411GB, 1221 - 230 -


Appendix

Fig. 17: Alternative 'star connection' link between basic units and the on-site ethernet

The VCUs are connected to the switch by a category 5e network cable at the RJ45 socket on the VCU. The maximum length of the cable is 100 m. Intermediary switches or routers or optic fiber converters can be used to make longer connections.

The ethernet switch of the central unit only (= unit on which the scales software is installed) is available for external connection in systems in which several VCUs have been assigned to one scales. The ethernet ports of the other VCU units (software VIO xxxxx) are not served.

14.11.1.1

Ethernet Addressing

14.11.1.1.1

MAC Addresses

The manufacturer of any device that can be connected to the ethernet assigns that device a MAC address unique in the world and unalterable. It forms the basis of physical communication between two subscribers. Ad- dresses in the IP protocol (IP address) were introduced to simplify the administration of small and of very large networks (WWW). Routers and switches decode the IP address and transmit the message to the subscriber with the corresponding MAC address. Subscribers in a subnetwork delimited by a router can be reached by means of a broadcast command to all subscribers. This allows subscribers in subnetworks to be found.

14.11.1.1.2

IP Addressing

Every subscriber in a (sub)network must have a unique address that has been assigned once only. As opposed to office networks, addresses in industrial control networks are assigned permanently as the subscribers in the network seldom change. The ethernet address setting consists of the components: ▪

IP Address

▪

Subnetwork Mask

▪

Gateway Address


Appendix

14.11.1.1.3

IP Address

Unique address of the subscriber in the subnetwork. The bits of the address labeled by the subnetwork mask must be identical for all subnetwork subscribers. Subscriber addresses in the subnetwork must differ at those parts in the address which have the value zero in the subnetwork mask.

14.11.1.1.4

Subnetwork Mask

This mask determines the addressable range of a subnetwork. All subscribers in a subnetwork must have addresses that coincide in those bits that have the value 1 in the subnetwork mask. For example: Subnetwork mask: 255.255.255.0 Corresponds in binary to: 11111111.11111111.11111111.00000000 In this example, all subscribers in the subnetwork must have addresses that coincide in the upper 24 bits. The distinction is made in the lower 8 bits so that 255 subscriber addresses in this subnetwork can be addressed.

In private networks an address range within 192.168.x.x is often used.

14.11.1.1.5

Gateway

Information addressed to subscribers with addresses outside of the range determined by the subnetwork mask are reached through the gateway. As no subscribers outside of the subnetwork are addressed in self-contained industrial control networks, the gateway address is usually left at the default setting 0.0.0.0.

14.11.1.1.6

Setting the IP Address in DISOCONT Tersus Systems

The addresses of the subscribers in a network intended for process control tasks are generally permanent. Even in the event that the equipment is not integrated into a network, we urgently advise giving adjacent equipment different IP addresses in the same subnet. Otherwise, there might be problems in the PC network configuration if the cable connection is jacked to the PC so that it will not be possible to establish communication (for instance, via service tools such as EasyServe or DISOPLAN) until the PC has adapted its configuration to the modified environment. The keyboard is used to set the address in the DISOCONT Tersus VHM operating panel. Either a VHM operating panel or the PC-based service tool EasyServe is required in order to set the address of the central unit VCU. Changing the address in a running system can cause complete loss of communication, also to other partners! To make sure, the address should only be set when the plant briefly allows an interruption in communication.

The address is set using the DISOCONT Tersus VHM operating panel as follows:

1: Is the VCU connected to a user-side network?

BV-H6411GB, 1221 - 232 -


Appendix

Yes

No

Has an IP address been already assigned or cleared for the VHM operating panel?

Use the factory default addresses:

(The address for the VCU must anyway have been already determined in the user-side network)

VHM: Address 192.168.240.021

VCU(s): Address 192.168.240.001

Subnetwork mask: 255.255.255.000 Establish a connection between the VCU and the VHM in the same subnetwork. The easiest method is to plug a cable from the operating panel directly into the VCU.

Yes

No

Generate an address list for the VCUs in the subnetwork.

Use the keyboard to set the Cannot be configured address of the operating panel. using the VHM operating panel. Disconnect the VCU from the user-side network and repeat from step 1. 2: Is the VHM operating panel connected to the same subnetwork as the VCU (not through a router)?

Yes

No Connect the VHM operating panel and the central unit VCU to the same network. Continue with step 2.

Search the network for VCU(s) using the operating panel. Select the VCU to be set and enter the IP address (VCU parameter). If necessary, reintroduce the VCU into the user-side network.

The address of the central unit VCU is set with the PC -based service tool analogously to the method with the operating panel VHM. It may be necessary to adapt the network configuration of the PC. This generally requires administrator rights on the PC.

14.11.2 RS-485 Hardware Several VCU control units assigned to one scales can be connected to each other by RS-485 interfaces. A VHM operating panel can also be connected to a VCU for communication across long distances. The same interface hardware is also used by some forms of the interface to the plant-side controller. The three connections men-


Appendix

tioned may not be connected to each other in the DISOCONT Tersus. For this reason the VCU has three separate interfaces for the different communication tasks.

Fig. 18: Possible RS-485 connections

To avoid electrical reflections on the transmission cable, each of the cable ends - and these only - must be terminated with a resistance. The cabling of an RS-485 network should therefore be made in one link, though short distribution feeders are permitted. The total length of cable in a network is maximum 1000 m.

Fig. 19: Bus termination for the transmission cable

The bus termination resistances in the DISOCONT Tersus system are integrated into the VCU and VHM components and can be connected using a jumper if required.

The two data wires in the cable used are a twisted pair cable and are individually screened. Further lines, e.g. to supply a peripheral instrument, can also be included in the cable.

BV-H6411GB, 1221 - 234 -


Appendix

The 'A' and 'B' connections of all devices must be connected.

Fig. 20: RS-485 bus wiring

14.12 Basics of EMC-Compliant Cabling All units of the DISOCONT Tersus have been designed and tested for the anti-interference required of a device in an industrial environment. They meet the following specifications: EN 61000-6-2 (Immunity to Interference for Industrial Environments) EN 61999-6-4 (Electromagnetic Interference for Industrial Environments) It is not authorized for use in living areas. Certain steps must be taken when cabling to guarantee the high interference resistance. The following figure shows correctly mounted cables. Insulate the cable in the area of the screen plate and contact the cable screen on the screen plate with the clamps included. Use cable binders to relieve tension.

Fig. 21: Fix cable with cable binders and clamps

1

cable binders for the pull relief

2

Connecting cable shielding braid

3

Screen clamp

There are several slits beneath each cable lead-through. The cable clamps will press the cable screen against the shielding plate if they are inserted into these slits. This will correctly earth the screening. M-shaped slits can also be used as pull relief for cable binders.


Appendix

14.12.1 Thoughts on the Cable Connections The small number of components makes a DISOCONT Tersus system quite simple to assemble. Nevertheless you should always check to see what cables are required and whether their quantity and size will fit through the existing lead-throughs (refer to the table in the section 'Accessories Recommended Cables'). →

The correct plug type for each input (and output) can be found in the technical specifications of the individual units, e.g. Phoenix MSTB, grid size 3.5 mm. Each type has a maximum cable diameter that can be used. The 2 maximum wire cross section for Phoenix MSTB plug-in connectors with a grid size of 5 mm is 2.5 mm , for 2

MSTB connectors with a grid size of 3.5 mm maximum 1.5 mm . Correct cabling is indispensable for optimal electromagnetic interference protection. Please follow the corresponding recommendations.

14.12.2 Screened Cables The screen of screened cables in generally connected at both ends to GND with a broad-contact connection. The DISOCONT Tersus is supplied with mounting plates that have an appropriate contact surface in the area around the cable feed. The outer sheathing is removed from the cables and the cables are then clamped with the special screen clamps against the contact surface. The screen shielding braid can also be attached to the mounting plates using a cable binder if clamps are not available. If the contact point of the signal wires is far from the contact point of the screen, the screen should be left all the way up to the connecting point of the cable. Then the outer sheathing need only be removed from the cable at the contact point of the screen. The screen can then be fit as described above.

14.12.3 Unscreened Cables Unscreened cables can be strain relieved mechanically with the screening plate. There are T-shaped metal stays on the mounting plate to which cable binders can be connected.

14.13 Checking the Weight Measurement Instrumentation Most of the function errors are signaled by event messages. A test connector can be used to perform a basic function inspection if a displayed weight value is evidently wrong despite correct parameterization. A simple voltage metering check cannot be made using a measuring instrument due to the alternating voltage supply to the load cells. A test connector can show up any errors between the load cells, cabling and the measuring electronics.

BV-H6411GB, 1221 - 236 -


Appendix

Fig. 22: Test Connector

The test connector is plugged into the load cell cable input on the DISOCONT Tersus. Once plugged in, the raw measured value can be read off at the service values of the measuring electronics. It must be: raw measured value 1.5 mV/V ± 3%. Note: If other resistance values are used in the test connector, the raw measuring value can be calculated using this formula: raw measuring value ~ 500 * R2 / R1 [mV/V]. The measuring amplifier is working properly if the raw measuring value lies within this range. The measured load display in kg depends on the setting of the scales' characteristic data. A weight value of approximately 75 kg is shown if the parameter factory settings are used.

14.14 Technical Data VCU 20103

Fig. 23: VCU 20103 in 3D representation with mounting kit


Appendix

14.14.1 Dimensions and Position of the Plugs

Fig. 24: Dimensions and position of the plugs VCU 20103 with mounting kit I

4 x Ø6.8

Required installation area 4 x boreholes for fastening bolts

BV-H6411GB, 1221 - 238 -


Appendix

14.14.2 General Technical Data

Operating temperature range (outside of housing)

-25 °C ... 50 °C

Storage temperature range

-40 °C ... 85 °C

Humidity

20 % ... 90 % rel. humidity, non-condensing

Protection class

IP20 (intended for installation in a housing)

Weight

2.3 kg

Approbation

CE, UL, ATEX see separate chapter

DISOCONT Tersus has a shock-mounted real-time clock. If system is powered off, the clock continues running for approximately one week provided that the system has been operating for at least 30 hours. The clock buffer is maintenance-free.

14.14.3 Power Supply The VCU 20103 is powered by an a.c. voltage supply.

DANGER Life-threatening voltages

The device must be installed in a housing that obstructs access to live components if the electronics are powered by dangerously high voltages (U > 40 V) or if there are dangerous voltages at the outputs. A tool must be required to open this housing. Alternatively, the device can be installed in a room accessible only to specialist personnel. If not installed in the housing, the live connections have protection class IP20 only. Therefore, great care should be taken if the housing is open. The supply voltage should be switched off before the housing is opened.

AC Voltage Infeed

Rated voltage

115 VAC

230 VAC

Maximum input current during continuous operation

0.8 A

0.55 A

Input voltage failure bridging time

15 ms

80 ms


Appendix

Switch-on current (peak current)

16 A

36 A

Frequency range

47 – 63 Hz

Maximum voltage range

85 … 265 VAC

Safety recommendation for the customer

16 A device fuses, type C as per EN 60898

Isolation input low voltage –

3 kV

Terminal clamp

PE: Connection to the fitting panel L, N: Connection X8: 1-2

Maximum wire cross-section at clamp

2.5 mm

2

14.14.4 Auxiliary Voltage for External Subscribers The VCU 20103 can supply external subscribers such as operating consoles or external relays and valves with voltage. Output Voltage

24 VDC ±10 %

Output current

0.3 A in total

Maximum wire cross-section at plug

2.5 mm

2

Overload protection

Permanently short-circuit proof

Connection

X9:1 0 VDC (GND)

Supply for operating panel

X9:2 +24 VDC

VHM (with an RS485 connection [➙ 264])

X9:3 0 VDC (GND)

Supply to any external consumers

X9:4 +24 VDC

14.14.5 Load Cell Input VME0120 The VCU 20103 has two VME0120 measuring channels. The VME0120 subassemblies are connected to connector strips of the VFE0123 (upper circuit board) below the cover and are each fixed with two M3 x 5 bolts.

Weighing channels: VME0120 at connector strip X51.3 VME0120 at connector strip X51.4

BV-H6411GB, 1221 - 240 -

⇒ ⇒

Weighing channel LC1 with connection X91 Weighing channel LC2 with connection X92


Appendix

Number of inputs

Max. 2

Type

High-resolution input for DMS load cell

Load cell supply voltage

12 V

Maximum output current as a sum for both inputs

210 mA

Load cell sensitivity

1 ... 3 mV/V (max. 26 mV input voltage)

Cable break)monitoring interval (short circuit, cable

100 ms

corresponds to max. 6 load cells with 350 Ω internal resistance

Resolution of the measured value

24 Bit = 16 MIO digits

Temperature drift

< 10 ppm / °C

Maximum cable length to load cell

500 m (use a special cable from the recommended cable list)


1.5 mm

Connection

6-conductor system; in the case of load cells with 4 conductors, the terminals Ref and U will require bridging in the interconnecting box.

Channel designation

Weighing channel LC1: plug X91

2

Weighing channel LC2: plug X92

Fig. 25: VME0120: Load cell connection, Pin 1 (X91 or X92)


Appendix

Fig. 26: VME0120: Load cell input X91 or X92

The colors of the load cell cable conductor vary depending on the load cell m odel and manufacturer. The following table can be used as a reference. More details can be found on the load cell data sheet.

DISOCONT

Schenck RT 2.8 mV/V

Schenck PWS 2 mV/V

VBB and HBM Z6 2 mV/V

Schenck SF4 / SB4 2 mV/V

Tedea 1250

OUT 1

Black

Black

Black

Black

Black

REF 1

Black

Blue

Grey

Black

Brown

STOCK SBeam

Red

Terminal box DKK

82 82.1

IN 1

Red

Red

Red

Red

White

Green

28

IN 2

White

White

White

White

Red

White

27

REF 2

Blue

Orange

Green

Green

Blue

Black

81.1

OUT 2

Blue

Green

Blue

Green

Green

81

Tab. 10 : DISOCONT Load Cell Connection, Wire Colors

The load cell cable screen should have a large surface area, e.g. it should be attached with a clam p to the VCU fitting panel (see chapter 'Basic Information on EMC-Compatible Wiring'). The entire stretch of cable between contact point of the screen to the VME0120 plug should be screened. The screen is removed just before the plug. Suitable terminal boxes are available for connecting together several load cells of one weighing point. The cable should be laid separately from working cables. The wire pairs IN, REF and OUT are twisted in the cable and must be screened pairwise. The cable itself will also require screening as a whole.

BV-H6411GB, 1221 - 242 -


Appendix

14.14.6 Digital Connections 14.14.6.1

Digital inputs

The VCU 20103 has inputs for external switching contacts and inputs for directly connecting proximity sensors. The logical denotation of the inputs is determined by parameters using the software. LEDs behind the plug indicate the state of the inputs.

14.14.6.1.1

Digital Inputs 24 VDC for General Use

Digital Standard Input

Number of inputs

12

Input voltage

18 ... 36 VDC

Internal resistance

> 3.5 kΩ

Supply voltage

24 VDC (not isolated)

Potential separation

Non-floating against GND and internal +24VDC


2.5 mm


2

X1:5

+

X1:6

Signal

X1:3

+

DI2

X1:4 X1:1

Signal +

DI3

X1:2

Signal

X2:5

+

X2:6

Signal

X2:3

+

X2:4

Signal

X2:1

+

X2:2

Signal

X3:5

+

DI1

DI4

DI5

DI6

DI7

X3:6

Signal

X3:3

+

DI8

X3:4 X3:1

Signal +

DI9

X3:2

Signal

Appendix

Digital Standard Input

Common connection of all inputs

X4:6

+

X4:7

Signal

X4:4

+

X4:5

Signal

X4:1

+

X4:2 X4:3

Signal Common

DI10

DI11

DI12

Connecting a switching contact

Fig. 27: Digital input: switching contact connection

Connecting an external signal voltage

Fig. 28: Digital input: external signal voltage connection

The common connection has the electrical potential of the housing

Connecting a two-wire sensor (not conform to EN 60947-5-6 (NAMUR))

BV-H6411GB, 1221 - 244 -


Appendix

Fig. 29: Connecting a two-wire sensor

Take note of the technical data of the sensor when connecting it. The current limiting diode (CLD) must be dimensioned so that the voltage between Sig and Common is less than 2 V when the sensor is not switched on. On the other hand, the current through the sensor should not exceed 50 mA. W hen switched on, the voltage should be at least 18 V.

14.14.6.1.2

Digital Inputs as per EN 60947-5-6 for Connecting Sensors

Sensor input as per DIN EN 60947-5-6 (NAMUR)

Number of inputs

2

Frequency range if used as impulse input for measuring 0.03 Hz ... 3 kHz speed Monitoring

Short circuit and cable break

Switching level if connecting external voltage

2.5 V

Supply voltage

8 V; not isolated; short-circuit proof

Cable

Use screened cables to connect a sensor. Screen attached to the VCU 20100.


2.5 mm

Connections

X5:5

2

+

X5:6

0V

X5:3

+

X5:4

0V

Connecting a Sensor as per EN 60947-5-6 or a Switch (without cable monitoring)


DI13

DI14

Appendix

Fig. 30: Digital input: connecting a sensor or a contact at the sensor input

Connecting an external signal voltage

Fig. 31: Digital input: connecting an external signal voltage at the sensor input

The 0 V connection is connected to the electrical potential of the housing.

14.14.6.1.3

Connecting the Sensors for Calibration Markers

The sensor for markers on the belt are connected to sockets CAL-1 and CAL-2 during adjustment. Socket

0V

24 VDC

Signal input

5

2

1

2

4

1

If both sockets CAL-A (X30) and CAL-B (X31) are used (plugs W901, W902, W903 to position 2 - 3) Sensor A at CAL-A Sensor B at CAL-B If socket CAL-B (X31) is used for both sensors (plugs W901, W902, W903 to position 1 - 2) Sensor A Sensor B

5

Tab. 11 : Pin assignment for belt marker sensors

Maximum permissible current from the supply: 100 mA Internal resistance of the inputs: 4.4 k Ω Input voltage for ON state: 5 ... 24 VDC

BV-H6411GB, 1221 - 246 -


Appendix

14.14.6.1.4

Connecting the Speed Sensor

The following alternatives for the speed sensor are supported: - Proximity switch as per EN 60947-5-6; see Digital Inputs as per EN 60947-5-6 for Connecting Sensors [➙ 245] - Inductive signal transmitter at logic input DI15 Connections for isolated sensors

X5:1-2 (no preferential polarity)

Maximum signal voltage Internal resistance

±15 V 20 kΩ

Maximum input frequency

3 kHz

Maximum cross-section of the connecting cable wires

2.5 mm

2

Tab. 12 : Technical data for the inductive transmitter input

14.14.6.2

Digital Outputs

14.14.6.2.1

Relay Outputs

The unit has 11 equal rela y outputs and one relay output with special functions. The logical denotation of the outputs is determined by parameters using the software. LEDs beside plug X10 show the state of the outputs.

DANGER Life-threatening voltages The device must be installed in a housing that obstructs access to live components if the electronics are powered by dangerously high voltages (U > 40 V) or if there are dangerous voltages at the outputs. A tool must be required to open this housing. Alternatively, the device can be installed in a room accessible only to specialist personnel. If not installed in the housing, the live connections have protection class IP20 only. Therefore, great care should be taken if the housing is open. The supply voltage should be switched off before the housing is opened.

Number of outputs

12

Description Connections


DO1 ... DO12 Logic output

Plug

Pin NO contact

Pin root contact

Pin NC contact

DO1 DO2

X10: X10:

1 4

2 5

3 6

DO3

X11:

1

2

3

Contact type

Form C: Changeover con ac

Appendix

DO4

X11:

4

5

6

DO5

X13:

1

2

3

DO6

X13:

4

5

6

DO7

X14:

1

2

3

DO8

X14:

4

5

6

DO9

X15:

1

2

3

DO10 DO11

X15: X16:

4 1

5 2

6 -

DO12

X16:

3

4

-

X16

5

6

-

Form A: Closing contact

2


2.5 mm

Contact rating

DO01 – DO11: 230 VAC

Max. contact voltage

DO12: 24 VDC

Isolated against each other

230 VAC base isolation

Isolation against control low voltage

DO01 – DO11: 230 VAC double isolation (protective separation)

Max. switching current (ohmic load)

DO01 – DO11: 1.5 A DO12: 50 mA

Service life

6

DO01 – DO11: Minimum 20*10 cycles 6

DO12: Minimum 500*10 cycles

Note: DO12 is implemented twice and intended for the control of external electromechanical counters. Alternatively, the electronic output [➙ 249] DO13 can be used to control an external counter. The power for DO12 must

be taken from the integrated power supply of the VCU 20103. The figure shows the proper connections for X16: 5 and 6. X16: 3 and 4 have to be connected in a similar manner.

BV-H6411GB, 1221 - 248 -


Appendix

Fig. 32: Connection of an external totalizer at DO12

14.14.6.2.2

Electronic Output

An electronic output is available for signals that switch often. This connection is usually used if an electronic counter or the counter input of a controller programmable from memory for the integration of the required quantity of bulk material is to be attached. Number of outputs

1

Type

Open collector

Description Connections

DO13 X6: 1-2


2.5 mm

Contact rating

30 VDC

2

Max. voltage Isolation against control low voltage

63 VDC

Max. switching current (ohmic load)

50 mA

Fig. 33: Electronic output VCU 20103


Appendix

14.14.7 Analog Connections Assembly VCU 20103 is equipped with one analog output and two analog outputs. It can be backfitted with up to four further output channels (inputs or outputs).

14.14.7.1

Integrated Analog Input

Number of inputs

1

Connections

0V 0 … 20 mA

X6: 5 X6: 3

Ri = 100 Ω

0 … 10 V

X6: 4

Ri = 27 kΩ

Resolution

16 Bit

Maximum wire cross-section

2.5 mm

Isolated from all other voltages

230 VAC

2

Tab. 13 : Technical data of the analog input

This input is used primarily for setpoint entries.

14.14.7.2

Integrated Analog Outputs

The VCU 20103 has two analog outputs as standard. Type

Current output 0(4) – 20 mA; max. 11 V

Galvanic isolation

For 230 VAC, base isolation from all other voltages

Resolution

14 Bit


2.5 mm

Connections

A01

A02

14.14.7.3

2

X6:8

+U

X6:9

0V

X6:6

+U

X6:7

0V

Optional Analog Channels

It can be backfitted with up to four further output channels (inputs or outputs) in sockets A10 - A13 beneath the cover. Once the supply voltage has been shut off, the cover must be rem oved before they can be installed. The optional assemblies are installed on the lower circuit board and locked in place with the plastic retainer. The

BV-H6411GB, 1221 - 250 -


Appendix

additional equipment is identified by attaching the stickers supplied to the cover at the corresponding intended socket position. The analog channel connections are always available at plug X12, but have no function if the optional cards are not installed. The software must be informed that the optional cards have been installed using the parameter 2 settings in block 1. Maxim um cross-section of the connecting wire: 2.5 mm . Channel

Signal

Pin plug X12:

A10

0V

1

A11

A12

A13

Signal

2

0V

3

Signal

4

0V

5

Signal

6

0V

7

Signal

8

Tab. 14 : Connections

14.14.7.3.1

Analog Input VAI 20100

Fig. 34: VAI 20100: 1 analog input

Component type

Analog input VAI 20100

Circuit board

VAI0120

Input range

Bridge W100: 2-3

Bridge W100: 1-2

0(4) – 20 mA

0 – 10 V

Ri = 100 Ω

Ri = 35 kΩ

Resolution


16 Bit

Appendix

Galvanic isolation

14.14.7.3.2

For 230 VAC base isolation against control low voltage

Analog Outputs VAO 20100 / 20103

Fig. 35: VAO 20100 or VAO 20103: 1 analog output

Component type

Current output VAO 20100

Voltage output VAO 20103

Circuit board

VAO0120

VAO0123

Range

0(4) – 20 mA

0 – 10 V

max. 11 V

max. 50 mA

Galvanic isolation Resolution

For 230 VAC base isolation against control low voltage 14 Bit

14.15 Touchscreen Operating Panel VHM Operators and service personnel can use the VHM operating panel ('Human-Machine Interface') to operate comfortably the DISOCONT weighing electronics. It provides access to all parameters and process variables.

BV-H6411GB, 1221 - 252 -


Appendix

The VHM has a touchscreen for displa ying and entering inputs. This allows work to be carried out in harsh and dirty industrial environments. A lot of VHMs are only used for service jobs since the operation of a feeder often does not require an operator panel because it is controlled by the plant's process control system. This is why there is also a portable version available for mobile applications.

14.15.1 General Technical Data Display

5.7" color display 115 x 86 mm 320 x 240 pixel 400 cd/m

2

Contrast 600:1 Input

5.7" Resistive touch

Operating temperature range (outside the housing)

-20 ... +60°C

Storage temperature range

-40 ... +85°C

Humidity

20 ... 90 % relative humidity, non-condensing

Protection class

IP 65 from the front if correctly installed in the console panel or the housing. Rear protection depends on the housing.

Weight


1 kg

Appendix

Approbation

CE, UL, ATEX see separate chapter

14.15.2 Power Supply A) Working voltage for the VHM

The VHM can be supplied with DC voltage either by separate clamps (x4) or the ethernet interface (x3). Rated voltage UB:

24 VDC; 0.15 A

Power consumption:

3.5 W

Operating voltage range:

19 ... 32 VDC

Connection X4: (Phoenix Combicon housing part)

Maximum wire cross-section at plug: 1.5 mm

2

NOTE: power source can also be the VCU.

Connection X3: Ethernet socket ETH (RJ45) Precondition: VHM connected to VCU by means of a special cable to VCU:X96 (RJ45 red)

(CAUTION: NOT a PoE standard)

B) Auxiliary voltage for external devices

The VHM can supply peripherals with a regulated 5 V voltage supply: Connection X1: (Phoenix Combicon housing part)

BV-H6411GB, 1221 - 254 -


Appendix

This 5 V supply can also be drawn from connection VHM:X2 (type A USB socket).

14.15.3 Data Interfaces The device has the following interfaces: ▪

Ethernet

▪

Serial interfaces:

▪

USB (the software supports the connection of a bluetooth adapter only)

The data cable screens should be attached using the cable clam ps with a broad contact area to the plate.

14.15.3.1

Ethernet

We recommend that you connect device using the ethernet connection for distances of less than 100 m . The connection is made at socket X3 with a standard patch cable.

NOTE: Pins 4+5 and 7+8 can power the device as well as supply it with data signals. A special coded cable is required for a direct connection to the VCU. Refer to the chapter 'Power Supply' for details.

14.15.3.2

Serial Interfaces:

A serial interface is used to make connections over longer distances (> 100 m). The device has two serial interfaces, though in DISOCONT Tersus systems only the RS-485 interface is supported. NOTE: The device can be powered using the unassigned wires in the data cable from the VCU.


Appendix

RS-485 - connection X4: 1 + 2 (Phoenix Combicon housing part)

Maximum wire cross-section at plug: 1.5 mm 2 Bus termination W600: 1-2

RS-232 - connection X1: 1 + 2 + 3 (Phoenix Combicon housing part)

Maximum wire cross-section at plug: 1.5 mm

2

14.15.4 Housing Models 14.15.4.1

Built-In Console Panel Units

This equipment is intended for being installed in the front of a control cubicle or in operating panel. This equipment has a seal. They are pushed from the front into the opening and compactly pressed with the retention frame from behind to the sheet of the cutout. The contact surface has to be plane. The screws of the retention frame should be tightened with a torque of 3 Nm so that the entire front frame is lying on the sheet of the cutout. This ensures protection class IP 65 from the start. Excessive torques can cause damage to the frame. The back of the equipment has protection class IP 20. The housing has to ensure the protection against foreign matter and water that may be needed in the application with the built-in units that the equipment is built into.

BV-H6411GB, 1221 - 256 -


Appendix

14.15.4.1.1

VHM 20100 Basic Unit

Fig. 36: VHM 20100 Rear view with holding frame

Fig. 37: VHM 20100 Front view with holding frame


Appendix

Fig. 38: Dimensions VHM 20100

Console panel section (width x height): 186

+1.1

mm x 138

+1.1

mm

Size of the device front surface (width x height): 202 x 154 mm Power supply: 24 VDC (separate 24 V power supply unit or power supplied by the VCU)

14.15.4.1.2

VHM 20101 with Power Supply Unit

Built-in console panel unit with own power supply

BV-H6411GB, 1221 - 258 -


Appendix

Fig. 39: VHM 20101 Rear view

Fig. 40: Dimensions VHM 20101


Appendix

The power supply unit mounted on the rear increases the installation depth compared to the VHM 20100 by 70 mm. All other technical details and dimensions of the VHM 20101 are identical with those of the VHM 20100. Integrated power supply: Input 85 ... 264 VAC (nominal value: 110 ... 230 VAC) Output: 24 VDC wired to the operating panel electronics

14.15.4.2

Portable Devices

A portable device can be connected as needed for service work.

14.15.4.2.1

VHM 20110 with Cable Connection

Fig. 41: VHM 20110 with ethernet cable connection

Technical Data (if different from basic unit):

Model

VHM 20110

Protection class

IP65

BV-H6411GB, 1221 - 260 -


Appendix

Power Supply

24 VDC via data cable

Communication connections

Ethernet

Coded ethernet cable protection class IP 20; length 2 m

V079339.B02

Coded cable protection class IP 65 when plugged

Optional Extras and Accessories:

Functions

Model

Ethernet cable incl. power supply for connection to the VCU as protection class IP 20

VSC 20100

Ethernet cable incl. power supply for connection to the VCU as protection class IP 65 Carrying strap Holding frame for mounting locally the VHM 20110 at the scales

Fig. 42: Holding frame VHM 20110


Appendix

14.15.4.2.2

VHM 20121 Wireless

The holding frame for VHM 20100 is replaced on this device by a low cover plate that provides space for the battery power supply. The device has protection class IP if all charging inputs are sealed 65.

Fig. 43: VHM 201xx

The device is equipped with bluetooth adapter, batteries and a battery charger. To charge the batteries, open the cover in a clean environment and plug in the loading cable. The device can also be run with the loading cable plugged in permanently but will then have protection class IP 20 only. The on-off switch is located beside the screw connection for the charging unit.

The device can be powered for at least 3 hours if using new, fully-loaded batteries.

Technical Data (if different from basic unit):

Model

VHM 201xx

Protection class

IP65

Power Supply

Nickel metal hydride batteries (NiMH)

Charger connection

24 VDC (charge controller is built into the VHM)

BV-H6411GB, 1221 - 262 -


Appendix

Communication

Wireless to the VCU via Bluetooth

Accessories and Spare Parts:

Carrying strap Spare battery pack (device must be opened for replacement)

14.15.5 Connecting and Commissioning the Operating Panel The operating panel can communicate with the VCU via ethernet, RS-485 data cable or bluetooth (wireless). For reasons of safety we recommend using a cable connection for normal operation. The communication partner (VCU) can be selected at the VHM regardless of the connection type. However, this selection is made differently depending on the type. The mode of connection must be set at the operating panel.

14.15.5.1

Connecting the VHM Operating Panel via Ethernet

The shortest display buildup time and change times are achieved with an Ethernet connection. The connection can be permanent for normal operation or can be plugged as required for service access.

The connection is an RJ45 plug X3 on the operating panel. This plug can also supply power to the VHM via the data cable (not Power over Ethernet).

The following example connections can be combined, though for each a data connection and the power supply must be guaranteed.

Fig. 44: Example connection VHM with power supply via RJ 45


Appendix

The cables between the VCU and VHM have to maintain the Cat5e specification. It can either be connected with a prefabricated cable with a coded jack for the Ethernet X96 socket of the VCU or with cut goods and a cased coded jack for field mounting.

Fig. 45: Example connection network with alternatives for the power supply

14.15.5.2

Connection via RS-485

An RS-485 cable connection is selected if the distance between the operating panel and the VCU is greater than 100 m and there is no network available. No more than one operating panel can be operated at the sam e data bus.

BV-H6411GB, 1221 - 264 -


Appendix

Fig. 46: Example connection for long distance between operating panel and VCU

Fig. 47: Example connection operating panel with power supply from VCU

The communication cable must be terminated physically at both ends by a activatable bus term ination. An incorrect or no bus termination can lead to interruptions in the data transfer.

Bus termination plug

VCU: W410

VHM: W600 and W601

First and last device at the bus

Position 1-2

Position 1-2

All other devices

Position 2-3

Position 2-3

14.15.5.3


Caution: external influences can disturb the bluetooth connection. Safety considerations mean that the wireless connection may not be used for normal operation. For this reason bluetooth access is intended for service work only.


Appendix

Use the operating panel VHM 201xx with built-in bluetooth adapter to establish a bluetooth connection. Plug the VCU bluetooth adapter into the USB socket. In demanding circumstances the bluetooth adapter can be connected by cable and installed in a separate housing at a location more favorable for transm ission. The cable length may not exceed 10 m.

Bluetooth constructs a separate wireless TCP/IP network in a separate IP address range. The connection is established in stages. The connection is selected by choosing the bluetooth communication partner. The subordinate communication layers are then connected automatically.

The range of the bluetooth transmission depends heavily on the physical ambient conditions. Ranges of around 30 m are typical if the partners are within sight of each other (with no glass barrier between them).

14.16 Connecting EasyServe A computer on which the service software EasyServe is installed can be connected directly to sockets X93/94/95 on the VCU with a standard ethernet cable if this connection can be directly accessed. It can also be connected to the M12 jack with a special cable if the VCU is installed in a field housing. You can find instructions on special cables in the appropriate chapter in the appendix.

Note: Using other cables can cause damage to the computer.

EasyServe can also communicate with a VCU via WLAN. This requires installing an external wireless WLAN access point.

14.17 Prefabricated system cables Prefabricated VSC2xxxx cables are available for m aking it easier to connect the assemblies via Ethernet.

BV-H6411GB, 1221 - 266 -


Appendix

Fig. 48: M12 system cable for field cabling

Fig. 49: System cable for control cubicle installation

Fig. 50: Obsolete system cables (only used as spare parts)


Appendix

Type

Material no.

Length [m]

VSC20173

V079339.B01

1

V079339.B02

2

V079339.B03

5

VSC28000

V120820.B01

3

VSC28001

V120821.B01

0.13

VSC28003 VSC28004

V120823.B01 V120824.B01

3 0.2

Color

Red

Green

VSC28005

V120825.B01

4

RJ45/RJ45 standard Ethernet cables

V048409.B02

2

V130402.B01

30

Red

V130402.B01

30

Yellow

V130402.B01

30

Grey

V061894.B01

Cut-to-size area

Grey

Cat 5e Ethernet cables

Grey

RJ45 jack for packaging in the field without tools

Standard RJ45

V083761.B01

-

Coded for VCU X96

V083761.B02

-

V097862.B01

-

M12 plug

M12 plug, 8-pole

Obsolete cables (only used as spare parts)

VSC20170

V087748.B01

0.1

Black

VSC20171

V090181.B01

2.5

Yellow

VSC20172

V090274.B01

2

Red

Sealing cap for VSC20170

V087559.B01

-

Tab. 15 : Details of the system cables

Prefabricated assemblies are available for making it easier to connect VCU and VHM via RS485.

BV-H6411GB, 1221 - 268 -


Appendix

Fig. 51: Alternatives for connecting VHM via RS485

Used for great distances (not in an explosive atmosphere):

M12-5P 5-pole M12 plug/socket, not compatible to the Ethernet connection VAK 20170 Terminal box with socket Material: V095290.B01 VHM 20110-M12-5P The operating units with cables and plugs Material: V096478.B01

If connected in an explosive atmosphere:

EL Plug and socket for use in an explosive atmosphere VAK20170-3D Terminal box with socket Material: V095753.B01


Appendix

If connected in an explosive atmosphere:

VHM 20110-3D The operating units with cables and plugs Material: V064086.B01

14.18 WLAN access point The Ethernet network can also be extended wirelessly with an adapter by installing a WLAN access point. For reasons of safety, WLAN access may only be used for service work. We have only shown the procedure here schematically due to the fact that technology changes very rapidly in this detail. 1

Configure the WLAN access point with the service program supplied with the equipment. Encoding should be activated.The local regulations for WLAN networks should be complied with. The IP address of the adapter has to be in the IP subnet of the VCU.

2

Mechanically install the WLAN access point and connect the power supply

3

Establish an Ethernet connection between the WLAN access point and network with standard cables.

4

The WLAN adapter installed in the opposite mobile point provides a wireless network. The IP address should be set for this network. It has to be in the same IP subnet as that of the VCUs and it has to be unambiguous in the subnet.

5

The connection to the WLAN access point should be established in the mobile equipment.

6

The VCU of EasyServe or a browser is now accessed with the well-known methods.

Tab. 16 : W LAN access configuration

An example of a suitable WLAN access point Schenck Process Material Type

ALL0258

Protection class

IP 54

BV-H6411GB, 1221 - 270 -


Appendix

Power Supply

24VDC Plug-in power supply unit and PoE.Injector in the scope of supply

Fig. 52: WLAN access point ALL0258

14.19 Basics of EMC-Compliant Cabling All units of the DISOCONT Tersus have been designed and tested for the anti-interference required of a device in an industrial environment. They meet the following specifications: EN 61000-6-2 (Immunity to Interference for Industrial Environments) EN 61999-6-4 (Electromagnetic Interference for Industrial Environments) It is not authorized for use in living areas. Certain steps must be taken when cabling to guarantee the high interference resistance. The following figure shows correctly mounted cables. Insulate the cable in the area of the screen plate and contact the cable screen on the screen plate with the clamps included. Use cable binders to relieve tension.


Appendix

Fig. 53: Fix cable with cable binders and clamps

1

cable binders for the pull relief

2

Connecting cable shielding braid

3

Screen clamp

There are several slits beneath each cable lead-through. The cable clamps will press the cable screen against the shielding plate if they are inserted into these slits. This will correctly earth the screening. M-shaped slits can also be used as pull relief for cable binders.

14.19.1 Thoughts on the Cable Connections The small number components makes a DISOCONT Tersus system their quitequantity simple toand assemble. you should always of check to see what cables are required and whether size will Nevertheless fit through the existing lead-throughs (refer to the table in the section 'Accessories Recommended Cables'). →

The correct plug type for each input (and output) can be found in the technical specifications of the individual units, e.g. Phoenix MSTB, grid size 3.5 mm. Each type has a maximum cable diameter that can be used. The 2

maximum wire cross section for Phoenix MSTB plug-in connectors with a grid size of 5 mm is 2.5 mm , for 2 MSTB connectors with a grid size of 3.5 mm maximum 1.5 mm . Correct cabling is indispensable for optimal electromagnetic interference protection. Please follow the corresponding recommendations.

14.19.2 Screened Cables The screen of screened cables in generally connected at both ends to GND with a broad-contact connection. The DISOCONT Tersus is supplied with mounting plates that have an appropriate contact surface in the area around the cable feed. The outer sheathing is removed from the cables and the cables are then clamped with the special screen clamps against the contact surface. The screen shielding braid can also be attached to the mounting plates using a cable binder if clamps are not available.

BV-H6411GB, 1221 - 272 -


Appendix

If the contact point of the signal wires is far from the contact point of the screen, the screen should be left all the way up to the connecting point of the cable. Then the outer sheathing need only be removed from the cable at the contact point of the screen. The screen can then be fit as described above.

14.19.3 Unscreened Cables Unscreened cables can be strain relieved mechanically with the screening plate. There are T-shaped metal stays on the mounting plate to which cable binders can be connected.

14.20 EC Declaration of Conformity


Appendix

-s-

schenck proct'ss

EG-Konformitatserklarung Declaration of con formit y Hie11nIerkliirldas Unlernehm en I The Company

Schenck Pro cess GmbH, Pallas wiesenstr. 100,64293 Darms tadt, Deutschland die Konformitat des Produktcs I herewith declares c onformi ty of the product I

D SOCONT Tersus Wagesystem I Weighing system VCU 2010x, VHM 201xx, VFG 201x x Optional gefolgt von I Opiionsl followed by

-3D (ATEX Vari ante I ATEX variant )

mit folgenden einschlagigen Best mrnungen I with applicablo rcq1.1lations below EG - Richtline i I EC - Directive 20061951EG/EC (Niederspannung I Low 'loltage) 200411081EGIEC 94/9/EC

{Eiektromagnelische VerlfaglichkeI El ectromagnetic compatibility) (ATEX; nur Variante x-30 i valiant x-30 only )

Angewendc tc harmonisierte No rmen I Harmoniz ed standa rds app li ed EN 6020LI-1 2006 iiCI-te.R:-tEi fVOI M-\SCI-I!NEN"· ELEKTRISCf-IE AUSRVES1\INO VON SCHI JAtl GCI/.EI:-1£ ANOR:JERI,INGI;I-1 rE ;::-;-N;-6 -:-;---l-,200;;-1;--l-i;;;;;,;:.,;.;r';""OFi,i,oii ;; ;;s'rfi ;;:1;-0101

,:m ,;i, oi.;,;?. 'irroc: r:: L ·f

.·:.F:::L :.· ; ;en·

All GEMtiNt

N"OROEfliJ)o.QE;I\ SAF{TY RtCU.'R£l(£1flSf:O.'? F.I ECTRlCAt ED!JIPMFNT FDR MEASliRPMF!.'>n , 00.\fTRO/. AN ))(..1.BORATORV US£. GENER/IL REOu!foEr, •f'NT'/i

.

EN 61140

2002

$Q-1Uf:Z: <3-EC-:i N ELE'I.TRISCUEN SCt Lo\C. CE'·'e-NSAVE AW'ORDe UNOEN ru:n A'iLACii U N O 6£HHU$Ml fEl. AA'JT£CTKm J..GIJNT .. ELECTRiCSHOCK • CO.W J{)fVJ..SPf=CTSF
EN 61000-6-2

2005

CLOIO USTR E;BEREICHE ElECTROMAGNETiC 00\lP.ATIBfUTY 1/JUVN.'TV FOI< /# )JJS7>JVA EINIRON,'V.ENTS

EN 61000-6-4

2007

[ U:::'T<.HiRt'U . SSCHDUNG FUEii. DUSTRlESERE IC E Et.EC TF.C\'o(A$1\'ItTIC CO.\lFAnOttiTY(f MCJ, GfNF.RIC STANDARDSE·_t.(fSStQNSTANDARD FOR I!\'IJUS7R!M... E N•t•R.CN•LENTS

EN 60079-0

2009

txPLOStON l\£;11 Gt I."HIOS F't-ER € . it!L0:G.iiRAETE • AllGEM;tN£ I.N OU ; HUN:. ; l'"i EX?LOSIVE ;m.tOSP HEN.ES PM70.EOliiPMfNT ·
EN 60079-31

2009

GXPLOG:IONSF"AE!t G£ A. i/CSPHA ERE TEt! 3t; CERA!:ll: S.lNJ9£)if'.-0S! SSC>f'JfZI)Uf:.CHCEH;\ELISE"l• EXPLOSIVE ANOSPHEF
""

•

•

•

•

(ppa. Groll) (leiter Ent\hi(:klung/ Head nevelopmenU

BV-H6411GB, 1221 - 274 -


Index

Index .PAR Files ................................................................................................................................................................................ 50 2-Sensor Slip.......................................................................................................................................................................... 151 2-Sensor Slip active ............................................................................................................................................................... 151 2-sensor slip monitoring ......................................................................................................................................................... 216 About This Manual ..................................................................................................................................................................... 1 Access Rights Limitation FB................................................................................................................................................... 161 Access to Feeder Commands and Parameters........................................................................................................................ 49 Adaptation 1........................................................................................................................................................................... 122 Adaptation 2........................................................................................................................................................................... Address.......................................................................................................................................................................... 159, 122 160 Afterflow Measurement Time ................................................................................................................................................... 97 AI Moisture Measurement ..................................................................................................................................................... 123 Analog calibration................................................................................................................................................................... 147 Analog Channel A10 ................................................................................................................................................................ 79 Analog Channel A11 ................................................................................................................................................................ 80 Analog Channel A12 ................................................................................................................................................................ 80 Analog Channel A13 ................................................................................................................................................................ 80 Analog Connections ............................................................................................................................................................... 248 Analog I/O Points ..................................................................................................................................................................... 25 Analog Input 1 Max ................................................................................................................................................................ 147 Analog Input 1 Min ................................................................................................................................................................. 147 Analog Input 2 Max ................................................................................................................................................................ 147 Analog Input 2 Min ................................................................................................................................................................. 147 Analog Input 3 Max ................................................................................................................................................................ 147 Analog Input 3 Min ................................................................................................................................................................. 147 Analog Input 4 Max ................................................................................................................................................................ 148 Analog Input 4 Min ................................................................................................................................................................. 148 Analog Input 5 Max ................................................................................................................................................................ 148 Analog Input 5 Min ................................................................................................................................................................. 148 Analog Input VAI 20100 ......................................................................................................................................................... 249 Analog Output 1 Max ............................................................................................................................................................. 148 Analog Output 1 Min .............................................................................................................................................................. 148 Analog Output 1 Test Value ................................................................................................................................................... 150 Analog Output 2 Max ............................................................................................................................................................. 149 Analog Output 2 Min .............................................................................................................................................................. 148 Analog Output 2 Test Value ................................................................................................................................................... 150 Analog Output 3 Max ............................................................................................................................................................. 149 Analog Output 3 Min .............................................................................................................................................................. 149 Analog Output 3 Test Value ................................................................................................................................................... 150 Analog Output 4 Max ............................................................................................................................................................. 149 Analog Output 4 Min .............................................................................................................................................................. 149 Analog Output 4 Test Value ................................................................................................................................................... 150 Analog Output 5 Max ............................................................................................................................................................. 149 Analog Output 5 Min .............................................................................................................................................................. 149 Analog Output 5 Test Value ................................................................................................................................................... 151 Analog Output 6 Max ............................................................................................................................................................. 150 Analog Output 6 Min .............................................................................................................................................................. 150 Analog Output 6 Test Value ................................................................................................................................................... 151 Analog Outputs ...................................................................................................................................................................... 127 Analog Outputs VAO 20100 / 20103 ...................................................................................................................................... 250 Analog Trim Function ............................................................................................................................................................... 25 Angle ........................................................................................................................................................................................ 95 AO Actual Flow Rate............................................................................................................................................................. 127 AO Actual Flow Rate (2nd).................................................................................................................................................... 130 AO Belt Load......................................................................................................................................................................... 128 AO Density ............................................................................................................................................................................ 130 AO Deviation ......................................................................................................................................................................... 129 AO Flow Rate corrected........................................................................................................................................................ 124


Index

AO Flow Rate Offset............................................................................................................................................................. 125 AO Flow Rate Range ............................................................................................................................................................ 125 AO Motor Speed Control....................................................................................................................................................... 118 AO PLC 1 .............................................................................................................................................................................. 164 AO PLC 2 .............................................................................................................................................................................. 165 AO Setpoint........................................................................................................................................................................... 127 AO Speed.............................................................................................................................................................................. 129 Appendix ................................................................................................................................................................................ 205 Auxiliary Voltage for External Subscribers ............................................................................................................................. 238 Basic (CAL 1) ........................................................................................................................................................................... 20 Basic Tare .............................................................................................................................................................................. 117 Basics of EMC-Compliant Cabling ................................................................................................................................. 233, 269 Baud rate........................................................................................................................................................................ 159, 160 Baud Rate .............................................................................................................................................................................. 156 Belt Circuit No. ....................................................................................................................................................................... 117 Belt Circuit Time..................................................................................................................................................................... 116 Belt Drift ................................................................................................................................................................................. 108 Belt drift and slip identification via mark in the belt ................................................................................................................. 218 Belt Drift Monitoring.................................................................................................................................................................. 26 Belt Influence Compensation (BIC) .......................................................................................................................................... 28 Belt Load.................................................................................................................................................................................... 8 Belt Load Offset ..................................................................................................................................................................... 128 Belt Load Range .................................................................................................................................................................... 128 Belt Load, Nominal................................................................................................................................................................... 25 Belt Monitoring ......................................................................................................................................................................... 26 Belt Monitoring ....................................................................................................................................................................... 105 Belt Motion Monitor Delay ...................................................................................................................................................... 106 Belt Paddle Feedback Permissive.......................................................................................................................................... 135 Belt Skew ............................................................................................................................................................................... 109 Belt slip identification.............................................................................................................................................................. 216 Belt Slippage Monitoring .......................................................................................................................................................... 28 Belt Slippage with Belt Marking................................................................................................................................................ 28 Belt Speed.................................................................................................................................................................................. 9 BIC Active .............................................................................................................................................................................. 107 Built-In Console Panel Units................................................................................................................................................... 254 Bypass ................................................................................................................................................................................... 121 Byte Sequence....................................................................................................................................................................... 158 CA01 Event Error LC Input................................................................................................................................................... 182 CA02 Event Tachometer Input ............................................................................................................................................. 182 CA09 Event Primary Tacho Failure...................................................................................................................................... 182 Calculating the setpoint .......................................................................................................................................................... 205 Calibrating the Feeder.............................................................................................................................................................. 42 Calibration ........................................................................................................................................................................ 52, 182 Calibration ................................................................................................................................................................................ 18 Calibration Data ..................................................................................................................................................................... 115 Calibration probe location................................................................................................................................................... 20, 21 Calibration Probe Span .......................................................................................................................................................... 115 Calibration Weight.................................................................................................................................................................. 117 Calibration Weight Test ............................................................................................................................................................ 55 CC_FC speed controller......................................................................................................................................................... 120 Chain Motion Delay ................................................................................................................................................................ 126 Chain Test................................................................................................................................................................................ 55 Characteristic Value Sensor 1................................................................................................................................................ 152 Characteristic Value Sensor 2................................................................................................................................................ 152 Checking the Weight Measurement Instrumentation.............................................................................................................. 234 Cleanout control ..................................................................................................................................................................... 125 CleanOut ON OFFTime................................................................................................................................................................. Time............................................................................................................................................................... 126 CleanOut 126 CO01 Event Controller Limited............................................................................................................................................. 183 CO05 Event Volum. caused by LC-error.............................................................................................................................. 183 Codepage................................................................................................................................................................................. 87

BV-H6411GB, 1221 - 276 -


Index

Commonly Changed Parameters ............................................................................................................................................. 15 Communication EasyServe.................................................................................................................................................... 156 Communication Fieldbus........................................................................................................................................................ 157 Configuration.................................................................................................................................................................. 158, 162 Configuration HMI Values ...................................................................................................................................................... 178 Connecting a PC with EasyServe to a Scales Controller (VCU) .............................................................................................. 33 Connecting and Commissioning the Operating Panel............................................................................................................ 261 Connecting EasyServe........................................................................................................................................................... 264 Connecting the Sensors for Calibration Markers.................................................................................................................... 244 Connecting the Speed Sensor ............................................................................................................................................... 245 Connecting the VHM Operating Panel via Ethernet ............................................................................................................... 261 Connecting to Feeder............................................................................................................................................................... 48 Connection between a VHM Operating Panel and a Scales Controller (VCU)......................................................................... 31 Connection between a Web Browser and a VCU Scales Controller ........................................................................................ 34 Connection via Bluetooth ........................................................................................................................................... 32, 34, 263 Connection via Ethernet........................................................................................................................................................... 33 Connection via Ethernet Cable................................................................................................................................................. 32 Connection via RS-232 ............................................................................................................................................................ 33 Connection via RS485.............................................................................................................................................................. 32 Connection via RS-485 .......................................................................................................................................................... 262 Connection via WLAN .............................................................................................................................................................. 34 Control Offset speed controller............................................................................................................................................... 120 Control Sources ....................................................................................................................................................................... 88 Controller................................................................................................................................................................................ 183 Controller Magnitude Offset ................................................................................................................................................... 119 Counter 1 Unit .......................................................................................................................................................................... 83 Counter 2 Unit .......................................................................................................................................................................... 84 Counter 3 Unit .......................................................................................................................................................................... 84 Daily Total Time ..................................................................................................................................................................... 154 Damaged / Defective Electrical Components ............................................................................................................................. 6 Data Format ........................................................................................................................................................................... 160 Data Interfaces....................................................................................................................................................................... 253 Data Log Value 1 ................................................................................................................................................................... 154 Data Log Value 10 ................................................................................................................................................................. 156 Data Log Value 2 ................................................................................................................................................................... 155 Data Log Value 3 ................................................................................................................................................................... 155 Data Log Value 4 ................................................................................................................................................................... 155 Data Log Value 5 ................................................................................................................................................................... 155 Data Log Value 6 ................................................................................................................................................................... 155 Data Log Value 7 ................................................................................................................................................................... 155 Data Log Value 8 ................................................................................................................................................................... 156 Data Log Value 9 ................................................................................................................................................................... 156 Data Log Values....................................................................................................................................................................... 40 Data Logging.......................................................................................................................................................................... 154 DC_Mode ................................................................................................................................................................................. 87 Default Analog I/O .................................................................................................................................................................. 199 Default Digital Inputs .............................................................................................................................................................. 197 Default Digital Outputs ........................................................................................................................................................... 198 Default I/O Points ................................................................................................................................................................... 197 Definitions .................................................................................................................................................................................. 8 Density Offset......................................................................................................................................................................... 130 Density Range........................................................................................................................................................................ 130 Density Setpoint ....................................................................................................................................................................... 94 Deviation Offset...................................................................................................................................................................... 129 Deviation Range..................................................................................................................................................................... 129 DI Acknowledge Events ........................................................................................................................................................ 131 DI DI DI DI DI

Belt Monitor ........................................................................................................................................................... BIC fMotion reeze......................................................................................................................................................................... Chain Motion Monitor........................................................................................................................................................ Coal Flow Monitor ............................................................................................................................................................. Coal on belt switch............................................................................................................................................................


105 107 126 136 134

Index

DI DI DI DI DI DI DI DI DI DI DI DI

Discharge Pluggage ......................................................................................................................................................... 133 External Event 1 ............................................................................................................................................................... 132 External Event 2 ............................................................................................................................................................... 138 External Event 3 ............................................................................................................................................................... 139 External Event 4 ............................................................................................................................................................... 140 Jog backward ................................................................................................................................................................... 138 Jog forward....................................................................................................................................................................... 138 Local Mode ....................................................................................................................................................................... 131 Local Start ........................................................................................................................................................................ 137 Lower Setpoint.................................................................................................................................................................... 90 Mode Switch Lock............................................................................................................................................................. 140 Motor feedback................................................................................................................................................................. 135

DI OFF/Maint CTRL .............................................................................................................................................................. 137 DI Raise Setpoint .................................................................................................................................................................... 90 DI Remote CTRL................................................................................................................................................................... 137 DI Reset Totalizer 1 .............................................................................................................................................................. 132 DI Reset Totalizer 2 .............................................................................................................................................................. 132 DI Sensor 1 ........................................................................................................................................................................... 151 DI Sensor 2 ........................................................................................................................................................................... 152 DI Source Belt Sensor........................................................................................................................................................... 106 DI Volumetric Mode............................................................................................................................................................... 140 Digital Connections ................................................................................................................................................................ 241 Digital inputs........................................................................................................................................................................... 241 Digital Inputs .......................................................................................................................................................................... 131 Digital Inputs 24 VDC for General Use ................................................................................................................................... 241 Digital Inputs as per EN 60947-5-6 for Connecting Sensors.................................................................................................. 243 Digital Outputs........................................................................................................................................................................ 245 Digital Outputs........................................................................................................................................................................ 140 Dimensions and Position of the Plugs .................................................................................................................................... 236 Discharge Pluggage Delay..................................................................................................................................................... 133 Display Formats ....................................................................................................................................................................... 82 Display Functions..................................................................................................................................................................... 38 DO Actual Flow Rate MAX .................................................................................................................................................... 143 DO Actual Flow Rate MIN ..................................................................................................................................................... 143 DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO

ALARM ........................................................................................................................................................................... 142 ALARM (2nd) .................................................................................................................................................................. 142 Belt Drift .......................................................................................................................................................................... 109 Belt Skew........................................................................................................................................................................ 109 Belt Slip........................................................................................................................................................................... 108 CleanOut Timer .............................................................................................................................................................. 125 Deviation......................................................................................................................................................................... 143 Dual Tacho active ........................................................................................................................................................... 105 Feeder Run Forward....................................................................................................................................................... 141 Feeder Run Forward (2nd) ............................................................................................................................................. 141 Feeder Run Reverse....................................................................................................................................................... 142 Feeder Run Reverse (2nd) ............................................................................................................................................. 142 Feeder running (2nd) ...................................................................................................................................................... 141 Feeder Started................................................................................................................................................................ 141 Feeding........................................................................................................................................................................... 146 Feeding (2nd) ................................................................................................................................................................. 146 FRI Frequency .................................................................................................................................................................. 87 Load MAX ....................................................................................................................................................................... 144 Load MIN ........................................................................................................................................................................ 143 Local Mode ..................................................................................................................................................................... 145 Moisture active................................................................................................................................................................ 124 Moisture MAX ................................................................................................................................................................. 124

DO DO DO DO DO

PLC 2 1 .............................................................................................................................................................................. .............................................................................................................................................................................. PLC PLC 3 .............................................................................................................................................................................. PLC 4 .............................................................................................................................................................................. PLC 5 ..............................................................................................................................................................................

BV-H6411GB, 1221 - 278 -

163 163 163 164 164


Index

DO DO DO DO DO DO DO DO DO DO DO DO

PLC 6 .............................................................................................................................................................................. 164 PLC 7 .............................................................................................................................................................................. 164 PLC 8 .............................................................................................................................................................................. 164 Pulse Counter ................................................................................................................................................................... 84 Remote CTRL ................................................................................................................................................................. 146 Remote CTRL (2nd)........................................................................................................................................................ 146 Scale Start ...................................................................................................................................................................... 140 Slip 2............................................................................................................................................................................... 153 Speed MAX..................................................................................................................................................................... 144 Speed MIN...................................................................................................................................................................... 144 Start Prefeeder ............................................................................................................................................................... 142 Volumetric Mode ............................................................................................................................................................. 144

DO Volumetric Mode (2nd).................................................................................................................................................... 145 DO WARNING ...................................................................................................................................................................... 145 DO WARNING (2nd) ............................................................................................................................................................. 145 DT-9 Parameter List ................................................................................................................................................................. 62 DT-9 Setup............................................................................................................................................................................... 13 EC Declaration of Conformity................................................................................................................................................. 271 Effective Platform Length ......................................................................................................................................................... 94 Electrical System.................................................................................................................................................................... 183 Electronic Output.................................................................................................................................................................... 247 Ethernet.................................................................................................................................................................................. 253 Ethernet.................................................................................................................................................................................. 162 Ethernet Addressing............................................................................................................................................................... 229 Ethernet Hardware ................................................................................................................................................................. 228 Event Actual Flow Rate MAX ........................................................................................................................................ 112, 187 Event Actual Flow Rate MIN ......................................................................................................................................... 111, 192 Event Acyclic Communication ....................................................................................................................................... 162, 196 Event Analog Input < Offset.......................................................................................................................................... 104, 184 Event Belt Drift .............................................................................................................................................................. 109, 188 Event Belt Motion Monitor ............................................................................................................................................. 106, 190 Event Belt Skew ............................................................................................................................................................ 109, 188 Event Chain Motion Monitor .......................................................................................................................................... 127, 189 Event Coal Flow ............................................................................................................................................................ 137, 191 Event Event Event Event Event Event Event Event Event Event Event Event Event Event Event Event Event Event Event Event Event Event

Coal on Belt ........................................................................................................................................................ 135, 191 Communication ARM7 .......................................................................................................................................... 79, 196 Communication HMI 1................................................................................................................................................... 78 Communication VHM serial......................................................................................................................................... 195 Controller Limited................................................................................................................................................ 103, 183 Cyclic Communication......................................................................................................................................... 157, 195 Deviation ............................................................................................................................................................. 103, 188 Discharge Pluggage............................................................................................................................................ 133, 189 Error LC Input ....................................................................................................................................................... 99, 182 External Event 1.................................................................................................................................................. 131, 194 External Event 2.................................................................................................................................................. 138, 194 External Event 3.................................................................................................................................................. 139, 194 External Event 4.................................................................................................................................................. 139, 194 FCB-Error............................................................................................................................................................ 173, 185 LC Input < MIN.................................................................................................................................................... 100, 191 LC Input > MAX................................................................................................................................................... 100, 186 Load MAX ........................................................................................................................................................... 113, 187 Load MIN ............................................................................................................................................................ 112, 192 Loss of Material................................................................................................................................................... 134, 190 Maint. Electric...................................................................................................................................................... 153, 193 Maint.Feeder Run ............................................................................................................................................... 153, 193 Memory ............................................................................................................................................................... 104, 195

Event Event Event Event Event

Moisture MAX...................................................................................................................................................... 124, 190 185 Motor Start .......................................................................................................................................................... 136, NAMUR Error V103-DI13 .................................................................................................................................... 132, 184 NAMUR Error V103-DI14 .................................................................................................................................... 132, 184 Power Failure...................................................................................................................................................... 101, 183


Index

Event Event Event Event Event Event Event Event Event Event Event Event

Primary Tacho Failure......................................................................................................................................... 105, 182 Remote TCI too small ........................................................................................................................................... 86, 186 Run Disabled ........................................................................................................................................................ 91, 184 Setpoint Limited .................................................................................................................................................. 101, 192 Slip ...................................................................................................................................................................... 107, 188 Slip 2 ................................................................................................................................................................... 152, 189 Speed MAX ......................................................................................................................................................... 114, 187 Speed MIN .......................................................................................................................................................... 113, 192 Stand-By ............................................................................................................................................................... 98, 193 Tachometer Input .................................................................................................................................................. 99, 182 Temperature-MAX............................................................................................................................................... 114, 186 Volum. caused by LC-error ................................................................................................................................... 97, 183

Event (Error) Messages ......................................................................................................................................................... 181 Event Group: Calibration........................................................................................................................................................ 182 Event Group: Controller.......................................................................................................................................................... 183 Event Group: Electrical System.............................................................................................................................................. 183 Event Group: Interlock............................................................................................................................................................ 184 Event Group: Material Flow.................................................................................................................................................... 185 Event Group: MAX ................................................................................................................................................................. 186 Event Group: Mechanic.......................................................................................................................................................... 188 Event Group: MIN .................................................................................................................................................................. 191 Event Group: Sequence Monitoring ....................................................................................................................................... 192 Event Group: System Message.............................................................................................................................................. 195 Event Groups ................................................................................................................................................................... 61, 181 Event Log Values ..................................................................................................................................................................... 40 Events ...................................................................................................................................................................................... 52 Events Details ........................................................................................................................................................................ 182 Exiting HMI Configuration......................................................................................................................................................... 38 Expert Mode............................................................................................................................................................................. 51 Factor Deviation ..................................................................................................................................................................... 102 FCB analog outputs ............................................................................................................................................................... 169 FCB digital outputs................................................................................................................................................................. 174 FCB Variant............................................................................................................................................................................ 173 FCB_AO 01 ............................................................................................................................................................................ 169 FCB_AO 02 ............................................................................................................................................................................ FCB_AO 03 ............................................................................................................................................................................ FCB_AO 04 ............................................................................................................................................................................ FCB_AO 05 ............................................................................................................................................................................ FCB_DO 01............................................................................................................................................................................ FCB_DO 02............................................................................................................................................................................ FCB_DO 03............................................................................................................................................................................ FCB_DO 04............................................................................................................................................................................ FCB_DO 05............................................................................................................................................................................ FCB_DO 06............................................................................................................................................................................ FCB_DO 07............................................................................................................................................................................ FCB_DO 08............................................................................................................................................................................ FCB_DO 09............................................................................................................................................................................ FCB_DO 10............................................................................................................................................................................ FCB_DO 11............................................................................................................................................................................ FCB_DO 12............................................................................................................................................................................ FCB_DO 13............................................................................................................................................................................ FCB_DO 14............................................................................................................................................................................ FCB_DO 15............................................................................................................................................................................ FCB_DO 16............................................................................................................................................................................ FCB_DO 17............................................................................................................................................................................ FCB_DO 18............................................................................................................................................................................

169 170 171 172 174 174 174 175 175 175 175 175 175 175 176 176 176 176 176 176 177 177

FCB_DO 20............................................................................................................................................................................ 19............................................................................................................................................................................ 177 177 FCB_DO Feed rate controller (CTRL) ................................................................................................................................................... 212 Feedback Filter Override Threshold ....................................................................................................................................... 110 Feeder control .......................................................................................................................................................................... 97

BV-H6411GB, 1221 - 280 -


Index

Feeder Definition...................................................................................................................................................................... 80 Feeder Monitoring .................................................................................................................................................................... 98 Feeder Start ............................................................................................................................................................................. 88 Feedrate Control ........................................................................................................................................................................ 9 Feedrate Setpoint..................................................................................................................................................................... 88 Fig. 1: Weigh Roller Adjustment ............................................................................................................................................... 19 Fig. 10: Belt drift and slip measurement ................................................................................................................................. 219 Fig. 11: The VCF monitoring mechanism ............................................................................................................................... 220 Fig. 12: A block diagram of moisture correction ..................................................................................................................... 221 Fig. 13: Example of a function block link ................................................................................................................................ 222 Fig. 14: Binary function blocks ............................................................................................................................................... 224 Fig. 15: Analog function blocks .............................................................................................................................................. 225 Fig. 16: Alternative 'series connection' link between basic units and the on-site ethernet...................................................... 228 Fig. 17: Alternative 'star connection' link between basic units and the on-site ethernet ......................................................... 229 Fig. 18: Possible RS-485 connections ................................................................................................................................... 232 Fig. 19: Bus termination for the transmission cable................................................................................................................ 232 Fig. 2: Principle of belt-drift monitoring..................................................................................................................................... 26 Fig. 20: RS-485 bus wiring ..................................................................................................................................................... 233 Fig. 21: Fix cable with cable binders and clamps................................................................................................................... 233 Fig. 22: Test Connector.......................................................................................................................................................... 235 Fig. 23: VCU 20103 in 3D representation with mounting kit ................................................................................................... 235 Fig. 24: Dimensions and position of the plugs VCU 20103 with mounting ki t......................................................................... 236 Fig. 25: VME0120: Load cell connection, Pin 1 (X91 or X92)................................................................................................. 239 Fig. 26: VME0120: Load cell input X91 or X92....................................................................................................................... 240 Fig. 27: Digital input: switching contact connection ................................................................................................................ 242 Fig. 28: Digital input: external signal voltage connection........................................................................................................ 242 Fig. 29: Connecting a two-wire sensor ................................................................................................................................... 243 Fig. 3: Block diagram for calculating the setpoint ................................................................................................................... 205 Fig. 30: Digital input: connecting a sensor or a contact at the sensor input............................................................................ 244 Fig. 31: Digital input: connecting an external signal voltage at the sensor input .................................................................... 244 Fig. 32: Connection of an external totalizer at DO12.............................................................................................................. 247 Fig. 33: Electronic output VCU 20103 .................................................................................................................................... 247 Fig. 34: VAI 20100: 1 analog input ......................................................................................................................................... 249 Fig. 35: VAO 20100 or VAO 20103: 1 analog output ............................................................................................................. 250 Fig. 36: VHM 20100 Rear view with holding frame ................................................................................................................ 255 Fig. 37: VHM 20100 Front view with holding frame................................................................................................................ 255 Fig. 38: Dimensions VHM 20100............................................................................................................................................ 256 Fig. 39: VHM 20101 Rear view .............................................................................................................................................. 257 Fig. 4: Switch-on logic ............................................................................................................................................................ 206 Fig. 40: Dimensions VHM 20101............................................................................................................................................ 257 Fig. 41: VHM 20110 with ethernet cable connection .............................................................................................................. 258 Fig. 42: Holding frame VHM 20110 ........................................................................................................................................ 259 Fig. 43: VHM 201xx................................................................................................................................................................ 260 Fig. 44: Example connection VHM with power supply via RJ 45 ............................................................................................ 261 Fig. 45: Example connection network with alternatives for the power supply......................................................................... 262 Fig. 46: Example connection for long distance between operating panel and VCU ............................................................... 263 Fig. 47: Example connection operating panel with power supply from VCU.......................................................................... 263 Fig. 48: M12 system cable for field cabling ............................................................................................................................ 265 Fig. 49: System cable for control cubicle installation.............................................................................................................. 265 Fig. 5: Measuring the feed rate (MEASURE) ......................................................................................................................... 210 Fig. 50: Obsolete system cables (only used as spare parts) .................................................................................................. 265 Fig. 51: Alternatives for connecting VHM via RS485.............................................................................................................. 267 Fig. 52: WLAN access point ALL0258.................................................................................................................................... 269 Fig. 53: Fix cable with cable binders and clamps................................................................................................................... 270 Fig. 6: Feed rate control (CTRL) ............................................................................................................................................ 212 Fig. 7: Effect of the controller parameters on the controller output with a discontinuous control deviation on t=0.................. 214 Fig. 9: 8: 2-sensor Upper controller magnitude........................................................................................................................................... limit.................................................................................................................................. 217 216 Fig. slip identification Filter Actual Flow Rate .......................................................................................................................................................... 110 Filter Actual Flow Rate analog .............................................................................................................................................. 110 Filter Belt Load ...................................................................................................................................................................... 111


Index

Filter Belt Speed.................................................................................................................................................................... 111 Filter Deviation ...................................................................................................................................................................... 111 Filters ..................................................................................................................................................................................... 110 Five Safety Rules of ElectricalEngineering................................................................................................................................ 6 Fixed mode configuration ....................................................................................................................................................... 165 FLOAT-Format ....................................................................................................................................................................... 160 Flow Rate Offset .................................................................................................................................................................... 128 Flow Rate Range ................................................................................................................................................................... 128 Flow Rate Units........................................................................................................................................................................ 83 Format Data ........................................................................................................................................................................... 156 Function Blocks for Analog Signals........................................................................................................................................ 225 Function Blocks for Binary Signals......................................................................................................................................... 223 Gateway................................................................................................................................................................................. 163 Gateway................................................................................................................................................................................. 230 General Information ................................................................................................................................................................. 57 General Technical Data.................................................................................................................................................. 237, 251 Gravimetric............................................................................................................................................................................... 10 Handling the Function Blocks................................................................................................................................................. 223 Hardware Modules................................................................................................................................................................... 78 HI01 Event LC Input > MAX ................................................................................................................................................. 186 HI02 Event Actual Flow Rate MAX............................................................................................... ................................ ........ 187 HI03 Event Load MAX.......................................................................................................................................................... 187 HI04 Event Speed MAX ....................................................................................................................................................... 187 HI05 Event Deviation............................................................................................................................................................ 188 HMI Value 01 ......................................................................................................................................................................... 178 HMI Value 02 ......................................................................................................................................................................... 178 HMI Value 03 ......................................................................................................................................................................... 178 HMI Value 04 ......................................................................................................................................................................... 178 HMI Value 05 ......................................................................................................................................................................... 178 HMI Value 06 ......................................................................................................................................................................... 178 HMI Value 07 ......................................................................................................................................................................... 178 HMI Value 08 ......................................................................................................................................................................... 179 HMI Value 09 ......................................................................................................................................................................... 179 HMI Value 10 ......................................................................................................................................................................... 179 Hourly Total Time................................................................................................................................................................... Housing Models ..................................................................................................................................................................... I-Component TN..................................................................................................................................................................... ID Preset Value 1 ................................................................................................................................................................... ID Preset Value 2 ................................................................................................................................................................... ID Preset Value 3 ................................................................................................................................................................... ID Preset Value 4 ................................................................................................................................................................... ID Preset Value 5 ................................................................................................................................................................... ID Preset Value 6 ................................................................................................................................................................... ID Preset Value 7 ................................................................................................................................................................... ID Preset Value 8 ................................................................................................................................................................... ID Read Value 1..................................................................................................................................................................... ID Read Value 10................................................................................................................................................................... ID Read Value 11................................................................................................................................................................... ID Read Value 12................................................................................................................................................................... ID Read Value 13................................................................................................................................................................... ID Read Value 14................................................................................................................................................................... ID Read Value 15................................................................................................................................................................... ID Read Value 16................................................................................................................................................................... ID Read Value 2..................................................................................................................................................................... ID Read Value 3..................................................................................................................................................................... ID Read Value 4.....................................................................................................................................................................

154 254 118 165 165 165 165 166 166 166 166 166 168 168 168 168 168 168 168 166 167 167

ID Read Read Value Value 6..................................................................................................................................................................... 5..................................................................................................................................................................... ID ID Read Value 7..................................................................................................................................................................... ID Read Value 8..................................................................................................................................................................... ID Read Value 9.....................................................................................................................................................................

167 167 167 167 167

BV-H6411GB, 1221 - 282 -


Index

IL01 Event Run Disabled...................................................................................................................................................... 184 IL10 Event FCB-Error........................................................................................................................................................... 185 Initial Configuration .................................................................................................................................................................. 37 Installation ................................................................................................................................................................................ 47 Integrated Analog Input.......................................................................................................................................................... 248 Integrated Analog Outputs ..................................................................................................................................................... 248 Interlock.................................................................................................................................................................................. 184 IP Address...................................................................................................................................................................... 162, 230 IP Addressing......................................................................................................................................................................... 229 KP speed controller................................................................................................................................................................ 120 Language ................................................................................................................................................................................. 80 LB: Pulses per Belt................................................................................................................................................................... 24 LC Characteristic Value............................................................................................................................................................ 94 LC Filter.................................................................................................................................................................................. 110 LC Rated Capacity ................................................................................................................................................................... 94 Level/Temperatur Sensor Delay............................................................................................................................................. 136 Lever Ratio............................................................................................................................................................................... 95 Limit Actual Flow Rate MAX.................................................................................................................................................. 112 Limit Actual Flow Rate MIN ................................................................................................................................................... 111 Limit Load MAX ..................................................................................................................................................................... 113 Limit Load MIN ...................................................................................................................................................................... 112 Limit Speed MAX .................................................................................................................................................................. 114 Limit Speed MIN.................................................................................................................................................................... 113 Limit Values............................................................................................................................................................................ 111 LO01 Event LC Input < MIN ................................................................................................................................................. 191 LO02 Event Actual Flow Rate MIN....................................................................................................................................... 192 LO03 Event Load MIN.......................................................................................................................................................... 192 LO04 Event Speed MIN ....................................................................................................................................................... 192 Load Cell Input VME0120 ...................................................................................................................................................... 238 Load cross section ................................................................................................................................................................... 96 Loading Custom Default Parameters ....................................................................................................................................... 50 Loading Factory Default Parameters........................................................................................................................................ 51 Logger cycle time ................................................................................................................................................................... 154 Loss of Flow Trip Delay.......................................................................................................................................................... 134 Lower Limit............................................................................................................................................................................. 119 MAC Addresses ..................................................................................................................................................................... 229 Maintenance Electric .............................................................................................................................................................. 153 Maintenance Feeder Run....................................................................................................................................................... 153 Maintenance interval .............................................................................................................................................................. 153 Maintenance Speed ................................................................................................................................................................. 86 Material Flow.......................................................................................................................................................................... 185 Material Test ............................................................................................................................................................................ 56 MAX ....................................................................................................................................................................................... 186 Maximum Feedrate .................................................................................................................................................................. 89 Measuring Principle.................................................................................................................................................................... 8 Measuring the feed rate (MEASURE).................................................................................................................................... 208 Mechanic................................................................................................................................................................................ 188 MF05 Event Moisture MAX .................................................................................................................................................. 185 MF13 Event Temperature-MAX ........................................................................................................................................... 186 MF14 Event Remote TCI too small ...................................................................................................................................... 186 MIN......................................................................................................................................................................................... 191 Minimum Feedrate ................................................................................................................................................................... 90 Minimum System Requirements .............................................................................................................................................. 47 Modbus-Version ..................................................................................................................................................................... 158 Mode Select Enable/Disable .................................................................................................................................................... 92 Moist correction (MOIST) ....................................................................................................................................................... 221 Moisture ................................................................................................................................................................................. Moisture Active....................................................................................................................................................................... Moisture MAX......................................................................................................................................................................... Moisture Offset....................................................................................................................................................................... Moisture Range......................................................................................................................................................................


122 122 124 123 123

Index

Moisture Select ...................................................................................................................................................................... 122 Monitoring Standstill after Startup ............................................................................................................................................ 28 Monitoring the mechanism ..................................................................................................................................................... 220 Motion monitoring (BMM) ....................................................................................................................................................... 216 Net Mask ................................................................................................................................................................................ 163 Nominal Belt Load.................................................................................................................................................................... 25 Nominal Flow Rate................................................................................................................................................................... 81 Nominal Moisture ................................................................................................................................................................... 123 Nominal Speed......................................................................................................................................................................... 82 Offset FCB_AO 1................................................................................................................................................................... 169 Offset FCB_AO 2................................................................................................................................................................... 170 Offset FCB_AO 3................................................................................................................................................................... 170 Offset FCB_AO 4................................................................................................................................................................... 171 Offset FCB_AO 5................................................................................................................................................................... 172 Operating and Control Access ................................................................................................................................................. 31 Operating Modes – OFF/Maintenance..................................................................................................................................... 10 Operating Modes - Remote ...................................................................................................................................................... 10 Operating the Feeder ............................................................................................................................................................... 52 Operating the HMI in 'Off/Maintenance' Mode.......................................................................................................................... 39 Operating the HMI in 'Remote' Mode ....................................................................................................................................... 39 Operation Using EasyServe ..................................................................................................................................................... 47 Operation Using the 196NT Display......................................................................................................................................... 45 Operation Using the Touch Screen HMI................................................................................................................................... 37 Optional Analog Channels...................................................................................................................................................... 248 Options..................................................................................................................................................................................... 54 Overview .................................................................................................................................................................................... 7 Own Address.......................................................................................................................................................................... 156 P01 - Hardware Modules.......................................................................................................................................................... 78 P01.01 - Event Communication HMI 1 .................................................................................................................................... 78 P01.02 - Event Communication ARM7.................................................................................................................................... 79 P01.03 - Analog Channel A10.................................................................................................................................................. 79 P01.04 - Analog Channel A11.................................................................................................................................................. 80 P01.05 - Analog Channel A12.................................................................................................................................................. 80 P01.06 - Analog Channel A13.................................................................................................................................................. 80 P02 - Feeder Definition ............................................................................................................................................................ 80 P02.01 - Language................................................................................................................................................................... 80 P02.02 - Units .......................................................................................................................................................................... 81 P02.03 - Scale Name ............................................................................................................................................................... 81 P02.04 - Password ................................................................................................................................................................... 81 P02.05 - Nominal Flow Rate .................................................................................................................................................... 81 P02.06 - Nominal Speed .......................................................................................................................................................... 82 P02.07 - Display Formats......................................................................................................................................................... 82 P02.08 - Flow Rate Units ......................................................................................................................................................... 83 P02.09 - Counter 1 Unit............................................................................................................................................................ 83 P02.10 - Counter 2 Unit............................................................................................................................................................ 84 P02.11 - Counter 3 Unit............................................................................................................................................................ 84 P02.12 - DO Pulse Counter..................................................................................................................................................... 84 P02.13 - Totalizer Increment .................................................................................................................................................... 85 P02.14 - Pulse Length Total..................................................................................................................................................... 85 P02.15 - Event Remote TCI too small ..................................................................................................................................... 86 P02.16 - Maintenance Speed................................................................................................................................................... 86 P02.17 - DO FRI Frequency.................................................................................................................................................... 87 P02.18 - Remote FRI Frequency ............................................................................................................................................. 87 P02.20 - Codepage .................................................................................................................................................................. 87 P02.21 - DC_Mode................................................................................................................................................................... 87 P03 - Control Sources .............................................................................................................................................................. 88 P03.01 -- Feedrate Feeder Star t............................................................................................................................................................... 88 Setpoint ...................................................................................................................................................... 88 P03.02 P03.03 - Setpoint Range .......................................................................................................................................................... 89 P03.04 - Setpoint Offset ........................................................................................................................................................... 89 P03.05 - Maximum Feedrate.................................................................................................................................................... 89

BV-H6411GB, 1221 - 284 -


Index

P03.06 - Minimum Feedrate..................................................................................................................................................... 90 P03.07 - DI Raise Setpoint...................................................................................................................................................... 90 P03.08 - DI Lower Setpoint ..................................................................................................................................................... 90 P03.09 - Raise/Lower Response Time..................................................................................................................................... 91 P03.10 - Source Run Enable.................................................................................................................................................... 91 P03.11 - Event Run Disabled.................................................................................................................................................. 91 P03.12 - Mode Select Enable/Disable...................................................................................................................................... 92 P03.13 - Speed Setpoint .......................................................................................................................................................... 93 P03.14 - Run Mode Select ....................................................................................................................................................... 93 P03.15 - Density Setpoint......................................................................................................................................................... 94 P04 - Rated Data ..................................................................................................................................................................... 94 P04.01 - LC Characteristic Value ............................................................................................................................................. 94 P04.02 - LC Rated Capacity..................................................................................................................................................... 94 P04.03 - Effective Platform Length........................................................................................................................................... 94 P04.04 - Lever Ratio ................................................................................................................................................................ 95 P04.05 - Angle ......................................................................................................................................................................... 95 P04.06 - Speed Measurement ................................................................................................................................................. 95 P04.07 - Source Load Cell ....................................................................................................................................................... 96 P04.08 - Source Load Cell 2 .................................................................................................................................................... 96 P04.09 - Tachometer Pulses per Rev ..................................................................................................................................... 96 P04.10 - Load cross section..................................................................................................................................................... 96 P05 - Feeder control ................................................................................................................................................................ 97 P05.01 - Volum on LC failure ................................................................................................................................................... 97 P05.02 - Event Volum. caused by LC-error ............................................................................................................................. 97 P05.03 - Afterflow Measurement Time ..................................................................................................................................... 97 P05.04 - Zero Drop-Out Active................................................................................................................................................. 98 P05.05 - Zero Drop-Out Limit ................................................................................................................................................... 98 P06 - Feeder Monitoring........................................................................................................................................................... 98 P06.01 - Event Stand-By......................................................................................................................................................... 98 P06.02 - Stand-By Limit Value ................................................................................................................................................. 99 P06.03 - Event Tachometer Input ........................................................................................................................................... 99 P06.04 - Event Error LC Input ................................................................................................................................................. 99 P06.05 - Event LC Input < MIN ............................................................................................................................................. 100 P06.06 - Event LC Input > MAX ............................................................................................................................................ 100 P06.07 - Event Setpoint Limited............................................................................................................................................ 101 P06.08 - Event Power Failure ............................................................................................................................................... 101 P06.09 - Time Deviation......................................................................................................................................................... 102 P06.10 - Threshold Deviation................................................................................................................................................. 102 P06.11 - Factor Deviation....................................................................................................................................................... 102 P06.12 - Event Deviation....................................................................................................................................................... 103 P06.13 - Event Controller Limited ......................................................................................................................................... 103 P06.14 - Event Memory......................................................................................................................................................... 104 P06.15 - Event Analog Input < Offset.................................................................................................................................... 104 P06.16 - DO Dual Tacho active............................................................................................................................................. 105 P06.17 - Event Primary Tacho Failure .................................................................................................................................. 105 P07 - Belt Monitoring.............................................................................................................................................................. 105 P07.01 - DI Belt Motion Monitor ............................................................................................................................................ 105 P07.02 - Belt Motion Monitor Delay ........................................................................................................................................ 106 P07.03 - Event Belt Motion Monitor ....................................................................................................................................... 106 P07.04 - DI Source Belt Sensor ............................................................................................................................................ 106 P07.05 - BIC Active................................................................................................................................................................ 107 P07.06 - DI BIC freeze ..........................................................................................................................................................107 P07.07 - Slip Value ................................................................................................................................................................ 107 P07.08 - Event Slip ............................................................................................................................................................... 107 P07.09 - DO Belt Slip ............................................................................................................................................................ 108 P07.10 - Sensor Length ......................................................................................................................................................... 108 P07.11 -- Sensor Sensor Off Width ........................................................................................................................................................... P07.12 set........................................................................................................................................................... P07.13 - Belt Drift ................................................................................................................................................................... P07.14 - Event Belt Drift........................................................................................................................................................ P07.15 - Belt Skew.................................................................................................................................................................


108 108 108 109 109

Index

P07.16 - Event Belt Skew...................................................................................................................................................... 109 P07.17 - DO Belt Drift............................................................................................................................................................ 109 P07.18 - DO Belt Skew ......................................................................................................................................................... 109 P08 - Filters............................................................................................................................................................................ 110 P08.01 - LC Filter ................................................................................................................................................................... 110 P08.02 - Filter Actual Flow Rate............................................................................................................................................ 110 P08.03 - Filter Actual Flow Rate analog................................................................................................................................ 110 P08.04 - Feedback Filter Override Threshold ........................................................................................................................ 110 P08.05 - Filter Belt Load........................................................................................................................................................ 111 P08.06 - Filter Belt Speed ..................................................................................................................................................... 111 P08.07 - Filter Deviation........................................................................................................................................................ 111 P09 - Limit Values .................................................................................................................................................................. 111 P09.01 - Limit Actual Flow Rate MIN .................................................................................................................................... 111 P09.02 - Event Actual Flow Rate MIN................................................................................................................................... 111 P09.03 - Limit Actual Flow Rate MAX ................................................................................................................................... 112 P09.04 - Event Actual Flow Rate MAX.................................................................................................................................. 112 P09.05 - Limit Load MIN........................................................................................................................................................ 112 P09.06 - Event Load MIN...................................................................................................................................................... 112 P09.07 - Limit Load MAX ...................................................................................................................................................... 113 P09.08 - Event Load MAX..................................................................................................................................................... 113 P09.09 - Limit Speed MIN ..................................................................................................................................................... 113 P09.10 - Event Speed MIN.................................................................................................................................................... 113 P09.11 - Limit Speed MAX .................................................................................................................................................... 114 P09.12 - Event Speed MAX .................................................................................................................................................. 114 P09.13 - Temperature MAX ................................................................................................................................................... 114 P09.14 - Event Temperature-MAX ........................................................................................................................................ 114 P10 - Calibration Data............................................................................................................................................................ 115 P10.01 - Calibration Probe Span............................................................................................................................................ 115 P10.02 - Pulses per length ..................................................................................................................................................... 115 P10.03 - Range Correction TW .............................................................................................................................................. 115 P10.04 - Range Correction TC............................................................................................................................................... 116 P10.05 - Range Correction TM .............................................................................................................................................. 116 P10.06 - Belt Circuit Time ...................................................................................................................................................... 116 P10.07 - Simulation Travel (Belt Rev.) ................................................................................................................................... 117 P10.08 - Calibration Weight ................................................................................................................................................... 117 P10.09 - Test Chain Weight ................................................................................................................................................... 117 P10.10 - Basic Tare ............................................................................................................................................................... 117 P10.11 - Belt Circuit No.......................................................................................................................................................... 117 P11 - Rate controller .............................................................................................................................................................. 118 P11.01 - P-Component KP..................................................................................................................................................... 118 P11.02 - I-Component TN ...................................................................................................................................................... 118 P11.03 - AO Motor Speed Control ........................................................................................................................................ 118 P11.04 - Lower Limit .............................................................................................................................................................. 119 P11.05 - Upper Limit .............................................................................................................................................................. 119 P11.06 - Controller Magnitude Offset ..................................................................................................................................... 119 P11.07 - Position at STOP ..................................................................................................................................................... 119 P11.08 - KP speed controller ................................................................................................................................................. 120 P11.09 - VAP Active............................................................................................................................................................... 120 P11.10 - Platform Dis.Length ................................................................................................................................................. 120 P11.11 - CC_FC speed controller .......................................................................................................................................... 120 P11.12 - Control Offset speed controller ................................................................................................................................ 120 P11.13 - Bypass..................................................................................................................................................................... 121 P11.14 - Setpoint Filter 1st Ord.............................................................................................................................................. 121 P11.15 - Setpoint Filter 2nd Ord............................................................................................................................................. 121 P11.16 - Adaptation 1 ............................................................................................................................................................ 122 P11.17 - Adaptation 2 ............................................................................................................................................................ 122 P12 - Moisture........................................................................................................................................................................ P12.01 - Moisture Active ........................................................................................................................................................ 122 122 P12.02 - Moisture Select ........................................................................................................................................................ 122 P12.03 - AI Moisture Measurement....................................................................................................................................... 123 P12.04 - Nominal Moisture..................................................................................................................................................... 123

BV-H6411GB, 1221 - 286 -


Index

P12.05 - Moisture Offset ........................................................................................................................................................ 123 P12.06 - Moisture Range ....................................................................................................................................................... 123 P12.07 - DO Moisture active ................................................................................................................................................. 124 P12.08 - Moisture MAX .......................................................................................................................................................... 124 P12.09 - DO Moisture M AX................................................................................................................................................... 124 P12.10 - Event Moisture MAX ............................................................................................................................................... 124 P12.11 - AO Flow Rate corrected ......................................................................................................................................... 124 P12.12 - AO Flow Rate Offset............................................................................................................................................... 125 P12.13 - AO Flow Rate Range.............................................................................................................................................. 125 P12.14 - Pulse Counter corrected ..........................................................................................................................................125 P13 - Cleanout control............................................................................................................................................................ 125 P13.01 - DO CleanOut Timer ................................................................................................................................................ 125 P13.02 - CleanOut ON Time .................................................................................................................................................. 126 P13.03 - CleanOut OFF Time ................................................................................................................................................ 126 P13.04 - DI Chain Motion Monitor ......................................................................................................................................... 126 P13.05 - Chain Motion Delay ................................................................................................................................................. 126 P13.06 - Event Chain Motion Monitor ................................................................................................................................... 127 P14 - Analog Outputs ............................................................................................................................................................. 127 P14.01 - AO Setpoint ............................................................................................................................................................ 127 P14.02 - Setpoint Offset ......................................................................................................................................................... 127 P14.03 - Setpoint Range ........................................................................................................................................................ 127 P14.04 - AO Actual Flow Rate .............................................................................................................................................. 127 P14.05 - Flow Rate Offset ...................................................................................................................................................... 128 P14.06 - Flow Rate Range ..................................................................................................................................................... 128 P14.07 - AO Belt Load .......................................................................................................................................................... 128 P14.08 - Belt Load Offset ....................................................................................................................................................... 128 P14.09 - Belt Load Range ...................................................................................................................................................... 128 P14.10 - AO Speed ............................................................................................................................................................... 129 P14.11 - Speed Offset............................................................................................................................................................ 129 P14.12 - Speed Range........................................................................................................................................................... 129 P14.13 - AO Deviation........................................................................................................................................................... 129 P14.14 - Deviation Offset ....................................................................................................................................................... 129 P14.15 - Deviation Range ...................................................................................................................................................... 129 P14.16 - AO Actual Flow Rate (2nd) ..................................................................................................................................... 130 P14.17 - AO Density ............................................................................................................................................................. 130 P14.18 - Density Offset .......................................................................................................................................................... 130 P14.19 - Density Range ......................................................................................................................................................... 130 P15 - Digital Inputs................................................................................................................................................................. 131 P15.01 - DI Acknowledge Events .......................................................................................................................................... 131 P15.02 - DI Local Mode......................................................................................................................................................... 131 P15.03 - Event External Event 1 ........................................................................................................................................... 131 P15.04 - DI External Event 1................................................................................................................................................. 132 P15.05 - Event NAMUR Error V103-DI13 ............................................................................................................................. 132 P15.06 - Event NAMUR Error V103-DI14 ............................................................................................................................. 132 P15.07 - DI Reset Totalizer 1 ................................................................................................................................................ 132 P15.08 - DI Reset Totalizer 2 ................................................................................................................................................ 132 P15.09 - DI Discharge Pluggage........................................................................................................................................... 133 P15.10 - Discharge Pluggage Delay ...................................................................................................................................... 133 P15.11 - Event Discharge Pluggage ..................................................................................................................................... 133 P15.12 - DI Coal on belt switch ............................................................................................................................................. 134 P15.13 - Loss of Flow Trip Delay ........................................................................................................................................... 134 P15.14 - Event Loss of Material ............................................................................................................................................ 134 P15.15 - Event Coal on Belt .................................................................................................................................................. 135 P15.16 - Belt Paddle Feedback Permissive ........................................................................................................................... 135 P15.17 - DI Motor feedback .................................................................................................................................................. 135 P15.18 - Event Motor Start.................................................................................................................................................... 136 P15.19 -- Level/Temperatur DI Coal Flow Monitor .............................................................................................................................................. P15.20 Sensor Delay .............................................................................................................................. P15.21 - Event Coal Flow...................................................................................................................................................... P15.23 - DI Remote CTRL .................................................................................................................................................... P15.24 - DI OFF/Maint CTRL................................................................................................................................................


136 136 137 137 137

Index

P15.25 - DI Local Start .......................................................................................................................................................... 137 P15.26 - DI Jog forward ........................................................................................................................................................ 138 P15.27 - DI Jog backward ..................................................................................................................................................... 138 P15.28 - Event External Event 2 ........................................................................................................................................... 138 P15.29 - DI External Event 2................................................................................................................................................. 138 P15.30 - Event External Event 3 ........................................................................................................................................... 139 P15.31 - DI External Event 3................................................................................................................................................. 139 P15.32 - Event External Event 4 ........................................................................................................................................... 139 P15.33 - DI External Event 4................................................................................................................................................. 140 P15.34 - DI Volumetric Mode ................................................................................................................................................ 140 P15.35 - DI Mode Switch Lock .............................................................................................................................................. 140 P16 - Digital Outputs .............................................................................................................................................................. 140 P16.01 - DO P16.02 - DO P16.03 - DO P16.04 - DO P16.05 - DO P16.06 - DO P16.07 - DO P16.08 - DO P16.09 - DO P16.10 - DO P16.11 - DO P16.12 - DO P16.13 - DO P16.14 - DO P16.15 - DO P16.16 - DO P16.17 - DO P16.18 - DO P16.19 - DO P16.20 - DO P16.21 - DO P16.22 - DO

Scale Start........................................................................................................................................................ 140 Feeder Started ................................................................................................................................................. 141 Feeder running (2nd)........................................................................................................................................ 141 Feeder Run Forward ........................................................................................................................................ 141 Feeder Run Forward (2nd)............................................................................................................................... 141 Feeder Run Reverse........................................................................................................................................ 142 Feeder Run Reverse (2nd)............................................................................................................................... 142 Start Prefeeder................................................................................................................................................. 142 ALARM ............................................................................................................................................................. 142 ALARM (2nd).................................................................................................................................................... 142 Deviation .......................................................................................................................................................... 143 Actual Flow Rate MIN....................................................................................................................................... 143 Actual Flow Rate MAX ..................................................................................................................................... 143 Load MIN.......................................................................................................................................................... 143 Load MAX............................... .......................................................................................................................... 144 Speed MIN ....................................................................................................................................................... 144 Speed MAX ...................................................................................................................................................... 144 Volumetric Mode .............................................................................................................................................. 144 Volumetric Mode (2nd) ..................................................................................................................................... 145 Local Mode....................................................................................................................................................... 145 WARNING ........................................................................................................................................................ 145 WARNING (2nd) ............................................................................................................................................... 145

P16.23 - DO Feeding ............................................................................................................................................................ 146 P16.24 - DO Feeding (2nd) ................................................................................................................................................... 146 P16.25 - DO Remote CTRL .................................................................................................................................................. 146 P16.26 - DO Remote CTRL (2nd) ......................................................................................................................................... 146 P17 - Analog calibration ......................................................................................................................................................... 147 P17.01 - Analog Input 1 Min ................................................................................................................................................... 147 P17.02 - Analog Input 1 Max .................................................................................................................................................. 147 P17.03 - Analog Input 2 Min ................................................................................................................................................... 147 P17.04 - Analog Input 2 Max .................................................................................................................................................. 147 P17.05 - Analog Input 3 Min ................................................................................................................................................... 147 P17.06 - Analog Input 3 Max .................................................................................................................................................. 147 P17.07 - Analog Input 4 Min ................................................................................................................................................... 148 P17.08 - Analog Input 4 Max .................................................................................................................................................. 148 P17.09 - Analog Input 5 Min ................................................................................................................................................... 148 P17.10 - Analog Input 5 Max .................................................................................................................................................. 148 P17.11 - Analog Output 1 Min ................................................................................................................................................ 148 P17.12 - Analog Output 1 Max ............................................................................................................................................... 148 P17.13 - Analog Output 2 Min ................................................................................................................................................ 148 P17.14 - Analog Output 2 Max ............................................................................................................................................... 149 P17.15 - Analog Output 3 Min ................................................................................................................................................ 149 P17.16 - Analog Output 3 Max ............................................................................................................................................... 149 P17.17 - Analog Output 4 Min ................................................................................................................................................ 149 P17.18 Max................................................................................................................................................ ............................................................................................................................................... P17.19 -- Analog Analog Output Output 4 5 Min P17.20 - Analog Output 5 Max ............................................................................................................................................... P17.21 - Analog Output 6 Min ................................................................................................................................................ P17.22 - Analog Output 6 Max ...............................................................................................................................................

BV-H6411GB, 1221 - 288 -

149 149 149 150 150


Index

P17.23 - Analog Output 1 Test Value..................................................................................................................................... P17.24 - Analog Output 2 Test Value..................................................................................................................................... P17.25 - Analog Output 3 Test Value..................................................................................................................................... P17.26 - Analog Output 4 Test Value..................................................................................................................................... P17.27 - Analog Output 5 Test Value..................................................................................................................................... P17.28 - Analog Output 6 Test Value..................................................................................................................................... P18 - 2-Sensor Slip ................................................................................................................................................................ P18.01 - 2-Sensor Slip active................................................................................................................................................. P18.02 - Source Sensor 1 ...................................................................................................................................................... P18.03 - DI Sensor 1............................................................................................................................................................. P18.04 - Characteristic Value Sensor 1 ................................................................................................................................. P18.05 - DI Sensor 2.............................................................................................................................................................

150 150 150 150 151 151 151 151 151 151 152 152

P18.06 - Characteristic Value Sensor 2 ................................................................................................................................. P18.07 - Slip Value 2 ............................................................................................................................................................. P18.08 - Event Slip 2............................................................................................................................................................. P18.09 - DO Slip 2 ................................................................................................................................................................ P19 - Maintenance interval..................................................................................................................................................... P19.01 - Maintenance Electric ............................................................................................................................................... P19.02 - Event Maint. Electric ............................................................................................................................................... P19.03 - Maintenance Feeder Run ........................................................................................................................................ P19.04 - Event Maint.Feeder Run......................................................................................................................................... P20 - Data Logging ................................................................................................................................................................ P20.01 - Hourly Total Time .................................................................................................................................................... P20.02 - Daily Total Time....................................................................................................................................................... P20.03 - Logger cycle time..................................................................................................................................................... P20.04 - Data Log Value 1 ..................................................................................................................................................... P20.05 - Data Log Value 2 ..................................................................................................................................................... P20.06 - Data Log Value 3 ..................................................................................................................................................... P20.07 - Data Log Value 4 ..................................................................................................................................................... P20.08 - Data Log Value 5 ..................................................................................................................................................... P20.09 - Data Log Value 6 ..................................................................................................................................................... P20.10 - Data Log Value 7 ..................................................................................................................................................... P20.11 - Data Log Value 8 ..................................................................................................................................................... P20.12 - Data Log Value 9 .....................................................................................................................................................

152 152 152 153 153 153 153 153 153 154 154 154 154 154 155 155 155 155 155 155 156 156

P20.13 - Data Log Value 10 ................................................................................................................................................... 156 P21 - Communication EasyServe .......................................................................................................................................... 156 P21.01 - Own Address ........................................................................................................................................................... 156 P21.02 - Baud Rate................................................................................................................................................................ 156 P21.03 - Format Data............................................................................................................................................................. 156 P22 - Communication Fieldbus .............................................................................................................................................. 157 P22.01 - Protocol Type........................................................................................................................................................... 157 P22.02 - Timeout Host ........................................................................................................................................................... 157 P22.03 - Event Cyclic Communication .................................................................................................................................. 157 P22.04 - Modbus-Version....................................................................................................................................................... 158 P22.05 - Word Sequence....................................................................................................................................................... 158 P22.06 - Byte Sequence ........................................................................................................................................................ 158 P22.07 - Configuration ........................................................................................................................................................... 158 P22.08 - Address ................................................................................................................................................................... 159 P22.09 - Resolution................................................................................................................................................................ 159 P22.10 - Baud r ate ................................................................................................................................................................. 159 P22.11 - Data Format............................................................................................................................................................. 160 P22.12 - Physics .................................................................................................................................................................... 160 P22.13 - Address ................................................................................................................................................................... 160 P22.14 - FLOAT-Format......................................................................................................................................................... 160 P22.15 - Address ................................................................................................................................................................... 160 P22.16 - Baud r ate ................................................................................................................................................................. 160 P22.17 -- Preset Parameter................................................................................................................................................................ P22.18 Count............................................................................................................................................................ P22.19 - READ_ID Count....................................................................................................................................................... P22.20 - Access Rights Limitation FB .................................................................................................................................... P22.21 - Remote IP Address FB ............................................................................................................................................


161 161 161 161 162

Index

P22.22 - Event Acyclic Communication................................................................................................................................. 162 P22.23 - Configuration ........................................................................................................................................................... 162 P23 - Ethernet ........................................................................................................................................................................ 162 P23.01 - IP Address ............................................................................................... ................................................................ 162 P23.02 - Net Mask ................................................................................................................................................................. 163 P23.03 - Gateway .................................................................................................................................................................. 163 P24 - PLC Outputs ................................................................................................................................................................. 163 P24.01 - DO PLC 1 ............................................................................................................................................................... 163 P24.02 - DO PLC 2 ............................................................................................................................................................... 163 P24.03 - DO PLC 3 ............................................................................................................................................................... 163 P24.04 - DO PLC 4 ............................................................................................................................................................... 164 P24.05 - DO PLC 5 ............................................................................................................................................................... 164 P24.06 - DO PLC 6 ............................................................................................................................................................... P24.07 - DO PLC 7 ............................................................................................................................................................... P24.08 - DO PLC 8 ............................................................................................................................................................... P24.09 - AO PLC 1 ............................................................................................................................................................... P24.10 - AO PLC 2 ............................................................................................................................................................... P25 - Fixed mode configuration ............................................................................................................................................. P25.01 - ID Preset Value 1..................................................................................................................................................... P25.02 - ID Preset Value 2..................................................................................................................................................... P25.03 - ID Preset Value 3..................................................................................................................................................... P25.04 - ID Preset Value 4..................................................................................................................................................... P25.05 - ID Preset Value 5..................................................................................................................................................... P25.06 - ID Preset Value 6..................................................................................................................................................... P25.07 - ID Preset Value 7..................................................................................................................................................... P25.08 - ID Preset Value 8..................................................................................................................................................... P25.09 - ID Read Value 1 ...................................................................................................................................................... P25.10 - ID Read Value 2 ...................................................................................................................................................... P25.11 - ID Read Value 3 ...................................................................................................................................................... P25.12 - ID Read Value 4 ...................................................................................................................................................... P25.13 - ID Read Value 5 ...................................................................................................................................................... P25.14 - ID Read Value 6 ...................................................................................................................................................... P25.15 - ID Read Value 7 ...................................................................................................................................................... P25.16 - ID Read Value 8 ......................................................................................................................................................

164 164 164 164 165 165 165 165 165 165 166 166 166 166 166 166 167 167 167 167 167 167

P25.17 - ID Read Value 9 ...................................................................................................................................................... P25.18 - ID Read Value 10 .................................................................................................................................................... P25.19 - ID Read Value 11 .................................................................................................................................................... P25.20 - ID Read Value 12 .................................................................................................................................................... P25.21 - ID Read Value 13 .................................................................................................................................................... P25.22 - ID Read Value 14 .................................................................................................................................................... P25.23 - ID Read Value 15 .................................................................................................................................................... P25.24 - ID Read Value 16 .................................................................................................................................................... P26 - FCB analog outputs ...................................................................................................................................................... P26.01 - FCB_AO 01 ............................................................................................................................................................. P26.02 - Offset FCB_AO 1..................................................................................................................................................... P26.03 - Range FCB_AO 1 .................................................................................................................................................... P26.04 - Reference FCB_AO 1 .............................................................................................................................................. P26.05 - FCB_AO 02 ............................................................................................................................................................. P26.06 - Offset FCB_AO 2 ..................................................................................................................................................... P26.07 - Range FCB_AO 2 .................................................................................................................................................... P26.08 - Reference FCB_AO 2 .............................................................................................................................................. P26.09 - FCB_AO 03 ............................................................................................................................................................. P26.10 - Offset FCB_AO 3..................................................................................................................................................... P26.11 - Range FCB_AO 3 .................................................................................................................................................... P26.12 - Reference FCB_AO 3 .............................................................................................................................................. P26.13 - FCB_AO 04 .............................................................................................................................................................

167 168 168 168 168 168 168 168 169 169 169 169 169 169 170 170 170 170 170 171 171 171

P26.14 -- Range Offset FCB_AO P26.15 FCB_AO 4..................................................................................................................................................... 4 .................................................................................................................................................... P26.16 - Reference FCB_AO 4 .............................................................................................................................................. P26.17 - FCB_AO 05 ............................................................................................................................................................. P26.18 - Offset FCB_AO 5.....................................................................................................................................................

171 172 172 172 172

BV-H6411GB, 1221 - 290 -


Index

P26.19 - Range FCB_AO 5 .................................................................................................................................................... 172 P26.20 - Reference FCB_AO 5 .............................................................................................................................................. 173 P26.21 - FCB Variant ............................................................................................................................................................. 173 P26.22 - Event FCB-Error ..................................................................................................................................................... 173 P27 - FCB digital outputs ....................................................................................................................................................... 174 P27.01 - FCB_DO 01 ............................................................................................................................................................. 174 P27.02 - FCB_DO 02 ............................................................................................................................................................. 174 P27.03 - FCB_DO 03 ............................................................................................................................................................. 174 P27.04 - FCB_DO 04 ............................................................................................................................................................. 175 P27.05 - FCB_DO 05 ............................................................................................................................................................. 175 P27.06 - FCB_DO 06 ............................................................................................................................................................. 175 P27.07 - FCB_DO 07 ............................................................................................................................................................. 175 P27.08 - FCB_DO 08 ............................................................................................................................................................. P27.09 - FCB_DO 09 ............................................................................................................................................................. P27.10 - FCB_DO 10 ............................................................................................................................................................. P27.11 - FCB_DO 11 ............................................................................................................................................................. P27.12 - FCB_DO 12 ............................................................................................................................................................. P27.13 - FCB_DO 13 ............................................................................................................................................................. P27.14 - FCB_DO 14 ............................................................................................................................................................. P27.15 - FCB_DO 15 ............................................................................................................................................................. P27.16 - FCB_DO 16 ............................................................................................................................................................. P27.17 - FCB_DO 17 ............................................................................................................................................................. P27.18 - FCB_DO 18 ............................................................................................................................................................. P27.19 - FCB_DO 19 ............................................................................................................................................................. P27.20 - FCB_DO 20 ............................................................................................................................................................. P28 - Configuration HMI Values............................................................................................................................................. P28.01 - HMI Value 01 ........................................................................................................................................................... P28.02 - HMI Value 02 ........................................................................................................................................................... P28.03 - HMI Value 03 ........................................................................................................................................................... P28.04 - HMI Value 04 ........................................................................................................................................................... P28.05 - HMI Value 05 ........................................................................................................................................................... P28.06 - HMI Value 06 ........................................................................................................................................................... P28.07 - HMI Value 07 ........................................................................................................................................................... P28.08 - HMI Value 08 ...........................................................................................................................................................

175 175 175 176 176 176 176 176 176 177 177 177 177 178 178 178 178 178 178 178 178 179

P28.09 - HMI Value 09 ........................................................................................................................................................... 179 P28.10 - HMI Value 10 ........................................................................................................................................................... 179 Parameter .............................................................................................................................................................................. 161 Parameter Block 01 - Hardware Modules................................................................................................................................. 78 Parameter Block 02 - Feeder Definition ................................................................................................................................... 80 Parameter Block 03 - Control Sources..................................................................................................................................... 88 Parameter Block 04 - Rated Data ............................................................................................................................................ 94 Parameter Block 05 - Feeder control ....................................................................................................................................... 97 Parameter Block 06 - Feeder Monitoring.................................................................................................................................. 98 Parameter Block 07 - Belt Monitoring..................................................................................................................................... 105 Parameter Block 08 - Filters................................................................................................................................................... 110 Parameter Block 09 - Limit Values ......................................................................................................................................... 111 Parameter Block 10 - Calibration Data ................................................................................................................................... 115 Parameter Block 11 - Rate controller ..................................................................................................................................... 118 Parameter Block 12 - Moisture............................................................................................................................................... 122 Parameter Block 13 - Cleanout control .................................................................................................................................. 125 Parameter Block 14 - Analog Outputs.................................................................................................................................... 127 Parameter Block 15 - Digital Inputs........................................................................................................................................ 131 Parameter Block 16 - Digital Outputs ..................................................................................................................................... 140 Parameter Block 17 - Analog calibration ................................................................................................................................ 147 Parameter Block 18 - 2-Sensor Slip ....................................................................................................................................... 151 Parameter Block 19 - Maintenance interval............................................................................................................................ 153 Parameter Block Block 21 20 -- Data Logging ....................................................................................................................................... Parameter Communication EasyServe ................................................................................................................. Parameter Block 22 - Communication Fieldbus ..................................................................................................................... Parameter Block 23 - Ethernet ............................................................................................................................................... Parameter Block 24 - PLC Outputs ........................................................................................................................................


154 156 157 162 163

Index Parameter Block 25 - Fixed mode configuration .................................................................................................................... 165 Parameter Block 26 - FCB analog outputs ............................................................................................................................. 169 Parameter Block 27 - FCB digital outputs .............................................................................................................................. 174 Parameter Block 28 - Configuration HMI Values.................................................................................................................... 177 Parameter Details .................................................................................................................................................................... 78 Parameter Log Values.............................................................................................................................................................. 40 Parameter Overview ................................................................................................................................................................ 62 Parameter Set .......................................................................................................................................................................... 49 Parameter Setup ...................................................................................................................................................................... 40 Parameters............................................................................................................................................................................... 57 Password ................................................................................................................................................................................. 81 P-Component KP ................................................................................................................................................................... 118 Performing Calibrations............................................................................................................................................................ 18 Physics................................................................................................................................................................................... 160 Platform Dis.Length................................................................................................................................................................ 120 PLC Functionality (Optional) .................................................................................................................................................. 222 PLC Outputs........................................................................................................................................................................... 163 Portable Devices .................................................................................................................................................................... 258 Position at STOP.................................................................................................................................................................... 119 Power Supply ................................................................................................................................................................. 237, 252 Prefabricated system cables .................................................................................................................................................. 264 Preset Count .......................................................................................................................................................................... 161 Print Parameters ...................................................................................................................................................................... 51 Probe Error......................................................................................................................................................................... 20, 22 Program EasyServe VPC 20150.............................................................................................................................................. 47 Protocol Type ......................................................................................................................................................................... 157 Pulse Counter corrected......................................................................................................................................................... 125 Pulse Length Total ................................................................................................................................................................... 85 Pulses per length ................................................................................................................................................................... 115 Raise/Lower Response Time ................................................................................................................................................... 91 Range Correction TC ............................................................................................................................................................. 116 Range Correction TM............................................................................................................................................................. 116 Range Correction TW............................................................................................................................................................. 115 Range FCB_AO 1 .................................................................................................................................................................. 169 Range FCB_AO 2 .................................................................................................................................................................. 170 Range FCB_AO 3 .................................................................................................................................................................. 171 Range FCB_AO 4 .................................................................................................................................................................. 172 Range FCB_AO 5 .................................................................................................................................................................. 172 Rate controller ........................................................................................................................................................................ 118 Rated Data ............................................................................................................................................................................... 94 Read/change Parameters ........................................................................................................................................................ 50 READ_ID Count ..................................................................................................................................................................... 161 Reference FCB_AO 1............................................................................................................................................................. 169 Reference FCB_AO 2............................................................................................................................................................. 170 Reference FCB_AO 3............................................................................................................................................................. 171 Reference FCB_AO 4............................................................................................................................................................. 172 Reference FCB_AO 5............................................................................................................................................................. 173 Relay Outputs ........................................................................................................................................................................ 245 Remote FRI Frequency............................................................................................................................................................ 87 Remote IP Address FB........................................................................................................................................................... 162 Resolution .............................................................................................................................................................................. 159 Restoring the Factory Default Settings..................................................................................................................................... 42 Retro-reflective Tape Clips................................................................................................................................................. 20, 22 RS-485 Hardware .................................................................................................................................................................. 231 Run Mode Select...................................................................................................................................................................... 93 Safety notes ............................................................................................................................................................................... 3 SC01 Event Setpoint Limited ............................................................................................................................................... 192 SC02 Event Stand-By .......................................................................................................................................................... 193 SC03 Event Run ............................................................................................................................................ 193 193 SC04 Event Maint.Feeder Maint. Electric................................................................................................................................................... SC05 Event External Event 1............................................................................................................................................... 194

BV-H6411GB, 1221 - 292 -


Index SC06 Event External Event 2............................................................................................................................................... 194 SC11 Event External Event 3............................................................................................................................................... 194 SC12 Event External Event 4............................................................................................................................................... 194 Scale Name.............................................................................................................................................................................. 81 Scale Operation Screens ......................................................................................................................................................... 52 Screened Cables............................................................................................................................................................ 234, 270 Sensor Length........................................................................................................................................................................ 108 Sensor Offset .........................................................................................................................................................................108 Sensor Width.......................................................................................................................................................................... 108 Sequence Monitoring ............................................................................................................................................................. 192 Serial Interfaces: .................................................................................................................................................................... 253 Serial Networks ...................................................................................................................................................................... 227 Service Values ......................................................................................................................................................................... 52 Setpoint Filter 1st Ord ............................................................................................................................................................ 121 Setpoint Filter 2nd Ord ........................................................................................................................................................... 121 Setpoint Offset ................................................................................................................................................................. 89, 127 Setpoint Range ................................................................................................................................................................ 89, 127 Setting the Current Time and D ate........................................................................................................................................... 43 Setting the IP Address in DISOCONT Tersus Systems ......................................................................................................... 230 Setting Time ............................................................................................................................................................................. 54 Setup Notes ............................................................................................................................................................................. 13 Setup Parameters .................................................................................................................................................................... 15 Signal Words.............................................................................................................................................................................. 4 Signal Words for Application Notes............................................................................................................................................ 5 Signal Words for Safety Warnings ............................................................................................................................................. 4 Simulation Mode ...................................................................................................................................................................... 42 Simulation Travel (Belt Rev.).................................................................................................................................................. 117 Slip Value ............................................................................................................................................................................... 107 Slip Value 2............................................................................................................................................................................ 152 Source Load Cell...................................................................................................................................................................... 96 Source Load Cell 2................................................................................................................................................................... 96 Source Run Enable .................................................................................................................................................................. 91 Source Sensor 1 .................................................................................................................................................................... 151 Span (CAL 2) ........................................................................................................................................................................... 21 Speed Measurement ................................................................................................................................................................ 95 Speed Offset ..........................................................................................................................................................................129 Speed Range ......................................................................................................................................................................... 129 Speed Setpoint......................................................................................................................................................................... 93 Stand-By Limit Value................................................................................................................................................................ 99 Start Program and Connect to Feeder ..................................................................................................................................... 47 Startup and Functional Check .................................................................................................................................................. 14 Subnetwork Mask................................................................................................................................................................... 230 Switch-on logic ....................................................................................................................................................................... 206 SY01 Event Memory ............................................................................................................................................................ 195 SY07 Event Communication VHM serial .............................................................................................................................. 195 SY08 Event Cyclic Communication...................................................................................................................................... 195 SY10 Event Acyclic Communication .................................................................................................................................... 196 SY12 Event Communication ARM7 ..................................................................................................................................... 196 System Message.................................................................................................................................................................... 195 TA: Tare ................................................................................................................................................................................... 24 Tab.1: Parameter for BIC and for belt motion monitoring......................................................................................................... 27 Tab.10: DISOCONT Load Cell Connection, Wire Colors ....................................................................................................... 240 Tab.11: Pin assignment for belt marker sensors .................................................................................................................... 244 Tab.12: Technical data for the inductive transmitter input ...................................................................................................... 245 Tab.13: Technical data of the analog input ............................................................................................................................ 248 Tab.14: Connections .............................................................................................................................................................. 249 Tab.15: Details of the system cables ..................................................................................................................................... 266 Tab.16: WLAN access configuration ...................................................................................................................................... 268 Tab.2: Setting Sequence adjustment and commissioning............................................................................................................... Tab.3: andfor adjusting the two-sensor belt slippage monitoring ..................................................................................... 27 29 Tab.4: Operating access .......................................................................................................................................................... 31


Tab.5: Functions available on the controller web page ............................................................................................................ 35 Tab.6: Controller parameters ................................................................................................................................................. 214 IndexSpecial cases of controller parameter setting ............................................................................................................. 214 Tab.7: Tab.8: Special modes of operation......................................................................................................................................... 215 Tab.9: Blocks available for processing binary signals............................................................................................................ 225 Tachometer Pulses per Rev.................................................................................................................................................... 96 TC: Span Calibration................................................................................................................................................................ 23 Technical Data VCU 20103.................................................................................................................................................... 235 Temperature MAX .................................................................................................................................................................. 114 Test Chain Weight.................................................................................................................................................................. 117 Testing ..................................................................................................................................................................................... 55 The 'Calibration' Screen ........................................................................................................................................................... 38 The 'Communication' Screen ................................................................................................................................................... 38 The 'Configuration' Screen....................................................................................................................................................... 38 The 'Display Settings' Screen................................................................................................................................................... 38 The 'Feeder' Screen................................................................................................................................................................. 38 The 'Home' Screen................................................................................................................................................................... 38 The 'Network' Screen ............................................................................................................................................................... 37 The procedure for adjusting the frequency output.................................................................................................................. 221 The 'Setup' Screen................................................................................................................................................................... 40 The 'Trend' Screen................................................................................................................................................................... 39 The 'Values' Screen ................................................................................................................................................................. 39 Thoughts on the Cable Connections .............................................................................................................................. 234, 270 Threshold Deviation ............................................................................................................................................................... 102 Time Deviation ....................................................................................................................................................................... 102 Timeout Host.......................................................................................................................................................................... 157 Totalizer Increment .................................................................................................................................................................. 85 Totals ......................................................................................................................................................................................... 9 Touchscreen Operating Panel VHM....................................................................................................................................... 250 Trending Data ........................................................................................................................................................................ 201 Trends ...................................................................................................................................................................................... 53 Trimming the Analog Inputs and Outputs ................................................................................................................................. 41 Two-Sensor Belt Slippage Monitoring ...................................................................................................................................... 29 Typical Operating Procedures.................................................................................................................................................. 43 Units ......................................................................................................................................................................................... 81 Unscreened Cables........................................................................................................................................................ 234, 271 Upper Limit............................................................................................................................................................................. 119 VAP Active ............................................................................................................................................................... .............. 120 VHM 20100 Basic Unit ........................................................................................................................................................... 255 VHM 20101 with Power Supply Unit ...................................................................................................................................... 256 VHM 20110 with Cable Connection ....................................................................................................................................... 258 VHM 20121 Wireless.............................................................................................................................................................. 260 Volum on LC failure.................................................................................................................................................................. 97 Volumetric ................................................................................................................................................................................ 10 Volumetric Control.................................................................................................................................................................... 10 WE01 Event Power Failure .................................................................................................................................................. 183 WE08 Event Analog Input < Offset....................................................................................................................................... 184 WE15 Event NAMUR Error V103-DI13 ................................................................................................................................ 184 WE16 Event NAMUR Error V103-DI14 ................................................................................................................................ 184 Web Server in the Scales Controller VCU................................................................................................................................ 35 Weigh Roller Adjustment.......................................................................................................................................................... 19 Weigh Span Length.................................................................................................................................................................... 9 What is the DISOCONT Tersus/DT-9?....................................................................................................................................... 7 WLAN access point ................................................................................................................................................................ 268 WM02 Event Slip.................................................................................................................................................................. 188 WM03 Event Belt Skew........................................................................................................................................................ 188 WM04 Event Belt Drift .......................................................................................................................................................... 188 WM05 Event Slip 2............................................................................................................................................................... 189 WM06 Event Chain Motion Monitor...................................................................................................................................... 189 WM07 Event Discharge Pluggage ....................................................................................................................................... 189 WM08 Event Loss of Material .............................................................................................................................................. 190 WM09 Event Motor Start ...................................................................................................................................................... 190 WM10 Event Belt Motion Monitor......................................................................................................................................... 190 WM11 Event Coal Flow........................................................................................................................................................ 191 WM12 Event Coal on Belt .................................................................................................................................................... 191 Word Sequence ..................................................................................................................................................................... 158 Zero Drop-Out Active ............................................................................................................................................................... 98 Zero Drop-Out Limit ................................................................................................................................................................. 98

BV-H6411GB, 1221 - 294 -





3.0 Certified Drawings


3.0 Certified Drawings

Section Index Title/Description

Drawing No.

Schematic Diagram-Gravimetric Feeder-Stock 196NT RPC

S11152

Remote Power Cabinet Dimension Drawing

S11158

Feeder Integral Cabinet Dimension Drawing

S11164




4.0 Mechanical Drawings and Parts Lists


4.0 Mechanical Drawings and Parts Lists Sl. No

Title/Description

Drawing No.

1

VFD Motor 7.5HP Upgrade Kit with Dual Tacho

D43566

2

Retro-Reflective Tape Assembly

A29466



5.0 Electric al/Electro nic Dra win gs and Parts Lists

Sectio n Index

Sl. No

Title / Description

Drawing No

1

Connection Diagram ‐ RPC

S11153

2

Cabinet Assembly Drawing‐RPC

S11154

3

Panel Assembly Drawing ‐ RPC

S11157

4

Connection Diagram –FIC

S11159

5

Cabinet Assembly Drawing‐FIC

S11160

6

Panel Assembly Drawing ‐ FIC

S11162

6.0 Vendor Information

Section Index Description

Stock Part No.

6.1

MOTOR

FE14364

6.2

BALDOR ELECTRIC MOTOR SERVICE / INSTRUCTION MANUAL

6.3

SPEED SENSOR

FE11705

6.4

VARIABLE FREQUENCY DRIVE

V003033.B06

Table of Contents

Table of Contents

Table of Contents

Integral Horsepower AC Induction Motors ODP, WPI, WPII Enclosure TEFC Enclosure Explosion Proof

Installation & Operating Manual

2/07

MN400

Table of Contents


Table of Contents

Table of Contents Section 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 .. Limited Warranty Notice Safety

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 .......

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 .. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 .. Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 .. Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 .. Section 2 & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Installation . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 .. Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 .. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 .. Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 .. Doweling Bolting &

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 .........

Power Connection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 .....

Conduit Box

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ........

AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 . Time First Start Up

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ..............

Coupled Up Start

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...........

Jogging and Repeated Starts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ........

Section 3 Maintenance & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 General Inspection Lubrication Bearings & Grease ofType

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 ...........

Relubrication Intervals Relubrication Procedure

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 .. Troubleshooting Chart

MN400

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 ....

Table of Contents i

Table of Contents

Section 1 General Information


Contents Table ofii

MN400

Table of Contents

Section 1 General Information Overview

This manual contains general procedures that apply to Baldor Motor products. Be sure to read and understand the Safety Notice statements in this manual. For your protection, do not install, operate or attempt to perform maintenance procedures until you understand the Warning and Caution statements. A Warning statement indicates a possible unsafe condition that can cause harm to personnel. A Caution statement indicates a condition that can cause damage to equipment.

Important:

This instruction manual is not i ntended to in clude a com prehensive listing of all d etails for al l procedures required for installation, operation and maintenance. This manual describes general guidelines that apply to most of the motor products shipped by Baldor. If you have a question about a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldor distributor for more information or clarification. Before you install, operate or perform maintenance, become familiar with the following: 

 

NEMA Publication MG-2, Safety Standard for Construction and guide for Selection, Installation and Use of Electric Motors and Generators. The National Electrical Code Local codes and Practices

Limited Warranty 1.

Most Baldor products are warranted for 18 mon ths from the date of shipme nt to Baldor’s cus tomer from Baldor’s district warehouse or, if applicable, from Baldor’s factory. Baldor Standard −E® standard efficient motors are warranted for 24 months. Standard−E is limited to three phase, general purpose, 1 −200 HP ratings that fall under the Energy Policy Act (EPAct). Baldor Super−E® premium efficient motors are warranted for 36 months. Baldor IEEE841 motors are warranted for 60 months. All warranty claims must be submitted to a Baldor Service Center prior to the expiration of the warranty period.

2.

Baldor will, at its option repair or replace a motor which fails due to defects in material or workmanship during the warranty period if: a. the purchaser presents the defective motor at or ships it prep aid to, the Bald or plant in Fort Smi th, Arkansas or one of the Baldor Authorized Service Centers and b. the purchaser gives written notification concerning the motor and the claimed defect including the date purchased, the task performed by the Baldor motor and the problem encountered.

3.

Baldor will not pay the cost of re moval of any ele ctric motor from any equipment, the cost of delivery to Fort Smith, Arkansas or a Baldor Authorized Service Center, or the cost of any incidental or consequential damages resulting from the claimed defects. (Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply to you.) Any implied warranty given by laws shall be limited to the duration of the warranty period hereunder. (Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.)

4.

Baldor Authorized Service Centers, when convinced to their satisfaction that a Baldor motor de veloped defects in material or workmanship within the warranty period, are authorized to proceed with the required repairs to fulfill Baldor’s warranty when the cost of such repairs to be paid by Baldor does not exceed Baldor ’s warranty repair allowance. Baldor will not pay overtime premium repair charges without prior written authorization.

5.

The cost of warranty repairs made by centers other than Baldor Authorized Service Centers WILL NOT be paid unless first authorized in writing by Baldor.

6.

Claims by a purchaser that a motor is defective even when a failure results within one hour after being placed into service are not always justified. Therefore, Baldor Authorized Service Centers must determine from the condition of the motor as delivered to the center whether or not the motor is defective. If in the opinion of a Baldor Authorized Service Center, a motor did not fail as a result of defects in material or workmanship, the center is to proceed with repairs only if the purchaser agrees to pay for such repairs. If the decision is in dispute, the purchaser should still pay for the repairs and submit the paid invoice and the Authorized Service Center’s signed service report to Baldor for further consideration.

7.

This warranty gives you specific legal rights, and you may also ha ve other rights which vary from state to state.

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General Information 1-1

Table of Contents

Safety Notice:

This equipment contains high voltage! Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt installation, operation and maintenance of electrical equipment. Be sure that you are completely familiar with NEMA publication MG-2, safety standards for construction and guide for selection, installation and use of electric motors and generators, the National Electrical Code and local codes and practices. Unsafe installation or use can cause conditions that lead to serious or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this equipment. WARNING:

Do not touch electrical connections before you first ensure that power has been disconnected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this equipment.

WARNING:

Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that all grounding instructions have been followed. Electrical shock can cause serious or fatal injury. National Electrical Code and Local codes must be carefully followed.

WARNING:

Avoid extended exposure to machinery with high noise levels. Be sure to wear ear protective devices to reduce harmful effects to your hearing.

WARNING:

This equipment may be connected to other machinery that has rotating parts or parts that are driven by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt to install operate or maintain this equipment.

WARNING:

Do not by-pass or disable protective devices or safety guards. Safety features are designed to prevent damage to personnel or equipment. These devices can only provide protection if they

WARNING:

remain operative. Avoid the use of automatic reset devices if the automatic restarting of equipment can be hazardous to personnel or equipment.

WARNING:

Be sure the load is properly coupled to the motor shaft before applying power. The shaft key must be fully captive by the load device. Improper coupling can cause harm to personnel or equipment if the load decouples from the shaft during operation.

WARNING:

Use proper care and procedures that are safe during handling, lifting, installing, operating and maintaining operations. Improper methods may cause muscle strain or other harm.

WARNING:

Before performing any motor maintenance procedure, be sure that the equipment connected to the motor shaft cannot cause shaft rotation. If the load can cause shaft rotation, disconnect the load from the motor shaft before maintenance is performed. Unexpected mechanical rotation of the motor parts can cause injury or motor damage.

WARNING:

Disconnect all electrical power from the motor windings and accessory devices before disassembly of the motor. Electrical shock can cause serious or fatal injury.

WARNING:

1-2 General Information

Do not use non UL/CSA listed explosion proof motors in the presence of flammable or combustible vapors or dust. These motors are not designed for atmospheric conditions that require explosion proof operation.

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Table of Contents

Section 1 General Information Safety Notice Continued WARNING:

Motors that are to be used in flammable and/or explosive atmospheres must display the UL label on the nameplate along with CSA listed logo. Specific service conditions for these motors are defined in NFPA 70 (NEC) Article 500.

WARNING:

UL Listed mo tors m ust on ly be se rviced b y UL A pproved Authorized Baldor Service Centers if these motors are to be returned to a hazardous and/or explosive atmosphere.

Caution:

To prevent premature equipment failure or damage, only qualified maintenance personnel should perform maintenance.

Caution:

Do not over −lubricate motor as this may cause premature bearing failure.

Caution:

Do not lift the motor and its driven l oad by the motor lifting hardware. The motor lifting hardware is adequate for lifting only the motor. Disconnect the load from the motor shaft before moving the motor.

Caution:

If eye bo lts are u sed f or lifting a m otor, be su re they a re securely tightened. The lifting direction should not exceed a 20° angle from the shank of the eye bolt or lifting lug. Excessive lifting angles can cause damage.

Caution:

To prevent equipment damage, be sure that the electrical service is not capable of delivering more than the maximum motor rated amps listed on the rating plate.

Caution:

If a HI POT test (High Potential Insulation test) must be performed, follow the precautions and procedure in NEMA MG1 and MG2 standards to avoid equipment damage.

If you have any questions or are uncertain about any statement or procedure, or if you require additional information please contact your Baldor distributor or an Authorized Baldor Service Center.

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General Information 1-3

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Section 1 General Information Receiving

Storage

Unpacking

Handling

Each Baldor Electric Motor is thoroughly tested at the factory and carefully packaged for shipment. When you receive your motor, there are several things you should do immediately. 1.

Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your motor.

2.

Verify that the part number of the motor you received is the same as the part number listed on your purchase order.

If the motor is not put into service immediately, the motor must be stored in a clean, dry and warm location. Several precautionary steps must be performed to avoid motor damage during storage. 1.

Use a “Megger” periodically to ensure that the integrity of the winding insulation has been maintained. Record the Megger readings. Immediately investigate any significant drop in insulation resistance.

2.

Do not lubricate bearings during storage. Motor bearings are packed with grease at the factory. Excessive grease can damage insulation quality.

3.

Rotate motor shaft at least 10 turns every two months during storage (more frequently if possible). This will prevent bearing damage due to storage.

4.

If the storage location is damp or humid, the motor windings must be protected from moisture. This can be done by applying power to the motors’ space heater (if available) while the motor is in storage.

Each Baldor motor is packaged for ease of handling and to prevent entry of contaminants. 1.

To avoid condensation inside the motor, do not unpack until the motor has reached room temperature. (Room temperature is the temperature of the room in which it will be installed). The packing provides insulation from temperature changes during transportation.

2.

When the motor has reached room temperature, remove all protective wrapping material from the motor.

The motor should be lifted using the lifting lugs or eye bolts provided. 1.

Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the motor and additional equipment connected to the motor by this method. The lugs or eye bolts provided are designed to lift only the motor. Never lift the motor by the motor shaft or the hood of a WPII motor.

2.

When lifting a WPII (Weather Proof Type 2) motor, do not lift the motor by inserting lifting lugs into holes on top of the cooling hood. These lugs are to be used for hood removal only. A spreader bar should be used to lift the motor by the cast lifting lugs located on the motor frame.

3.

If the motor must be mounted to a plate with the driven equipment such as pump, compressor etc., it may not be possible to lift the motor alone. For this case, the assembly should be lifted by a sling around the mounting base. The entire assembly can be lifted as an assembly for installation. Do not lift using the motor lugs or eye bolts provided. If the load is unbalanced (as with couplings or additional attachments) additional slings or other means must be used to prevent tipping. In any event, the load must be secure before lifting.

1-4 General Information

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Section 2 Installation & Operation Overview

Installation should conform to the National Electrical Code as well as local codes and practices. When other devices are coupled to the motor shaft, be sure to install protective devices to prevent future accidents. Some protective devices include, coupling, belt guard, chain guard, shaft covers etc. These protect against accidental contact with moving parts. Machinery that is accessible to personnel should provide further protection in the form of guard rails, screening, warning signs etc.

Location

It is important that motors be installed in locations that are compatible with motor enclosure and ambient conditions. Improper selection of the motor enclosure and ambient conditions can lead to reduced operating life of the motor. Proper ventilation for the motor must be provided. Obstructed airflow can lead to reduction of motor life. 1.

Open Drip−Proof/WPI motors are intended for use indoors where atmosphere is relatively clean, dry, well ventilated and non −corrosive.

2.

Totally Enclosed and WPIImotors may be installed where dirt, moisture or dust are present and in outdoor locations.

Severe Duty, IEEE 841 and Washdown Duty enclosed motors are designed for installations with high corrosion or excessive moisture conditions. These motors should not be placed into an environment where there is the presence of flammable or combustible vapors, dust or any combustible material, unless specifically designed for this type of service.

Mounting

The motor must be securely installed to a rigid foundation or mounting surface to minimize vibration and maintain alignment between the motor and shaft load. Failure to provide a proper mounting surface may cause vibration, misalignment and bearing damage. Foundation caps and sole plates are designed to act as spacers for the equipment they support. If these devices are used, be sure that they are evenly supported by the foundation or mounting surface. After installation is complete and accurate alignment of the motor and load is accomplished, the base should be grouted to the foundation to maintain this alignment. The standard motor base is designed for horizontal or vertical mounting. Adjustable or sliding rails are designed for horizontal mounting only. Consult your Baldor distributor or authorized Baldor Service Center for further information.

Alignment

Accurate alignment of the motor with the driven equipment is extremely important. 1.

Direct Coupling For direct drive, use flexible couplings if possible. Consult the drive or equipment manufacturer for more information. Mechanical vibration and roughness during operation may indicate poor alignment. Use dial indicators to check alignment. The space between coupling hubs should be maintained as recommended by the coupling manufacturer.

2.

End-Play Adjustment The axial position of the motor frame with respect to its load is also extremely important. The motor bearings are not designed for excessive external axial thrust loads. Improper adjustment will cause failure.

3.

Pulley Ratio The pulley ratio should not exceed 8:1.

4.

Belt Drive Align sheaves carefully to minimize belt wear and axial bearing loads (see End-Play Adjustment). Belt tension should be sufficient to prevent belt slippage at rated speed and load. However, belt slippage may occur during starting.

Caution: 5.

MN400

Do not over tension belts.

Sleeve bearing motors are only suitable for coupled loads.

Installation & Operation 2-1

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Section 1 General Information Doweling & Bolting

Power Connection

After proper alignment is verified, dowel pins should be inserted through the motor feet into the foundation. This will maintain the correct motor position should motor removal be required. (Baldor motors are designed for doweling.) 1.

Drill dowel holes in diagonally opposite motor feet in the locations provided.

2.

Drill corresponding holes in the foundation.

3.

Ream all holes.

4.

Install proper fitting dowels.

5.

Mounting bolts must be carefully tightened to prevent changes in alignment. Use a flat washer and lock washer under each nut or bolt head to hold the motor feet secure. Flanged nuts or bolts may be used as an alternative to washers.

Motor and control wiring, overload protection, disconnects, accessories and grounding should conform to the National Electrical Code and local codes and practices.

Conduit Box

For ease of making connections, an oversize conduit box is provided. The box can be rotated 360° in 90° increments. Auxiliary conduit boxes are provided on some motors for accessories such as space heaters, RTD’s etc.

AC Power

Connect the motor leads as shown on the connection diagram located on the name plate or inside the cover on the conduit box. Be sure the following guidelines are met: 1.

AC power is within plate for ratings). OR

±10%

of rated voltage with rated frequency. (See motor name

2.

AC power is within OR

±5%

3.

A combined variation in voltage and frequency of ±10% (sum of absolute values) of rated values, provided the frequency variation does not exceed ±5% of rated frequency.

of rated frequency with rated voltage.

Performance within these voltage and frequency variations are shown in Figure 2-2.

Figure 2-1 Accessory Connections One heater is installed in each end of motor. Leads for each heater are labeled H1 & H2. (Like numbers should be tied together).

Three thermisters are installed in windings and tied in series. Leads are labeled T1 & T2.

Winding RTDs are installed in windings (2) per phase. Each set of leads is labeled W1, W2, W3, W4, W5, & W6. * One bearing RTD is installed in Drive endplate (PUEP), leads are labeled RTDDE. * One bearing RTD is installed in Opposite Drive endplate (FREP), leads are labeled RTDODE. * Note RTD may have 2−Red/1−White leads; or 2 −White/1−Red Lead.

2-2 Installation Operation &

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Section 1 General Information Figure 2-2 Typical Motor Performance VS Voltage Variations +20

Maximum Torque

Full -Load Current +15 ) (% +10 e c n a +5 m r o f re P 0 r o t o M in −5 s e g n a −10 h C

Full -Load Current

Power Factor

Efficiency

Efficiency

−15 −20

Power Factor

Maximum Torque

−15

−10

−5

0

+5

+10

+15

Voltage Variations (%)

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Section 1 General Information First Time Start Up

Be sure that all power to motor and accessories is off. Be sure the motor shaft is disconnected from the load and will not cause mechanical rotation of the motor shaft. 1.

Make sure that the mechanical installation is secure. All bolts and nuts are tightened etc.

2.

If motor has been in storage or idle for some time, check winding insulation integrity with a Megger.

3.

Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical continuity.

4.

Be sure all shipping materials and braces (if used) are removed from motor shaft.

5.

Manually rotate the motor shaft to ensure that it rotates freely.

6. 7.

Replace all pan els and covers that were removed during installation. Momentarily apply power and check the direction of rotation of the motor shaft.

8.

If motor rotation is wrong, be sure power is off and change the motor lead connections. Verify rotation direction before you continue.

9.

Start the motor and ensure operation is smooth without excessive vibration or noise. If so, run the motor for 1 hour with no load connected.

10. After 1 hour of operation, disconnect power and connect the load to the motor shaft. Verify all coupling guards and protective devices are installed. Ensure motor is properly ventilated.

Coupled Start Up

This procedure assumes a coupled start up. Also, that the first time start up procedure was successful. 1.

Check the coupling and ensure that all guards and protective devices are installed.

2.

Check that the coupling is properly aligned and not binding.

3.

The first coupled start up should be with no load. Apply power and verify that the load is not transmitting excessive vibration back to the motor though the coupling or the foundation. Vibration should be at an acceptable level.

4. Run for approximately 1 hour with the driven equipment in an unloaded condition. The equipment can now be loaded and operated within specified limits. Do not exceed the name plate ratings for amperes for steady continuous loads.

Jogging and Repeated Starts Repeated starts and/or jogs of induction motors generally reduce the life of the motor winding insulation. A much greater amount of heat is produced by each acceleration or jog than by the same motor under full load. If it is necessary to repeatedly start or jog the motor, it is advisable to check the application with your local Baldor distributor or Baldor Service Center. Heating - Duty rating and maximum ambient temperature are stated on the motor name plate. Do not exceed these values. If there is any question regarding safe operation, contact your local Baldor distributor or Baldor Service Center.

2-4 Installation Operation &

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Section 3 Maintenance & Troubleshooting WARNING:

General Inspection

Inspect the motor at regular intervals, approximately every 500 hours of operation or every 3 months, whichever occurs first. Keep the motor clean and the ventilation openings clear. The following steps should be performed at each inspection: WARNING:

Relubrication & Bearings

Type of Grease

UL Listed mo tors m ust on ly be se rviced b y UL A pproved Authorized Baldor Service Centers if these motors are to be returned to a hazardous and/or explosive atmosphere.

Do not touch electrical connections before you first ensure that power has been disconnected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this equipment.

1.

Check that the motor is clean. Check that the interior and exterior of the motor is free of dirt, oil, grease, water, etc. Oily vapor, paper pulp, textile lint, etc. can accumulate and block motor ventilation. If the motor is not properly ventilated, overheating can occur and cause early motor failure.

2.

Use a “Megger” periodically to ensure that the integrity of the winding insulation has been maintained. Record the Megger readings. Immediately investigate any significant drop in insulation resistance.

3.

Check all electrical connectors to be sure that they are tight.

Bearing grease will lose its lubricating ability over time, not suddenly. The lubricating ability of a grease (over time) depends primarily on the type of grease, the size of the bearing, the speed at which the bearing operates and the severity of the operating conditions. Good results can be obtained if the following recommendations are used in your maintenance program. A high grade ball or roller bearing grease should be used. Recommended grease for standard service conditions is Polyrex EM (Exxon Mobil). Equivalent and compatible greases include: Texaco Polystar, Rykon Premium #2, Pennzoil Pen 2 Lube and Chevron SRI.

Relubrication Intervals

Recommended relubrication intervals are shown in Table 3-1. It is important to realize that the recommended intervals of Table 3-1 are based on average use. Refer to additional information contained in Tables 3-2, 3-3 and 3-4.

Table 3-1 Relubrication Intervals * NEMA / (IEC) Frame Size Upto210incl.(132) Over210to280incl.(180) Over280to360incl.(225) Over360to5800incl.(300)

10000 **

Rated Speed - RPM 6000 3600 1800 1200 900 2700Hrs. 5500Hrs. 12000Hrs. 18000Hrs. 22000Hrs. ** 3600Hrs. 9500Hrs. 15000Hrs. 18000Hrs. ** *2200Hrs. 7400Hrs. 12000Hrs. 15000Hrs. ** *2200Hrs. 3500Hrs. 7400Hrs. 10500Hrs.

*

Relubrication intervals are for ball bearings. For vertically mounted motors and roller bearings, divide the relubrication interval by 2.

**

For motors operating at speeds greater than 3600 RPM, contact Baldor for relubrication recommendations.

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Table 3-2 Service Conditions Severity of Service Standard Severe Extreme

Hours per day of Operation 8 16 Plus 16 Plus

Low Temperature

Ambient Temperature Maximum 40°C 50 °C >50 ° C* or Class H Insulation < −29° C **

Atmospheric Contamination Clean,LittleCorrosion Moderatedirt,Corrosion Severe dirt, Abrasive dust, Corrosion, Heavy Shock or Vibration

*

Special high temperature grease is recommended (Dow Corning DC44). Note that Dow Corning DC44 grease does not mix with other grease types. Thoroughly clean bearing & cavity before adding grease.

**

Special low temperature grease is recommended (Aeroshell 7).

Table 3-3 Relubrication Interval Multiplier SeverityofService Standard Severe Extreme LowTemperature

Multiplier 1.0 0.5 0.1 1.0

Some motor designs use different bearings on each motor end. This is normally indicated on the motor nameplate. In this case, the larger bearing is installed on the motor Drive endplate. For best relubrication results, only use the appropriate amount of grease for each bearing size (not the same for both).

Table 3-4 Bearings Sizes and Types

rame ze NEMA (IEC) 56 to 140 (90) 140 (90) 180 (100−112) 210 (132) 250 (160) 280 (180) 320 (200) 360 (225) 400 (250) 440 (280) 5000 to 5800 (315−450) 5000 to 5800 (315−450) 360 to 449 (225−280) AC Induction Servo 76Frame180(112) 77Frame210(132) *

80Frame250(160) Weight in grams = .005 DB of grease to be added

Bearing Description (These are the “Large” bearings (Shaft End) in each frame size) Volume of grease Weight of Grease to to be added Bearing add * in3 teaspoon oz (Grams) 6203 0.08 (2.4) 0.15 0.5 6205 0.15 (3.9) 0.2 0.8 6206 0.19 (5.0) 0.3 1.0 6307 0.30 (8.4) 0.6 2.0 6309 0.47 (12.5) 0.7 2.5 6311 0.61 (17) 1.2 3.9 6312 0.76 (20.1) 1.2 4.0 6313 0.81 (23) 1.5 5.2 6316 1.25 (33) 2.0 6.6 6319 2.12 (60) 4.1 13.4 6328 4.70 (130) 9.2 30.0 NU328 4.70 (130) 9.2 30.0 NU319 2.12 (60) 4.1 13.4 6207 6210 6213

0.22(6.1) 0.32(9.0) 0.49(14.0)

0.44 0.64 0.99

1.4 2.1 3.3

Note: Not all bearing sizes are listed. For intermediate bearing sizes, use the grease volume for the next larger size bearing.

3-2 Maintenance Troubleshooting &

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Caution: To avoid dam age to mot or bearings, grease must be k ept free of d irt. For an extremely dirty environment, contact your Baldor distributor or an authorized Baldor Service Center for additional information. Relubrication Procedure

Be sure that the grease you are adding to the motor is compatible with the grease already in the motor. Consult your Baldor distributor or an authorized service center if a grease other than the recommended type is to be used. Caution: Do not over −lubricate motor as this may cause premature bearing failure. With Grease Outlet Plug 1.

With the motor stopped, clean all grease fittings with a clean cloth.

2. Remove grease outlet plug. Caution: Over−lubricating can cause excessive bearing temperatures, premature lubrication breakdown and bearing failure. 3.

Add the recommended amount of grease.

4.

Operate the motor for 15 minutes with grease plug removed. This allows excess grease to purge.

5.

Re-install grease outlet plug.

Without Grease Provisions Note: Only a Baldor authorized and UL or CSA certified service center can disassemble a UL/CSA listed explosion proof motor to maintain it’s UL/CSA listing. 1.

Disassemble the motor.

2.

Add recommended amount of grease to bearing and bearing cavity. (Bearing should be about 1/3 full of grease and outboard bearing cavity should be about 1/2 full of grease.)

3.

Assemble the motor.

Sample Relubrication Determination Assume - NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an ambient temperature of 43° C and the atmosphere is moderately corrosive. 1.

Table 3-1 list 9500 hours for standard conditions.

2.

Table 3-2 classifies severity of service as “Severe”.

3.

Table 3-4 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added.

Note: Smaller bearings in size category may require reduced amounts of grease.

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Section 1 General Information Table 3-5 Troubleshooting Chart ymp om Motor will not start Excessive humming Motor Over Heating

osse auses Usually caused by line trouble, such as, single phasing at the starter. High Voltage. Eccentric air gap. Overload. Compare actual amps (measured) with nameplate rating. Single Phasing. Improper ventilation. Unbalanced voltage. Rotor rubbing on stator. Over voltage or under voltage. Open stator winding. Grounded winding. Improper connections.

Bearing Over Heating

Misalignment. Excessive belt tension. Excessive end thrust.

osse o u ons Check source of power. Check overloads, fuses, controls, etc. Check input line connections. Have motor serviced at local Baldor service center. Locate and remove source of excessive friction in motor or load. Reduce load or replace with motor of greater capacity. Check current at all phases (should be approximately equal) to isolate and correct the problem. Check external cooling fan to be sure air is moving properly across cooling fins. Excessive dirt build-up on motor. Clean motor. Check voltage at all phases (should be approximately equal) to isolate and correct the problem. Check air gap clearance and bearings. Tighten “Thru Bolts”. Check input voltage at each phase to motor. Check stator resistance at all three phases for balance. Perform dielectric test and repair as required. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical continuity. Refer to motor lead connection diagram. Check and align motor and driven equipment. Reduce belt tension to proper point for load. Reduce the end thrust from driven machine. 3

Excessive grease in bearing. Insufficient grease in bearing. Dirt in bearing. Vibration

Misalignment. Rubbing between rotating parts and stationary parts. Rotor out of balance. Resonance.

Noise Growling or whining

Foreignmaterialinairgapor ventilation openings. Bad bearing.


Remove grease until cavity is approximately /4 filled. Add grease until cavity is approximately 3/4 filled. Clean bearing cavity and bearing. Repack with correct grease until cavity is approximately 3/4 filled. Checkandalignmotoranddrivenequipment. Isolate and eliminate cause of rubbing. Have rotor balance checked are repaired at your Baldor Service Center. Tune system or contact your Baldor Service Center for assistance. Remove rotor and foreign material. Reinstall rotor. Check insulation integrity. Clean ventilation openings. Replace bearing. Clean all grease from cavity and new bearing. Repack with correct grease until cavity is approximately 3/4 filled.

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Suggested bearing and winding RTD setting guidelines Most large frame AC Baldor motors with a 1.15 service factor are designed to operate below a Class B (80°C) temperature rise at rated load and are built with a Class H winding insulation system. Based on this low temperature rise, RTD (Resistance Temperature Detectors) settings for Class B rise should be used as a starting point. Some motors with 1.0 service factor have Class F temperature rise. The following tables show the suggested alarm and trip settings for RTDs. Proper bearing and winding RTD alarm and trip settings should be selected based on these tables unless otherwise specified for specific applications. If the driven load is found to operate well below the initial temperature settings under normal conditions, the alarm and trip settings may be reduced so that an abnormal machine load will be identified. The temperature limits are based on the installation of the winding RTDs imbedded in the winding as specified by NEMA. Bearing RTDs should be installed so they are in contact with the outer race on ball or roller bearings or in direct contact with the sleeve bearing shell. Winding RTDs− Temperature Limit In C (40C Maximum Ambient) Motor Load Rated Load Rated Load to 1.15 S.F.



Note:

 

Class B Temp Rise  80°C (Typical Design) Alarm Tr i p 130 140 140 150

Class F Temp Rise  105°C Alarm 155 160

C l a s s H Te mp R i s e

Tr i p

Alarm

165 165

175 180



125°C

Tr i p 185 185

Winding RTDs are factory production installed, not from Mod −Express. When Class H temperatures are used, consider bearing temperatures and relubrication requirements.

Bearing RTDs− Temperature Limit In C (40C Maximum Ambient) Anti−F r i c t i on

Bearing Type Oil or Grease Standard* High Temperature**

Alarm 95 110

Sl e e ve Tr i p 100 115

Alarm 85 105

Tr i p 95 110

Note: * Bearing temperature limits are for standard design motors operating at Class B temperature rise. ** High temperature lubricants include some special synthetic oils and greases. Greases that may be substituted that are compatible with Polyrex EM (but considered as “standard” lubricants) include the following: − Texaco Polystar − Rykon Premium #2 − Chevron SRI #2 − Mobilith SHC−100 − Pennzoil Pennzlube EM −2 − Chevron Black Pearl − Darmex 707 − Darmex 711 − Petro−Canada Peerless LLG

See the motor nameplate for replacement grease or oil recommendation. Contact Baldor application engineering for special lubricants or further clarifications.

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Baldor District Offices Baldor District Offices Baldor District Offices

Table of Contents

BALDOR ELECTRIC COMPANY P.O. Box 2400 Ft. Smith, AR 72902−2400 (479) 646−4711 Fax (479) 648−5792 www.baldor.com

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9330 Progress Parkway • Mentor, OH 44060 • (800) 424-5757 Fax: (440) 639-8365 • e-mail: [email protected]

C-Face Ring Tachometers Features • • • • • • • • • • • • •

Slim line profile Full one year warranty Intrinsically safe barriers Easily and quickly installed Standard size units in stock Ideal for harsh environments Differential line driver outputs No need for an auxiliary shaft Single and quadrature models 10, 30, 60, 120, 200, 240 PPR Drop-in sensor – preset air gap Durable stainless steel sensors NEMA and IEC metric versions

Madison Electric Products ring tachometers are a convenient and efficient way to monitor motor shaft RPM when using NEMA “C”-face or metric flanged or faced motors. The ring tachometers are designed with a dual “C”-face mount to fit between your motor and gearbox, brake, clutch, etc…enabling the mounting of a pickup without the need for an auxiliary shaft or a coupling. Madison Electric non-contacting magnetic and Hall zero speed sensors are designed to indicate speed by reading rotating discontinuities, such as teeth on a gear. The sensors send the signal, either a sine wave or DC pulse train, to the motor controller. A Madison analog or digital meter is a great way to display the output. Custom sizes and scales are available.

Madison Electric ring tachometer kits include a precision machined ring tachometer with a drop-in analog or Hall effect speed sensor (no adjustment needed), four mounting bolts, conduit connection and a standard 30, 60, or 120 tooth gear.

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C-Face Ring Tachometers Applications include •

Rate meters – analog or digital

•

Speed switches

•

Direction sensing

•

Closed loop feedback

•

Intrinsically safe barriers

•

On-the-floor monitoring

Application notes One of the biggest complaints heard on the floor of plants and factories is the failure rate of nonindustrialized optical encoders. By applying variable reluctance and Hall effect technology, Madison Electric pickups are not affected by dust, oil, grease, dirt, etc…as happens with someoptical sensors.The sensors in the Madison Electric ring tachometer can handle shock and vibrations that hinder most highresolution encoders. Built tough to last in harsh industrial environments, the Madison Electric ring tachometer withstands shock, dirt, and vibrations that stop most high-resolution encoders. To satisfy single-shafted motors without the standard NEMA “C”-Face, Madison Electric has worked with companies and their engineers to design and produce customized ring tachometers to accommodate almost any motor manufactured.

Useful in any industry, the ring tachometer provides a simple and accurate method to monitor the speed of your application. When used in conjunction with an intrinsically safe barrier (p/n 9002/11-280-186), the Madison Electric ring tachometer is an ideal solution for installing an FM rated system in a volatile area. Factory set pick-ups insure all the user has to do is plug it in and run to have an intrinsica lly safe feedback. See our data sheets on p/n 9002/11-280-186 for additional information concerning the installation of an instrinscally safe system.

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C-Face Ring Tachometers Listed in the chart below are the common NEMA motor frames and corresponding Madison Electric Products frame code designation. A shaded Madison Code # indicates a non-stocking special order item.

Madison Code

Frame Size

Pilot

Pilot Depth

Bolt Circle

OD

Shaft

00

48C

3.000

0.125

3.750

5.625

0.500

01

56C 143TC 145TC 182C 184C

4.500

0.125

5.875

6.500

0.625 0.875 0.875 0.875 0.875

02

182TC 184TC 213C 215C 213TC 215TC 254TC 246TC 254TC 256TC

8.500

0.250

7.250

9.000

1.125 1.125 1.125 1.125 1.375 1.375 1.375 1.375 1.625 1.625

03

284UC 286UC 284TC

10.500

0.250

9.000

11.250

1.625 1.625 1.875

04

324UC 326UC 324TC 326TC

12.500

0.250

11.000

13.375

286TC

1.875 1.875 1.875 2.125 2.125

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C-Face Ring Tachometers Listed in the chart below are the common IEC (metric) frames and corresponding Madison Electric Products frame code designation. A shaded Madison Code # indicates a non-stocking special order item.

B5 Flange

B14 Face

IEC Frame

Madison Code

Pilot

Pilot Depth

Bolt Circle

OD

Madison Code

Pilot

Pilot Depth

Bolt Circle

OD

63

29

95 3.740

3 0.118

115 4.528

140 5.512

27

60 2.362

2.5 0.098

75 2.953

90 3.54

71

30

110 4.331

3.5 0.138

130 5.118

160 6.299

28

70 2.765

2.5 0.098

85 3.347

105 4.13

80

31

130 5.118

3.5 0.138

165 6.496

200 7.874

80 3.150

3 0.118

100 3.937

120 4.724

90

31

130 5.118

3.5 0.138

165 6.496

200 7.874

29

95 3.740

3 0.118

115 4.530

140 5.512

100

32

180 7.087

4 0.160

215 8.465

250 9.842

30

110 4.331

3.5 0.138

130 5.118

160 6.299

112

32

180 7.087

4 0.160

215 8.465

250 9.842

30

110 4.331

3.5 0.138

130 5.118

160 6.299

132

33

230 9.055

4 0.160

265 10.433

300 11.811

31

130 5.118

3.5 0.138

165 6.496

200 7.874

160

34

250 9.842

5 0.200

300 11.811

350 13.78

32

180 7.087

4 0.160

215 8.465

250 9.842

(mm in.)

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Plug ‘n Play Model ARTS-01/02 Nema “C” Face-Mounted Motor Ring Tachometer Kits Description Models ARTS-01/02 Ring Tachometers are easily installed on footmounted motors with “C” face mount end bells, or between a motor and gear case flange. The one piece cast aluminum ARTS Ring Tach and junction box is precision machined with a factory pre-set sensor

Wiring connections to the sensor are made through the gasketed junction box lid, and provide right or left conduit entry. A thread plug is provided with the kit for sealing the unused conduit entry.

gap. With our unique thefor sensor drops in at a constant predetermined gap, anddesign, is ready immediate installation.

Combining Madison Electric Tachometer with our Model A300 Analog RateaIndication Meter orRing our Model ADT-800 Digital Rate Meter completes your speed sensing and rate indication system.

Ring kits include a 60-tooth sensing gear, a drop-in Analog or Hall Effect Speed Sensor, and mounting hardware. Additional kits include 10-tooth, 30-tooth, 120-tooth, 200-tooth, and 240-tooth gears.

ARTS-01 Ring Tachometer

ARTS-02 Ring Tachometer

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Magnetic Pickup Speed Sensor Analog Variable Reluctance (VR) Speed Sensors are passive sensors and do not require any external power source. The sensor generates a sinusoidal output voltage proportional to target speed and inversely proportional to air gap. The output voltage, depending on air gap and target surface speed, ranges from a few millivolts at the slowest target speed to several volts at the highest target speed as illustrated in the graph below.

• • • • • •

•

The sensor is designed to drop-in at a constant predetermined air gap of

Resistance ................................. 650 +/- 20% Inductance ................................ 130 mH +/-20% Vibration Resistance ................. 20g Peak Shock Resistance ...................... 50g Peak Sensor Operating Temp ............ -40°C to + 100°C Wire Color Code....................... 2-wire, 20 AWG with 100% foil coverage; brown PVC jacket Polarity ..................................... With the approach of ferrous metal, white lead will go to posi-

0.005" to 0.010". This unique design provides for an efficient means of replacing the sensor without removing the ring tachometer.

tive with respect to the black lead

Model 1500-2510 Variable Reluctance (VR) Analog Speed Sensor PVC JACKET

STAINLESS STEEL CASE POSITIONING SNAP RING

Ø.373 .370

20 GA.

MAD ISON

ALL WIRE ENDS TINNED WHITE BLACK

1500-2510

6.00"

2.50" Ø .096

Typical outputs using our 60-tooth Gear at 1800 RPM RT-1 Hubless Gear - 16DP with 3.875 O.D. Rating at 1800 RPM

50 40

E G A T 30 L O V 20 P P

10 0

0.000

0.005

0.010

0.015

0.020

AIRGAP

RT-2 Hubless Gear - 10DP with 5.880 O.D. Rating at 1800 RPM

70 60 E G50 A T 40 L O V 30 P P 20

10 0

0.000

0.005

0.010 AIRGAP

0.015

0.020

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Hall Effect Speed Sensor Zero Speed non-contact sensors provide a constant amplitude output over target speed ranges from zero to 15K teeth/second and require an external 4.5 to 24 volts DC power source.The Madison Electric Products zero speed sensors include anopen collector output with sinking currents to 25 mA, operating temperature range to 130°C, short circuit protection, orientation insensitivity, and true zero speed sensing.

• • •

• • •

The sensor is designed to drop-in with a constant predetermined air gap. This unique design provides for an efficient means of replacing

• •

Input Voltage .................... 4.5 to 24 VDC Input Current .................... 10 mA max, output open Output Voltage .................. Logic 0: 400 mV, max @ 20 mA sink Logic 1: TTL comp., Vcc Output Current.................. 25 mA max, w/external pull-up resistor Signal Rise/Fall Time ....... 2uSec., typical Speed Range ..................... 0–15,000 teeth/second Dielectric Strength ............ 150 Vrms Operating Temperature ..... -20°C to + 100°C

•

the sensor without removing the ring tachometer.

•

Sensing Distance .............. 0.005" Wire Color Code............... 3-wire,to 200.025" AWG with stranded drain wire and 100% foil coverage; brown PVC jacket

Model 1500-2610 Hall Effect Speed Sensor Dimensions STAINLESS STEEL CASE POSITIONING SNAP RING

Ø .373 .370

SHIELD WIRE PVC JACKET

WHIT E BLACK RED

MAD I SON 1500-2610

2 .5 0 "

ALL WIRE ENDS TINNED 20 GA.

6 .0 0 "

Sensor Motor Frame Size

Shaft Dia . (Gear Bore)

Ring No.

Gear p/ n (Ref)

56C

5/8"

ARTS-01

4000-0902

143TC, 145TC, 182C, 184C

7/8"

ARTS-01

4000-0903

182TC, 184TC, 213C, 215C

1-1/8"

ARTS-02

4000-0908

213TC, 215TC, 254UC, 256UC

1-3/8"

ARTS-02

4000-0909

254TC, 256TC

1-5/8"

ARTS-02

4000-0910

Magnetic Pick-up

Hall Effect Speed Sensor

X

X

X X X X X X X X

Ring Tach Kit Model No.

A AR RT TS S--0 01 1--A Z ARTS-01-A ARTS-01-Z ARTS-02-A ARTS-02-Z ARTS-02-A ARTS-02-Z ARTS-02-A ARTS-02-Z

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Machined Steel Sensing Gears Sensing Gears are available in a number of sizes and styles in both hub type and hubless designs to accommodate most applications. Madison Electric stocks a wide variety of multiple gear-tooth and bore sizes as listed in the chart below. Custom split gears an d bore sizes are welcome and will be quoted as required.

Hubless gears are well suited for mounting in limited spaces or when a motor application has a short stub shaft. Split gears are convenient when a shaft end is not available to mount a hubless gear.

Hub Type Gear

Gear Type

No. Stock Bore Diametral of + 0.003 Pitch Teeth -0.000 10T 10T 10T 30T 30T 30T

30T 30T 60T 60T 60T 60T 60T 60T 60T 60T 60T 60T Hubless type 60T gear applicable 60T for Plug-n-Play 60T 60T 60T 60T 60T 120T 120T 120T 120T 120T 120T 120T 120T 120T 120T 120T 240T 240T

Hubless Type Gear

O.D. + 0.000 -0.005

Hub Dia. "D" ±0.010

Proj. "P" ±0.020

Face "F" ±0.020

Recommended Torque for Set Screws

Recommended Maximum Gear Speeds

Part Number

8DP 8DP 5DP

0.625 0.875 1.125 0.625 0.875 1.125

3.750 3.750 5.750 3.875 3.875 5.880

0.500 0.500 0.500 0.500 0.500 0.500

55 55 55 55 55 55

in. in. in. in. in. in.

lbs. lbs. lbs. lbs. lbs. lbs.

5000 5000 5000 5000 5000 5000

RPM RPM RPM RPM RPM RPM

4000-0110 4000-0112 4000-0115 4000-0702 4000-0703 4000-0710

5DP 5DP 16DP 16DP 16DP 16DP 16DP 16DP 16DP 16DP 16DP 10DP 10DP 10DP 10DP 10DP 10DP 10DP 10DP 31DP 31DP 31DP 31DP 21DP 21DP 21DP 21DP 21DP 21DP 21DP 41DP 41DP

1.375 1.625 0.375 0.500 0.625 0.750 0.875 14mm 19mm 24mm 28mm 1.125 1.375 1.625 1.875 2.000 38mm 2.250 2.437 0.625 0.750 0.875 1.000 28mm 1.125 1.250 1.375 1.500 1.625 3.000 0.625 1.125

5.880 5.880 3.875 3.875 3.875 3.875 3.875 3.875 3.875 3.875 3.875 5.880 5.880 5.880 5.880 5.880 5.880 5.880 5.880 3.875 3.875 3.875 3.875 5.880 5.880 5.880 5.880 5.880 5.880 5.880 5.880 5.880

0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500

55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in.

lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs.

5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM

4000-0712 4000-0714 4000-0900 4000-0901 4000-0902 4000-0920 4000-0903 4000-0904 4000-0905 4000-0906 4000-0907 4000-0908 4000-0909 4000-0910 4000-0911 4000-0912 4000-0913 4000-0914 4000-0916 4000-1010 4000-1011 4000-1012 4000-1013 4000-1019 4000-1020 4000-1021 4000-1022 4000-1024 4000-1025 4000-1026 4000-1035 4000-1040

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Gear Type

No. Stock Bore Diametral of +0.003 Pitch Teeth -0.000

O.D. +0.000 -0.005

Hub

30T 60T 60T 60T 60T 60T 60T 120T

8DP 23DP 23DP 23DP 11DP 11DP 11DP 42DP

1.125 0.500 0.625 0.875 1.125 1.375 1.625 0.500

3.988 2.570 2.570 2.570 5.360 5.360 5.360 2.895

Dia. "D" ±0.010 2.500 1.250 1.250 1.500 2.000 2.000 2.500 1.380

12 20 0T T 1 Hub type gear 120T not applicable 120T for Plug-n-Play 120T 200T 200T 200T 200T 200T 200T 200T 200T 200T

36 6D DP P 3 24DP 24DP 24DP 42DP 42DP 42DP 42DP 42DP 42DP 48DP 48DP 42DP

0 67 25 5 0..8 1.125 1.375 1.625 0.625 0.875 1.125 1.250 1.375 1.625 14mm 25mm 30mm

3..3 37 77 7 3 5.098 5.098 5.098 4.810 4.810 4.810 4.810 4.810 4.810 4.210 4.210 4.810

2..0 00 00 0 2 3.000 3.000 3.000 3.000 3.000 3.000 3.000 3.000 3.000 2.000 2.000 2.060

Face "F" ±0.020

Recommended Torque for Set Screws

Recommended Maximum Gear Speeds

Part Number

Proj. "P" ±0.020 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300

0.312 0.170 0.170 0.170 0.200 0.200 0.200 0.250

55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in.

lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs.

5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM

4000-3400 4000-1100 4000-0970 4000-0975 4000-1600 4000-1610 4000-1620 4000-2001

0..3 30 00 0 0 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300

0..2 25 50 0 0 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250

55 5 iin n.. 5 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in. 55 in.

bs s.. llb lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs.

50 00 00 0R RP PM M 5 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM 5000 RPM

40 00 00 0--2 20 01 00 0 4 4000-2200 4000-2210 4000-2220 4000-4300 4000-4310 4000-4320 4000-4360 4000-4377 4000-4380 4000-4500 4000-4515 4000-4370

Definitions Pitch –The distance between similar, equally spaced tooth surfaces, in a given direction and along a given curveor line. The single word “pitch” without qualification has been used to designate circular pitch, axial pitch, and diametral pitch, but such confusing usage should be avoided.

Pressure Angle– The angle between a tooth profile and a radial line at its pitch point. This has no significant effect on performance of the gear for exciting magnetic pickups. Pickups can be used with any pressure angle.

Pitch Circle– A circle, the radius of which is equal to the distance from the gear axis to the pitch point.

Outside Diameter (OD) – The outside diameter is the overall diameter of the gear to the top of the teeth. The OD is used to calculate surface speed when the gear is used to excite a magnetic pickup.

Pitch Diameter– The diameter of the pitch circle described by the tooth-to-tooth contact point when running in mesh with the teeth of Surface Speed– The output of a magnetic pickup is determined by the another gear. This point is roughly halfway between the root (bottom) linear surface speed of the outside diameter of the passing gear teeth. and the tip of the gear tooth. The pitch diameter is slightly smaller than Surface speed is normally expressed in inches/second. the outside diameter of the gear. Diametral Pitch (DP) – The ratio of the number of teeth to the number of inches of pitch diameter, i.e. the number of gear teeth to each inch of pitch diameter. For example, a 20 DP gear has 20-teeth for each inch of pitch diameter. Therefore, a 60-tooth, 20 DP gear would have a pitch diameter of 3".

Formulas Diametral Pitch=

Outside Diameter =

Number of Teeth Pitch Diameter Number of teeth + 2 Diametral Pitch

Surface Speed in inches/second =

RPM x OD x π

Output Frequency (Hz or teeth/sec) =

60 RPM x Number of gear teeth 60

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NEMA C-Face & IEC Metric Motor Frame Mounted Ring Tachometer Ordering Information To order fill in the following part numbers: ART

-

Channels SQDP-

Single Quad Dual Parallel

-

-

-

-

Frame Size 00 01 02 03 04 30 31 32 33 34

-

3.0 NEMA 4.5 NEMA 8.5 NEMA 10.5 NEMA 12.5 NEMA Metric 71D Metric 80D/90D Metric 100D/112D Metric 132D Metric 160D

-

Pick-Up

A - Analog Z - Hall Effect Y - Hall Effect w /o resistor

Differential Terminal Driver Block 1 - Yes 1 - Yes 0 - No 0 - No

L - Hall Effect w / Line Driver

99 - Special Frame (consult factory)

Example Part Number:

Lid Code M00 - Madison B00 - Blank Cxx - Custom

G ear Shaft PPR Size 010 0.500 030 0.625 060 0.875 120 1.125 200 1.375 240 1.625 1.875 14mm 19mm 24mm 28mm 30mm 38mm 42mm

ARTS-01-Z-1-1-B00-060-0.625

When ordering, fill in the above chart to determine your part number. Motor frame sizes can be found in the charts in this section. If you are unable to find your motor frame or require an OEM custom lid, please contact the Madison Electric Sales Department (800-424-5757).

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MC1000 Series Installation and Operation Manual

Table of Contents

NOTE! The manual covers software version M108314 and above. See paramter 63 for the software version of the drive you are working with. If you are working with an earlier software releaas, you will not have all of the functionality described in this manual, but the functionlity of the drive is fully documented in this manual. If you are working with M108313 or ealier, parameters 69 and 70 are described in this manual as parameters 98 and 99.

Table of Contents

Table of Contents 1.0 1.1 1.2 1.3 1.4 1.5

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PRODUCTS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PRODUCT CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 RECEIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CUSTOMER MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.0 3.0

MC1000 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MC1000 MODEL DESIGNATION CODE . . . . . . . . . . . . . . . . . . . . 3

4.0 5.0 6.0

MC1000 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MC1000 RATINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6.1 6.2

7.0 7.1 7.2

8.0 8.1 8.2

DESCRIPTION OF AC MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . 14 DRIVE FUNCTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 INSTALLATION AFTER A LONG PERIOD OF STORAGE . . . . . . . . . . . . . . 19 EXPLOSION PROOF APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

INPUT AC REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INPUT AC POWER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INPUT FUSING AND DISCONNECT REQUIREMENTS. . . . . . . . . . . . . . . . 20

9.0 10.0 11.0

VOLTAGE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 POWER WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 MC1000 POWER WIRING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . 22

12.0 13.0

INITIAL POWER UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 KEYPAD CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

13.1 KEYPAD FUNCTIONS (IN LOCAL MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . 24 13.2 MC1000 DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

14.0 15.0 15.1 15.2 15.3 15.4

16.0

CONTROL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 MC1000 CONTROL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . 34 MC1000 TERMINAL STRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 TWO-WIRE START/STOP CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 THREE-WIRE START/STOP CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 SPEED POT AND PRESET SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . 37

PROGRAMMING THE MC1000 DRIVE . . . . . . . . . . . . . . . . . . . . 38

16.1 PROGRAMMING THE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 16.2 PARAMETER ACCESS USING SPEED DIAL. . . . . . . . . . . . . . . . . . . . . . . . 40

17.0

PARAMETER MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

18.0 19.0

DESCRIPTION OF PARAMETERS. .. . . . . . . . . . . . . . . . . . . . . . 44 MC1000 PID SET POINT CONTROL . . . . . . . . . . . . . . . . . . . . . . 70

19.1 19.2 19.3 19.4 19.5 19.6

20.0 21.0

FEEDBACK DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 THE SYSTEM - DIRECT AND REVERSE ACTING. . . . . . . . . . . . . . . . . . . . 71 PID CONTROL - DIRECT AND REVERSE ACTING . . . . . . . . . . . . . . . . . . . 71 SET POINT REFERENCE SOURCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 TUNING THE PID CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 MC1000 DISPLAY IN PID MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 USER SETTING RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Table of Contents


Table of Contents

1.0 1.1

GENERAL PRODUCTS COVERED IN THIS MANUAL

This manual covers the AC Tech MC1000 Series Variable Frequency Drive.

1.2

PRODUCT CHANGES

AC Technology Corporation reserves the right to discontinue or make modifications to the design of its products and manuals without prior notice, and holds noobligation to make modifications to products sold previously. AC Technology Corporation also holds no liability for losses of any kind which may result from this action. Instruction manuals with the most up-to-date information are available for download from the AC Tech web site (www.actech.com).

1.3

WARRANTY

AC Technology Corporation warrants the MC Series AC motor control to be free of defects in material and workmanship for a period of 24 months from the date of shipment from AC Tech's factory. An MC Series control, or any component contained therein, which under normal use, becomes defective within the stated warranty time period, shall be returned to AC Technology Corporation, freight prepaid, for examination (contact AC Technology Corporation for authorization prior to returning any product). AC Technology Corporation reserves the right to make the final determination as to the validity of a warranty claim, and sole obligation is to repair or replace only components which have been rendered defective due to faulty material or workmanship. No warranty claim will be accepted for components which have been damaged due to mishandling, improper installation, unauthorized repair and/or alteration of the product, operation in excess of design specifications or other misuse, or improper maintenance. AC Technology Corporation makes no warranty that its products are compatible with any other equip ment, or to any specific application, to which they may be applied and shall not be held liable for any other consequential damage or injury arising from the use of its products. This warranty is in lieu of all other warranties, expressed or implied. No other person, firm orcorporation is authorized to assume, for AC Technology Corporation, any other liability in connection with the demonstration or sale of its products.

1.4

RECEIVING

Inspect all cartons for damage which may have occurred during shipping. Carefully unpack equipment andand/or inspect thoroughly for damage or shortage. Report any damage to carrier shortages to supplier. All major components and connections should be examined for damage and tightness, with special attention given to PC boards, plugs, knobs and switches.

1.5

CUSTOMER MODIFICATION

AC Technology Corporation, its sales representatives and distributors, welcome the opportunity to assist our customers in applying our products. Many customizing options are available to aid in this function. AC Technology Corporation cannot assume responsibility for any modifications not authorized by its engineering department.

1

Table of Contents

2.0

MC1000 SPECIFICATIONS

Storage Temperature

-20° to 70° C

Ambient Operating Temperature

Chassis (w/o cover)

-10° to 55° C

Type 1 (IP 31)

-10° to 50° C

(With 2.5, 6, and 8 kHz carrier, derate for higher carriers)

Type 4 (IP 65) Type 12 (IP 54)

-10° to 40° C -10° to 40° C

Ambient Humidity

Less than 95% (non-condensing)

Altitude

3300 feet (1000 m) above sea level without derating

Input Line Voltages

240/120 Vac, 240/200 Vac, 480/400 Vac, and 590/480 Vac

Input Voltage Tolerance

+10%, -15%

Input Frequency Tolerance

48 to 62 Hz

Output Wave Form

Sine Coded PWM

Output Frequency

0-120 Hz, Optional up to 1000 Hz

Carrier Frequency

2.5 kHz to 14 kHz

Frequency Stability

+0.00006% / °C

Service Factor

1.00

Efficiency

> 97% throughout speed range

Power Factor (displacement)

> 0.96

Overload Current Capacity

150% of output rating for 60 seconds 180% of output rating for 30 seconds

Speed Reference Follower

0-10 VDC, 4-20 mA

Control Voltage

15 VDC

Analog Outputs

0 - 10 VDC, or 2 - 10 VDC Proportional to speed and load

Digital Outputs

Form C relay: 2 A at 28 VDC or 120 Vac Open-collector outputs: 40 mA at 30 VDC

2

Table of Contents

3.0

MC1000 MODEL DESIGNATION CODE

The model number of an MC1000 Series drive gives a full description of the basic drive unit (see example below). EXAMPLE: M1450BP (MC1000, 480 Vac, 5 HP, Type 1 Enclosure, with a Remote Keypad Assembly) M1

4

50

B

Series:

M1

= M1000 Series Variable Speed AC Motor Drive

Input Voltage:

1 = 240/120 Vac (For 110, 115, 120, 230 and 240 Vac; 50 or 60 Hz) 2 = 240/200 Vac (For 208, 230, and 240 Vac; 50 or 60 Hz) 4 = 480/400 Vac (For 380, 415, 440, 460 and 480 Vac; 50 or 60 Hz) 5 = 590/480 Vac (For 440, 460, 480, 575 and 600 Vac; 50 or 60 Hz) Rating:

03 = ¼ HP (0.18 kW)

75 = 7½ HP (5.5 kW)

05 = ½ HP (0.37 kW)

100 = 10 HP (7.5 kW)

500 = 50 HP (37.5 kW) 600 = 60 HP (45 kW)

10 = 1HP(0.75kW)

150 = 15HP(11kW)

750 = 75HP(55kW)

15 = 1½HP (1.1 kW)

200 = 20 HP(15 kW)

1000

20 = 2 HP (1.5 kW)

250 = 25 HP (18.5 kW)

1250 = 125 HP (90 kW)

30 = 3HP (2.2 kW)

300 = 30 HP(22 kW)

1500 = 150 HP (110kW)

50 / 51 = 5 HP (3.7 kW)

400 = 40 HP (30vkW)

100 HP (75kW)

Input Phase:

S = Single phase input only. No character indicates three phase input only

Enclosure Type:

B = NEMA 1 - General Purpose, vented C = NEMA 4 - Water-tight and Dust-tight D = NEMA 12 - Oil-tight and Dust-tight E = NEMA 4X - Water-tight, Dust-tight, and Corrosion Resistant (Stainless Steel) Standard Options:

H = Additional Form C Relay circuit board J = Dynamic Braking circuit board K = Dynamic Braking & Additional Form C Relay board (not available on all HP sizes - consult factory) No character when this type of option is not specified

Interface Options:

P = Remote keypad assembly No character when this type of option is not specified

3

P

Table of Contents

4.0

MC1000 DIMENSIONS

4.1

TYPE 1 DIMENSIONS FOR MODELS RATED UP TO 30 HP AT 240/200 Vac AND 60 HP AT 590/480/400 Vac D

W

R

Q

Q

H

Conduit Holes:

W

S Dia. 0.88" Dia.

U V 1.00"

S Dia.

IF W = 10.26" T = 0.28" U = 0.44" V = 0.24"

P R

T Dia. Slot

N

IF W < 7.86" T = 0.20" U = 0.34" V = 0.19"

Mounting Tab Detail

HP (kW)

INPUT VOLTAGE

H

W

D

N

P

Q

R

S

0.25 (0.18)

240 / 120 M1103SB 7.50

4.70

3.33

2.35

1.60

1.37

5.50

0.88

240 / 120 M1105SB 7.50

6.12

3.63

3.77

1.80

1.37

5.50

0.88

0.5 (0.37)

240 240/200

MODEL

M1205SB 7.50 M1205B

7.50

240 / 120 M1110SB 7.50 1 (0.75)

240

4.70

3.63 4.22 4.33

2.35 2.35 3.77 2.35

1.90 1.90 2.40 2.60

1.37 1.37 1.37 1.37

5.50 5.50 5.50 5.50

0.88 0.88 0.88 0.88

M1210B

7.50

4.70

4.33

2.35

2.60

1.37

5.50

0.88

480/400

M1410B

7.50

4.70

3.63

2.35

1.90

1.37

5.50

0.88

7.50

4.70

3.63

2.35

1.90

1.37

5.50

0.88

240/120

M1115SB 7.50

6.12

4.22

3.77

2.40

1.37

5.50

0.88

240

M1215SB 7.50

6.12

4.22

3.77

2.40

1.37

5.50

0.88

M1215B

7.50

4.70

4.33

2.35

2.60

1.37

5.50

0.88

M1220SB 7.50

6.12

5.12

3.77

3.30

1.37

5.50

0.88

240/200 240

2 (1.5)

4.70 6.12

3.63

240/200 590

1.5 (1.1)

M1210SB 7.50

4.70

240/200

M1510B

M1220B

7.50

6.12

5.12

3.77

3.30

1.37

5.50

0.88

480/400

M1420B

7.50

6.12

4.22

3.77

2.40

1.37

5.50

0.88

590

M1520B

7.50

6.12

4.22

3.77

2.40

1.37

5.50

0.88

4

Table of Contents TYPE 1 DIMENSIONS (continued)

HP (kW)

INPUT VOLTAGE

3 (2.2)

240/200

M1230B

7.50

6.12

5.12

3.77

3.30

1.37

5.50

0.88

480/400

M1430B

7.50

6.12

5.12

3.77

3.30

1.37

5.50

0.88

240

590 5 (3.7)

7.5 (5.5)

10 (7.5)

15 (11)

20 (15)

25 (18.5)

30 (22)

240/200 480/400 590

MODEL

H

M1230SB 7.50

M1530B M1250B M1450B M1551B

7.50 7.88 7.50 7.88

W 6.12

6.12 7.86 6.12 7.86

D 5.12

5.12 5.94 5.12 5.94

N 3.77

3.77 5.13 3.77 5.13

P 3.30

3.30 3.95 3.30 3.95

Q 1.37

1.37 1.50 1.37 1.50

R 5.50

5.50 5.88 5.50 5.88

S 0.88

0.88 1.13 0.88 1.13

240/200

M1275B

9.38

7.86

6.84

3.93

4.19

2.00

5.88

1.13

480/400

M1475B

9.38

7.86

6.25

5.13

3.95

1.50

7.38

1.13

590

M1575B

9.38

7.86

6.25

5.13

3.95

1.50

7.38

1.13

240 / 200 M12100B 11.25 7.86

6.84

3.93

4.19

2.00

7.75

1.38

480 / 400 M14100B 9.38

6.84

3.93

4.19

2.00

5.88

1.13

590

M15100B 9.38

7.86 7.86

7.40

3.93

4.19

2.00

5.88

1.13

240/200

M12150B 12.75 7.86

6.84

3.93

4.19

2.00

9.25

1.38

480/400

M14150B 11.25 7.86

6.84

3.93

4.19

2.00

7.75

1.38

590

M15150B 12.75 7.86

6.84

240 / 200 M12200B 12.75 10.26 7.74 480/400

M14200B 12.75 7.86

6.84

590

M15200B 12.75 7.86

7.40

240 / 200 M12250B 15.75 10.26 8.35

3.93 5.13 3.93 3.93 5.13

4.19 5.00 4.19 4.19 5.00

2.00 2.50

9.75 9.25

1.38 1.38

2.00

9.25

1.38

2.00

9.25

1.38

2.50 12.25 1.38

480/400

M14250B 12.75 10.26 7.74

5.13

5.00

2.50

9.25

1.38

590

M15250B 12.75 10.26 7.74

5.13

5.00

2.50

9.25

1.38

240 / 200 M12300B 15.75 10.26 8.35

5.13

5.00

2.50 12.25 1.38

480/400

M14300B 12.75 10.26 7.74

5.13

5.00

2.50

9.25

1.38

590

M15300B 12.75 10.26 8.25

5.13

5.00

2.50

9.25

1.38

40 (30)

480/400

M14400B 15.75 10.26 8.35

5.13

5.00

2.50 12.25 1.38

590

M15400B 15.75 10.26 8.35

5.13

5.00

2.50 12.25 1.38

50 (37.5)

480/400

M14500B 19.75 10.26 8.55

5.13

5.75

2.50 16.25 1.75

590

M15500B 19.75 10.26 8.55

5.13

5.75

2.50 16.25 1.75

60 (45)

480/400

M14600B 19.75 10.26 8.55

5.13

5.75

2.50 16.25 1.75

590

M15600B 19.75 10.26 8.55

5.13

5.75

2.50 16.25 1.75

5

Table of Contents 4.2

TYPE 1 DIMENSIONS FOR MODELS RATED ABOVE 30 HP AT 240/200 Vac AND 60 HP AT 590/480/400 Vac 0.68"

W

0.31"

IF W = 13.00"

1.50" H

1.36"

0.36"

Dia. Mounting Tab Detail 0.92"

Q

0.43"

Conduit Holes: 1.13" Dia. S Dia.

Q

IF W > 16.64" 1.50"

D C

3.00"

0.44" Dia.

P

1.36"

N

HP/kW

INPUT VOLTAGE

N

C

P

Q

S

40/30

240 / 200 M12400B 25.00 13.00 10.50 5.56

6.50

6.50

2.62

1.38

60/45

240/200 M12600B 47.00 16.64 11.85

75/55

480 / 400 M14750B 29.00 16.64 11.85 7.14

MODEL

H

W

D

Seebelow 6.88

6.88

3.12

1.75

100/75 480/4 00 M141000B 29.00 24.42 11.85 11.12 7.25

6.50

4.50

2.50

125/90 480/4 00 M141250B 29.00 24.42 11.85 11.12 7.25

6.50

4.50

2.50

150/110 480 / 400 M141500B 29.00 36.66 11.85

CONDUIT HOLES FOR M12600B 4.26"

4.00"

CONDUIT HOLES FOR M141500B 7.45"

4.00"

6.88"

See below

7.25"

9.00"

7.00"

9.00"

6.50"

Conduit Holes: Large holes = 3.00" Small holes = 1.13"

Conduit Holes: Large holes = 1.75" Small hole = 1.13"

6


TYPE 4, 4X, AND 12 DIMENSIONS FOR MODELS RATED UP TO 30 HP AT 240/200 Vac AND 60 HP AT 590/480/400 Vac D

W

R

H

Conduit Holes: Q

Q

W

S Dia. 0.88" Dia. S Dia.

1.00"

P

IF W > 10.26" T = 0.28" U = 0.44" V = 0.24"

R

T Dia. Slot

N

IF W < 7.86" T = 0.20" U = 0.34" V = 0.19"

U V

Mounting Tab Detail

HP (kW)

INPUT VOLTAGE

0.25 (0.18) 0.5 (0.37)

1 (0.75)

1.5 (1.1)

2 (1.5)

3 (2.2)

MODEL

H

W

D

N

P

Q

R

S

240 /120

M1103S

7.88

6.12

3.63

3.06

2.00

1.37

5.88

0.88

240 /120

M1105S

7.88

7.86

3.75

4.80

2.10

1.37

5.88

0.88

240

M1205S

7.88

6.12

4.35

3.06

2.70

1.37

5.88

0.88

240/200

M1205

7.88

6.12

4.35

3.06

2.70

1.37

5.88

0.88

240 /200

M1110S

240

M1210S

7.88 7.88

7.86 6.12

4.90 4.35

4.80 3.06

3.25 2.70

1.37 1.37

5.88 5.88

0.88 0.88

240/200

M1210

7.88

6.12

4.35

3.06

2.70

1.37

5.88

0.88

480/400

M1410

7.88

6.12

4.35

3.06

2.70

1.37

5.88

0.88

590 240/120

M1510 M1115S

7.88 7.88

6.12 7.86

4.35 4.90

3.06 4.80

2.70 3.25

1.37 1.37

5.88 5.88

0.88 0.88

240

M1215S

7.88

7.86

4.90

4.80

3.25

1.37

5.88

0.88

240/200

M1215

7.88

6.12

5.25

3.06

3.60

1.37

5.88

0.88

240

M1220S

7.88

7.86

4.90

4.80

3.25

1.37

5.88

0.88

240/200 480/400

M1220

7.88

7.86

4.90

4.80

3.25

1.37

5.88

0.88

M1420

7.88

7.86

4.90

4.80

3.25

1.37

5.88

0.88

590

M1520

7.88

7.86

4.90

4.80

3.25

1.37

5.88

0.88

240

M1230S

7.88

7.86

5.90

4.80

4.25

1.37

5.88

0.88

240/200

M1230

7.88

7.86

5.90

4.80

4.25

1.37

5.88

0.88

480/400

M1430

7.88

7.86

4.90

4.80

3.25

1.37

5.88

0.88

590

M1530

7.88

7.86

7

4.90

4.80

3.25

1.37

5.88

0.88

Table of Contents DIMENSIONS - TYPE 4, 4X, AND 12 ENCLOSED (continued)

HP (kW) 5 (3.7)

7.5 (5.5)

10 (7.5)

15 (11)

20 (15)

25 (18.5)

INPUT VOLTAGE

MODEL

H

W

D

N

P

Q

R

S

240/200

M1250

9.75 10.26 7.20

5.13

5.25

2.00

7.75

1.13

480/400

M1450

7.88

4.80

4.25

1.37

5.88

0.88

590 240 / 200 480/400 590

M1550 M1275 M1475 M1575

7.88

7.86 7.86

5.90 5.90

11.75 10.26 8.35 9.75 10.26 7.20 9.75 10.26 7.20

4.80 5.13 5.13 5.13

4.25 5.75 5.25 5.25

1.37 2.00 2.00 2.00

5.88 9.75 7.75 7.75

0.88 1.13 1.13 1.13

240 / 200

M12100 13.75 10.26 8.35

5.13

5.75

2.00 11.75 1.38

480 / 400

M14100 11.75 10.26 8.35

5.13

5.75

2.00

9.75

M15100 11.75 10.26 8.35

5.13

5.75

2.00

240/200

M12150 15.75 10.26 8.35

5.13

5.75

2.00 13.75 1.38

480/400

M14150 13.25 10.26 8.35

5.13

5.75

2.00 11.75 1.38

590

M15150 13.75 10.26 8.35

5.13

5.75

2.00 11.75 1.38

240 / 200 M12200D* 15.75 10.26 8.35

5.13

5.75

2.00 11.75 1.38

480/400

5.13

5.75

2.00 13.75 1.38

M14200 15.75 10.26 8.35

9.75

1.13

590

1.13

590 M15200 15.75 10.26 8.35 5.13 5.75 2.00 13.75 1.38 240 / 200 M12250D* 20.25 10.26 8.35 5.13 5.75 2.00 16.25 1.38 5.13

5.75

2.00 11.75 1.38

M15250D* 15.75 10.26 8.35

5.13

5.75

2.00 11.75 1.38

240 / 200 M12300D* 20.25 10.26 8.35

5.13

5.75

2.00 16.25 1.38

480/400 M14300D* 15.75 10.26 8.35

5.13

5.75

2.00 11.75 1.38

M15300D* 15.75 10.26 8.35

5.13

5.75

2.00 11.75 1.38

40 (30)

480/400 M14400D* 20.25 10.26 8.35

5.13

5.75

2.00 16.25 1.38

M15400D* 20.25 10.26 8.35

5.13

5.75

2.00 16.25 1.38

50 (37.5)

480/400 M14500D* 21.00 13.72 8.35

5.13

6.10

2.00 16.25 1.38

M15500D* 21.00 13.72 8.35

5.13

6.10

2.00 16.25 1.38

60 (45)

480/400 M14600D* 21.00 13.72 8.35 590 M15600D* 21.00 13.72 8.35

5.13 5.13

6.10 6.10

2.00 16.25 1.38 2.00 16.25 1.38

30 (22)

480/400 M14250D* 15.75 10.26 8.35 590

590 590 590

*Models available in NEMA 12 only.

8


TYPE 12 DIMENSIONS FOR MODELS RATED ABOVE 30 HP AT 240/200 Vac AND 60 HP AT 590/480/400 Vac

0.68"

W

0.31"

R

1.36" H

1.50"

0.36" Dia.

IF W = 14.00" Mounting Tab Detail 0.92" Q

Q

0.43"

Conduit Holes: 1.13" Dia.

1.36"

S Dia. 0.44" Dia.

D

3.00"

P 1.50"

IF W > 18.00" N

HP/kW

INPUT VOLTAGE

N

P

Q

R

S

75/55

480 / 400 M14750D 37.00 18.00 13.30 7.50

8.00

3.13

7.14

1.75

100/75 480 / 400 M141000D 39.00 26.00 13.30 11.50 9.00

4.50

9.14

2.50

125/90 480 / 400 M141250D 39.00 26.00 13.30 11.50 9.00

4.50

9.14

2.50

MODEL

H

W

9

D

Table of Contents

5.0

MC1000 RATINGS

The following tables indicate the input and output ratings of the MC1000 Series. NOTE: The output current ratings are based on operation at carrier frequencies of 8 kHz and below. At full ambient temperature, operation at carrier frequencies above 8 kHz require derating the drive by multiplying the output current rating by the following factors: 0.94 at 10 kHz, 0.89 at 12 kHz, and 0.83 at 14 kHz. Refer to Parameter 23 - CARRIER in Section 18.0 - DESCRIPTION OF PARAMETERS.

M1100 SERIES RATINGS INPUT

MODEL

(120/240 Vac, 50 - 60 Hz)

FORMOTORS MODEL NUMBER1

1 2

OUT P UT

RATED

NOMINAL INPUT

CURRENT (AMPS)

(0 - 230 Vac)

NOMINAL 2

POWER

CURRENT

POWER

(KVA)

(AMPS)

(KVA)

HP

kW

PHASE

M1103S

0.25

0.18

1

6.0/3.0

0.72

1.4/1.4

0.56

M1105S

0.5

0.37

1

9.2/4.6

1.1

2.2/2.2

0.88

M1110S

1

0.75

1

16.28.1 /

1.9

4.04.0 /

1.6

M1115S

1.5

1.1

1

2110.4 /

2.5

5.25.2 /

2.1

See Section 3.0 for model number breakdown. See Section 8.0 for recommended fuse type.

10

Table of Contents


MODEL

(200/240 Vac, 50 - 60 Hz)


1 2

OUTPUT

RATED

(0 - 200/230 Vac)

NOMINAL INPUT

CURRENT (AMPS)

NOMINAL 2

POWER

CURRENT

POWER

(KVA)

(AMPS)

(KVA)

HP

kW

PHASE

M1205S

0.5

0.37

1

5.8/5.0

1.2

2.5/2.2

0.9

M1205

0.5

0.37

3

3.12.7 /

1.1

2.52.2 /

0.9

M1210S

1

0.75

1

10.49.0 /

2.2

4.64.0 /

1.6

M1210

1

0.75

3

5.54.8 /

2.0

4.64.0 /

1.6

M1215S

1.5

1.1

1

13.3/11.6

2.8

6.0/5.2

M1215

1.5

1.1

3

7.16.2 /

2.6

6.05.2 /

2.1

M1220S

2

1.5

1

17.114.9 /

3.6

7.86.8 /

2.7

M1220

2

1.5

3

9.3 8.1 /

3.4

7.8 6.8 /

2.7

M1230S M1230

3 3

2.2 2.2

1 3

24 21 / 13.011.3 /

5.0 4.7

11.0 9.6 / 11.0/9.6

3.8 3.8

M1250

5

3.7

3

2017.7 /

7.4

17.515.2 /

6.1

M1275

7.5

5.5

3

30 26 /

10.6

25 22 /

8.8

M12100

10

7.5

3

3732 /

13.2

3228 /

11.2

M12150

15

11

3

55 48 /

19.8

48 42 /

16.7

M12200

20

15

3

70 61 /

25.3

62 54 /

21.5

M12250

25

18.5

3

8977 /

32.0

7868 /

27.1

M12300

30

22

3

10490 /

37.6

9280 /

31.9

M12400

40

30

3

11999 /

41.0

120104 /

41.4

M12600

60

45

3

174/145

60.5

177/154

61.3


11

2.1

Table of Contents

M1400 SERIES RATINGS I NP UT

MODEL

(400/480 Vac, 50 - 60 Hz)


O UT P UT

RATED

NOMINAL INPUT

CURRENT (AMPS)

(0 - 400/460 Vac)

NOMINAL 2

POWER

CURRENT

POWER

(KVA)

(AMPS)

(KVA)

HP

kW

PHASE

M1410

1

0.75

3

2.82.4 /

2.0

2.32.0 /

1.6

M1420

2

1.5

3

4.7 4.1 /

3.4

3.9 3.4 /

2.7

M1430

3

2.2

3

6.6 5.7 /

4.7

5.5 4.8 /

3.8

M1450

5

3.7

3

10.28.9 /

7.3

8.77.6 /

6.1

M1475

7.5

5.5

3

14.7/12.8

10.6

12.6/11.0

8.8

M14100

10

7.5

3

18.3/15.9

13.2

16.0/14.0

11.2

M14150

15

11

3

28 24 /

19.8

24 21 /

16.7

M14200

20

15

3

36 31 /

25.3

31 27 /

21.5

M14250 M14300

25 30

18.5 22

3 3

4438 / 52 45 /

31.9 37.6

3934 / 46 40 /

27.1 31.9

M14400

40

30

3

68 59 /

49.0

60 52 /

41.4

M14500

50

37.5

3

8574 /

61.5

7565 /

51.8

M14600

60

45

3

10087 /

72.3

8877 /

61.3

M14750

75

55

3

10991 /

75.5

11096 /

76.5

M141000

100

75

3

139/116

96.4

143/124

98.8

M141250

125

90

3

175/146

121.4

179/156

124.3

M141500

150

110

3

202/168

139.7

207/180

143.4


1 2

12

Table of Contents


MODEL

(480/590 Vac, 50 - 60 Hz)


OUTPUT

RATED

NOMINAL INPUT

CURRENT (AMPS)

(0 - 460/575 Vac)

NOMINAL 2

POWER

CURRENT

POWER

(KVA)

(AMPS)

(KVA)

HP

kW

PHASE

M1510

1

0.75

3

1.91.9 /

1.9

1.61.6 /

1.6

M1520

2

1.5

3

3.3 3.3 /

3.4

2.7 2.7 /

2.7

M1530

3

2.2

3

4.6 4.6 /

4.7

3.9 3.9 /

3.9

M1550/51

5

3.7

3

7.17.1 /

7.3

6.16.1 /

M1575

7.5

5.5

3

10.5/10.5

10.7

9.0/9.0

8.8

M15100

10

7.5

3

12.5/12.5

12.8

11.0/11.0

11.0

M15150

15

11

3

19.3/19.3

19.7

17.0/17.0

16.9

M15200

20

15

3

25 25 /

25.4

22 22 /

21.5

M15250 M15300

25 30

18.5 22

3 3

3131 / 36 36 /

31.2 37.1

2727 / 32 32 /

26.9 31.9

M15400

40

30

3

47 47 /

47.5

41 41 /

40.8

M15500

50

37.5

3

5959 /

60.3

5252 /

51.8

M15600

60

45

3

71 71 /

72.5

62 62 /

61.7

1


2

13

6.1

Table of Contents

6.0 6.1

THEORY DESCRIPTION OF AC MOTOR OPERATION

Three phase AC motors are comprised of two major components, the stator and the rotor. The stator is a set of three electrical windings held stationary in the motor housing. The rotor is a metal cylinder, fixed to the motor drive shaft, which rotates within the stator. The arrangement of the stator coils and the presence of three phase AC voltage give rise to a rotating magnetic field which drives the rotor. The speed at which the magnetic field rotates is known as the synchronous speed of the motor. Synchronous speed is a function of the frequency at which the voltage is alternating and the number of poles in the stator windings. The following equation gives the relation between synchronous speed, frequency, and the number of poles: Ss = 120 f/p Where: Ss = Synchronous speed (rpm ), f = frequency (Hz), p = number of poles In three phase induction motors the actual shaft speed differs from the synchronous speed as load is applied. This difference is known as “slip”. Slip is commonly expressed as a percentage of synchronous speed. A typical value is three percent at full load. The strength of the magnetic field in the gap between the rotor and stator is proportional to the amplitude of the voltage at a given frequency. The output torque capability of the motor is, therefore, a function of the applied voltage amplitude at a given frequency. When operated below base (rated) speed, AC motors run in the range of “constant torque”. Constant torque output is obtained by maintaining a constant ratio between voltage amplitude (Volts) and frequency (Hertz). For 60 Hz motors rated at 230, 460, and 575 Vac, common values for this V/Hz ratio are 3.83, 7.66, and 9.58 respectively. Operating with these V/Hz ratios generally yields optimum torque capability. Operating at lower ratio values results in lower torque and power capability. Operating at higher ratio values will cause the motor to overheat. Most standard motors are capable of providing full torque output from 3 to 60 Hz. However, at lower speeds, where motor cooling fans become less effective, supplemental cooling may be needed to operate at full torque output continuously. If the frequency applied to the motor is increased while the volta ge remains constant, torque capability will decrease as speed increases. This will cause the horsepower capability of the motor to remain approximately constant. Motors run in this mode when operated above base speed, where drive output voltage is limited by the input line voltage. This operating range is known as the “constant horsepower” range. The typical maximum range for constant horsepower is about 2.3 to 1 (60 to 140 Hz). The diagram below depicts the characteristics of a typical AC induction motor with a 60 Hz base speed.

WARNING! Consult motor manufacturer before operating motor and/or driven equipment above base speed.

14

Table of Contents

CONSTANTTORQUE

150

CONSTANTHP

130

) % ( E U Q R O T

110

TORQUE

HORSEPOWER

90

TOR

R WE RSEPO HO

70 50

QU E

30 10 20

40

60

80

100

120

FREQUENCY (Hz)

6.1.1

VARIABLE TORQUE VS. CONSTANT TORQUE

Variable frequency drives, and the loads they are applied to, can generally be divided into two groups: constant torque and variable torque. Constant torque loads include: vibrating conveyors, punch presses, rock crushers, machine tools, and just about every other application that is not considered variable torque. Variable torque loads include centrifugal pumps and fans, which make up the majority of HVAC applications. Variable torque loads are governed by the affinity laws, which define the relationships between speed, flow, torque and horsepower. The diagram below illustrates these relationships: 100%

75%

%F

50%

W LO %

25%

E RQU TO

%

R HO

PO SE

WE

R

0% 0%

25%

50%

75%

100%

% SPEED

“Variable torque” refers to the fact that the torque required varies with the square of the speed. Also, the horsepower required varies withthe cube of the speed,resulting in a large reduction in horsepower for even a small reduction in speed. It is easily seen that substantial energy savings can be achieved by reducing the speed of a fan or pump. For example, reducing the speed to 50% results in a 50 HP motor having to produce only 12.5% of rated horsepower, or 6.25 HP.

15

Table of Contents Variable torque drives usually have a low overload capacity (110% - 120% for 60 seconds), because variable torque applications rarely experience overload conditions. To optimize efficiency and energy savings, variable torque drives are usually programmed to follow a variable V/Hz ratio. The term “constant torque” is not entirely accurate in terms of the actual torque required for an application. Many constant torque applications have reciprocating loads, such as vibrating conveyors and punch presses, where the rotational motion of the motor is being converted to alinear motion. In such cases, thetorque required can vary greatly at different points in the cycle. For constant torque loads, this fluctuation in torque is not a direct function of speed, as it is with a variable torque load. As a result, constant torque drives typically have a high overload rating (150% for 60 seconds) in order to handle the higher peak torque demands. To achieve maximum torque, constant torque drives follow a constant V/Hz ratio. Both MC Series product lines (MC1000 and MC3000) have full overload capacity (150% for 60 seconds, 180% for 30 seconds), so that either one can be used for either type of application. The V/Hz ratio can also be changed to optimize performance for either type of application.

16


DRIVE FUNCTION DESCRIPTION

The MC Series is a 16 bit microprocessor based, keypad programmable, variable speed AC motor drive. There are four major sections: an input diode bridge and filter, a power board, a control board, and an output intelligent power module.

6.2.1

DRIVE OPERATION

Incoming AC line voltage is converted to a pulsating DC voltage by the input diode bridge. The DC voltage is supplied to the bus filter capacitors through a charge circuit which limits inrush current to the capacitors during power-up. The pulsating DC voltage is filtered by the bus capacitors which reduces the ripple level. The filtered DC voltage enters the inverter section of the drive, composed of sixoutput intelligent insulated gate bi-polar transistors (IGBTs) which make up the three output legs of the drive. Each leg has one intelligent IGBT connected to the positive bus voltage and one connected to the negative bus voltage. Alternately switching on each leg, the intelligent IGBT produces an alternating voltage on each of the corresponding motor windings. By switching each output intelligent IGBT at a very high frequency (known as the carrier frequency) for varying time intervals, the inverter is able to produce a smooth, three phase, sinusoidal output current wave which optimizes motor performance.

6.2.2

CIRCUIT DESCRIPTION

The control section consists of a control board with a 16 bit microprocessor, keypad and display. Drive programming is accomplished via the keypad or the serial communications port. During operation the drive can be controlled via the keypad, by control devices wired to the control terminal strip, or by the serial communications port. The Power Board contains the control and protection circuits which govern the six output IGBTs. The Power Board also contains a charging circuit for the bus filter capacitors, a motor current feedback circuit, a voltage feedback circuit, and a fault signal circuit. The drive has several built in protection circuits. These include phase-to-phase and phase-to-ground short circuit protection, high and low line voltage protection, protection against excessive ambient temperature, and protection against continuous excessive output current. Activation of any of these circuits will cause the drive to shut down in a fault condition.

6.2.3

MC1000 INPUTS AND OUTPUTS

The drive has two analog inputs (0-10 VDC and 4-20 mA) that can be used for speed reference, PID set point reference, or PID feedback. A speed potentiometer (10,000 Ohm) can be used with the 0-10 VDC input. There are also two analog outputs: one is proportional to speed (frequency), and the other is proportional to load. The drive has three programmable outputs for status indication: one Form C relay and two open-collector outputs. NOTE: Models rated above 30 Hp at 200/240 Vac and 60 Hp at 400/480 Vac have a second Form C relay. Refer to Sections 14.0 - CONTROL WIRING and 15.0 - CONTROL WIRING DIAGRAMS for more information.

17

Table of Contents

7.0

INSTALLATION WARNING!

DRIVES MUST NOT BE INSTALLED WHERE SUBJECTED TO ADVERSE ENVIRONMENTAL CONDITIONS! DRIVES MUS T NOT BE INSTALLED WHERE SUBJECTED TO: COMBUSTIBLE, OILY, ORHAZARDOUS VAPORS OR DUST; EXCESSIVE MOISTURE OR DIRT; STRONG VIBRATION; EXCESSIVE AMBIENTTEMPERATURES. CONSULT AC TECHNOLOGY FOR MORE INFORMATION ON THE SUITABILITY OF A DRIVE TO A PARTICULAR ENVIRONMENT. The drive should be mounted on a smooth vertical surface capable of safely supporting the unit without vibrating. The LCD display has an optimum field of view, this should be considered when determining the mounting position. Chassis models must be installed in an electrical enclosure which will provide complete mechanical protection and maintain uniform internal temperature within the drive’s ambient operating temperature rating. All drive models MUST be mounted in a vertical position for proper heatsink cooling. Maintain a minimum spacing around the drive as follows:

SPACING REQUIREMENTS SPACING

HP

INCHES

mm

0.25 5-

2

50

7.5 25 -

4

100

60 30 -

6

150

150 75 -

8

200

All drive models MUST be mounted in a vertical position for proper heatsink cooling. Fans or blowers should be used to insure proper cooling in tight quarters. Do not mount drives above other drives or heat producing equipment that would impede the cooling of the drive. Note the ambient operating temperature ratings for each drive model. If it is necessary to drill or cut the drive enclosure or panel, extreme care must be taken to avoid damaging drive components or contaminating the drive with metal fragments (which cause shorting of electrical circuits). Cover drive components with a clean cloth to keep out metal chips and other debris. Use a vacuum cleaner to clean drive components after drilling, even if chips do not appear to be present. Do not attempt to use positive air pressure to blow chips out of drive, as this tends to lodge debris under electronic components. Contaminating the drive with metal chips can cause drive failure and will void the warranty.The MC1000 Series is UL approved for solid state motor overload protection. Therefore, a separate thermal overload relay is not required for single motor applications. In applications where one drive is operating more than one motor, a separate thermal overload relay is required for each motor per NEC.

18


INSTALLATION AFTER A LONG PERIOD OF STORAGE

WARNING! Severe damage to the drive can result if it is operated after a long period of storage or inactivity without reforming the DC bus capacitors! If input power has not been applied to the drive for a period of time exceeding three years (due to storage, etc), the electrolytic DC bus capacitors within the drive can change internally, resulting in excessive leakage current. This can result in premature failure of the capacitors if the drive is operated after such a long period of inactivity or storage. In order to reform the capacitors and prepare the drive for operation after a long period of inactivity, apply input power to the drive for 8 hours prior to actually operating the drive/motor system.

7.2

EXPLOSION PROOF APPLICATIONS

Explosion proof motors that are not rated for inverter use lose their certification when used for variable speed. Due to the many areas of liability that may be encountered when dealing with these applications, the following statement of policy applies: “AC Technology Corporation inverter products are sold with no warranty of fitness for a particular purpose or warranty of suitability foruse with explosion proof motors. AC Technology Corporation accepts noresponsibility for any direct, incidental or consequential loss, cost, or damage that may arise through the use ofagrees its AC to inverter products in these applications. The purchaser expressly assume all risk of any loss, cost, or damage that may arise from such application."

19

Table of Contents

8.0

INPUT AC REQUIREMENTS WARNING!

Hazard of electrical shock! Disconnect incoming power and wait three minutes before servicing the drive. Capacitors retain charge after power is removed.

8.1

INPUT AC POWER REQUIREMENTS

8.1.1

VOLTAGE

The input must voltage match thethan drive’s voltage rating. Voltage fluctuation notmust vary by greater 10%nameplate over voltage or 15% under voltage. NOTE: Drives with dual rated input voltage must be programmed for the proper supply voltage. Refer to Parameter 0 - LINEVOLTS in Section 18.0 - DESCRIPTION OF PARAMETERS. The UL file for this drive shows that it is suitable for use on a circuit capable of delivering not more than 200,000 RMS symmetrical amperes, at the drive’s rated voltage. The CSA file identifies a short-circuit withstand rating of 5,000 RMS symmetrical amperes at the drives rated voltage. Three phase voltage imbalance must be less than 2.0% phase to phase. Excessive phase to phase imbalance can cause severe damage to the drive’s power components. Motor voltage should match line voltage in normal applications. The drive’s maximum output voltage will equal the input voltage. Use extreme caution when using a motor with a voltage rating which is different from the input line voltage.

8.1.2

SUPPLY TRANSFORMER kVA RATINGS

If the kVA rating of the AC supply transformer is greater than ten times the input kVA rating of the drive, a drive isolation transformer, or a 2 - 3% input line reactor (also known as a choke) must be added.

8.2

INPUT FUSING AND DISCONNECT REQUIREMENTS

A circuit breaker or a disconnect switch with fuses must be provided in accordance with the National Electric Code (NEC) and all local codes. The MC1000 drive is capable of withstanding up to 150% current overload for 60 seconds. Select a fuse or magnetic trip circuit breaker rated at 1.5 times the input current of the drive (the minimum size should be 10 amps, regardless input current rating rating). Refer to Section 5.0 - MC1000 RATINGS.Minimum voltageofrating of the protection device should be 250 Vac for 240/120 Vac and 240/200 Vac rated drives, and 600 Vac for 480/400 Vac and 590/480 Vac drives. Use UL Class CC or Class T current-limiting type fuses with low I 2 T values, rated at 200,000 AIC. Recommended fuses are Bussman type KTK-R, JJN, and JJS, or equivalent.

20

Table of Contents

9.0

VOLTAGE SELECTION

M1100 Series drives are rated for 240/120 Vac, 50-60 Hz input. The drive will function with input voltage of 120 Vac (+ 10%, -15%) at 48 to 62 Hz when wired for 120 Vac input, or with input voltage of 240 Vac (+ 10%, - 15%), at 48 to 62 Hz, when wired for 240 Vac input. M1200 Seriesdrives are rated for 240/200 Vac, 50-60 Hz input. The drive willfunction with input voltages of 200 to 240 Vac (+ 10%, - 15%), at 48 to 62 Hz. M1400 Series drives are rated for 480/400 Vac, 50-60 Hz input. The drive will function with input voltages of 400 to 480 Vac (+ 10%, - 15%), at 48 to 62 Hz. M1500 Series drives are rated for 590/480 Vac, 50-60 Hz input. The drive will function with input voltages of 480 to 590 Vac (+ 10%, - 15%), at 48 to 62 Hz.

10.0 POWER WIRING WARNING! Hazard of electrical shock! Wait three minutes after disconnecting incoming power before servicing drive. Capacitors retain charge after power is removed. Note drive input and output current ratings and check applicable electrical codes for required wire type and size, grounding requirements, over current protection, and incoming power disconnect, before wiring the drive. Size conservatively to minimize voltage drop. Input fusing and a power disconnect switch or contactor MUST be wired in series with terminals L1, L2, and L3 (L1 and L2 if input is single phase). If one has not been supplied by AC Technology Corporation, a disconnect means must be wired during installation. This disconnect must be used to power down the drive when servicing, or when the drive is not to be operated for a long period of time, but should not be used to start and stop the motor. Repetitive cycling of a disconnect or input contactor (more than once every two minutes) may cause damage to the drive.

10.1

WIRING FOR SINGLE PHASE OR THREE PHASE INPUT

If the drive is name plated for 240/120 Vac single phase input, wire the input to terminals L1 and N and jumper terminals L1 to L2 for 120 Vac input voltage, or wire to terminals L1 and L2 (do not wire to N) for 240 Vac input voltage. Refer to Section 11.0 - MC1000 POWER WIRING DIAGRAM. If the drive is name plated for three phase input only, wire the input to terminals L1, L2, and L3. All three power output wires, from terminals T1, T2, and T3 to the motor, must be kept tightly bundled and run in a separate conduit away from all other power and control wiring. It is not recommended to install contactors or disconnect switches between the drive and motor. Operating such devices while the drive is running can potentially cause damage to the drive's power components. If such a device is required, it should only be operated when the drive is in a STOP state. If there is potential for the device to be opened while the drive is running, the drive must be programmed for COAST TO STOP (see Parameter 26 - STOP), and an auxiliary contact on the device must be interlocked with the drive's run circuit. This will give the drive a stop command at the same time the device opens, and will not allow the drive to start again until the device is closed.

21

Table of Contents

11.0 MC1000 POWER WIRING DIAGRAM L1 L2 N T1

T2

T3

L1

L2

L3

120 Vac SINGLE PHASE INPUT WIRING DIAGRAM

GND GND

L1 L2 N

THREE PHASE AC MOTOR

DISCONNECT MEANS (REQUIRED) GND

240 Vac SINGLE PHASE INPUT WIRING DIAGRAM

FUSED INPUT VOLTAGE

WARNING! Do not connect incoming AC power to output terminals T1, T2, or T3! Severe damage to the drive will result. INSTALL, WIRE, AND GROUND IN ACCORDANCE WITH ALL APPLICABLE CODES. NOTES: 1. Wire the motor for the proper voltage per the output rating of the drive. Motor wires MUST be run in a separate steel conduit away from control wiring and incoming AC power wiring. 2. Do not install contactors between the drive and the motor. Failure to do so may result in drive damage. See Section 10.1. 3. Remove any existing, and do not install, power factor correction capacitors between the drive and the motor. Failure to do so will result in drive damage. 4. Use only UL and CSA listed and approved wire. 5. Minimum wire voltage ratings: 300 V for 120, 200 and 240 Vac systems, and 600 V for 400, 480, and 590 Vac systems. 6. Wire gauge must be based on a minimum of 125% of the rated input/output current of the drive, and a minimum 75°C insulation rating. Use copper wire only. 7. Wire and ground in accordance with NEC or CEC, and all applicable local codes.

22

Table of Contents

12.0 INITIAL POWER UP WARNING! Hazard of electrical shock! Wait three minutes after disconnecting incoming power before servicing drive. Capacitors retain charge after power is removed. Before attempting to operate the drive, motor, and driven equipment be sure all procedures pertaining to installation and wiring have been properly followed.

WARNING! Severe damage to the drive can result if it is operated after a long period of storage or inactivity without reforming the DC bus capacitors! If input power has not been applied to the drive for a period of time exceeding three years (due to storage, etc), the electrolytic DC bus capacitors within the drive can change internally, resulting in excessive leakage current. This can result in premature failure of the capacitors if the drive is operated after such a long period of inactivity or storage. In order to reform the capacitors and prepare the drive for operation after a long period of inactivity, apply input power to the drive for 8 hours prior to actually operating the drive/motor system. Disconnect the driven load from the motor. Verify that the drive input terminals (L1, L2, and L3) are wired to the proper input voltage per the nameplate rating of the drive.

WARNING! DO NOT connect incoming AC power to output terminals T1, T2, and T3! Do not cycle input power to the drive more than once every two minutes. Damage to the drive will result. Energize the incoming powerline. The LCD display should light andflash “TESTING” and then show the voltage and horsepower rating of the drive. The display should then show “STOP > 20.00 HZ” which indicates that the drive is in a STOP condition, and the speed set point is 20.00 Hz:

STOP

>

20.00 HZ

If the display does not appear, remove the incoming power, wait three minutes for the bus capacitors to discharge, and verify correct installation and wiring. If the wiring is correct, re-apply incoming power and note the display for drive status. If the display still does not appear contact the factory for assistance. NOTE 1: If the drive's display is blank after power up,and it is a model equipped with heatsink fans, check to make sure the fans are operating (they should be spinning anytime power is applied to the drive). If they are not spinning, the drive's display will be blank and the drive cannot be operated. If the fans are clogged or jammed, disconnect power from the drive and remove any obstructions from the fans. Reapply power to the drive and check the fans. If they are spinning, the drive's display should appear and the drive should operate properly. If there are no obstructions, the fan itself may be defective. Please contact the factory for assistance.

23

Table of Contents If the drive powers up correctly, follow the procedure given below to check the motor rotation: 1. Use the  key to decrease the speed set point to the minimum value allowed (.50 Hz if Parameter 10 - MIN FRQ has not been changed). 2. Press the START key. The drive should indicate RUN, but if the speed set point is .50 Hz, the motor may not rotate. Press the  key to increase the speed set point until the motor starts to rotate. 3. If the motor is rotating in the wrong direction, press the STOP key and remove power from the drive. Wait three minutes for the bus capacitors to discharge, and swap any two of the motor wires connected to T1, T2, and T3. NOTE 2: The drive is phase insensitive with respect to incoming line voltage. Therefore, to change the motor rotation, the phases must be swapped at the drive output terminals or at the motor.

13.0 KEYPAD CONTROL The drive can be operated in a number of different ways: keypad (LOCAL), control devices wired to the terminal strip (REMOTE), serial communications (SERIAL), or a combination of each. The drive should firstbe operated from the keypad during initial start-up. Refer to Sections 14.0 - CONTROL WIRING, and 18.0 - DESCRIPTION OF PARAMETERS for information on remote operation.

13.1

KEYPAD FUNCTIONS (IN LOCAL MODE)

START/STOP

To start the drive, press the START key. To stop the drive, press the STOP key. NOTE: The STOP key is active in both LOCAL and REMOTE modes.

SPEED SET POINT

To increase the speed set point, press the  key. To decrease the speed set point, press the  key. NOTE: The  and  keys will only function if another speed reference source is not selected.

FORWARD/REVERSE To change rotation direction, press the FWD/REV key to select the desired direction, and then press the ENTER key within three seconds to confirm the change. NOTE: Parameter 27 - ROTATION must be set to FWD & AUTO/MANUAL

FAULT RESET

REV for this key to be active. To togg le betwe en AUTOMAT IC (term inal strip ) and MANUAL (keypad) speed control, press the AUTO/MAN key to select the desired mode, and then press the ENTER key within three seconds to confirm the change. NOTE: Parameter 28 - AUTO/MAN must be set to BOTH for this key to be active. See Section 14.0 - CONTROL WIRING for information on automatic speed references. Use the STOP key to reset a fault. If the fault condition has passed, pressing the STOP key will reset the fault and return the drive to a STOP condition. NOTE: If an OUTPUT fault occurs, there will be a 30 second delay before the fault can be cleared using the STOP key.

24


MC1000 DISPLAY

The following describes the possible display configurations for the MC1000 Series drive.

13.2.1 MC1000 DISPLAY IN STOP MODE When the drive is in the STOP mode, there are three possible displays. The first is the SPEED display, which looks like this: DRIVE STATUS

SPEED SET POINT

STOP

> 60.00 HZ

DIRECTION (FORWARD)

SPEED UNITS

NOTE: See Parameter 31 - UNITS for the SPEED UNITS display options. Pressing the ENTER key will change the display from the SPEED indication to the % LOAD indication: DRIVE STATUS

PERCENT LOAD

STOP

> 0% LOAD

DIRECTION (FORWARD)

Pressing the ENTER key again will change the display from the % LOAD indication to the VAC (motor voltage) indication: DRIVE STATUS

MOTOR VOLTAGE

STOP

>

0 VAC

DIRECTION (FORWARD)

Pressing ENTER again will change the display back to the SPEED indication.

25

Table of Contents The following table shows the possible DRIVE STATUS indications that can appear on the drive display:

DRIVE STATUS TABLE DISPLAY

DESCRIPTION

STOP

Drive to STOP mode - No output to motor.

RUN

Drive is in RUN mode and is within + 0.3 Hz of the speed set point.

FAULT

Drive has shut down due to a FAULT condition. If the fault condition has passed, pressing the STOP key will clear the fault and return the drive to the STOP mode.

LOCK

Drive is in FAULT LOCKOUT after five unsuccessful restart attempts.

BRAKE

DC BRAKE is energized.

LIMIT

Drive is in CURRENT LIMIT due to an overloaded motor, or ACCEL is set too fast.

F DEC

Drive is in DECEL FREEZE because DECEL is set too fast.

13.2.2 MC1000 DISPLAY IN RUN MODE When the drive is in the RUN mode, the default display will look like this: DRIVE STATUS

RUN

SPEED SET POINT

>

60.00 HZ

DIRECTION (FORWARD)

SPEED UNITS

As in the STOP mode, the ENTER key can be used to toggle the display from SPEED to % LOAD to VAC (motor voltage): DRIVE

PERCENT

STATUS

LOAD

RUN

> 85% LOAD

DIRECTION (FORWARD)

26

Table of Contents DRIVE STATUS

MOTOR VOLTAGE

RUN

>

460 VAC

DIRECTION (FORWARD)

NOTE: During acceleration and deceleration to the SPEED SETPOINT, the DRIVE STATUS will show the actual drive speed. When the SPEED SET POINT is reached, the DRIVE STATUS will change to RUN (or STOP if the drive is decelerating to a STOP).

13.2.3 MC1000 DISPLAY IN FAULT MODE When the drive trips into a fault, the display will automatically change to the FAULT display, which indicates the FAULT MESSAGE: DRIVE STATUS

FAULT MESSAGE

FAULT: OVERLOAD In FAULT mode, the ENTER key will toggle the display between four screens: FAULT, SPEED, % LOAD and VAC. The DRIVE STATUS for these displays will be FAULT. An example is shown below of the drive in the FAULT mode displaying SPEED. DRIVE STATUS

SPEED SET POINT

FAULT > 60.00 HZ DIRECTION (FORWARD)

SPEED UNITS

NOTE: To clear a FAULT, press the STOP key, issue a remote STOP command at TB-1, or use TB-13D (refer to Parameter 50 - TB13D).

27

Table of Contents 13.2.4 MC1000 DISPLAY IN AUXILIARY MODE If the ENTER key is held down, the display will enter the auxiliary mode, which indicates the control source (LOCAL, REMOTE, or SERIAL), AUTO or MANUAL mode, and the speed reference source. When the ENTER key is released, the display will return to the previous screen. An example of the auxiliary mode display is shown below: CONTROL SOURCE

AUTO/MAN MODE

SPEED REFERENCE SOURCE

LOCAL -- AUTO -- IDC The table below shows the possible SPEED REFERENCE SOURCE indications for the auxiliary mode display:

SPEED REFERENCE SOURCE TABLE DI S P L A Y

DESCRIPTION

KEY

KEYPAD - Change speed using the

VDC IDC

0 - 10 VDC analog input at TB-5A. 4 - 20 mA analog input at TB-5B.

SP#1

PRESETSPEED#1

SP#2

PRESETSPEED#2

SP#3

PRESETSPEED#3

SP#4

PRESETSPEED#4

JOG

JOG SPEED - In JOG mode, JOG SPEED = PRESET SPEED #2.

MOP

MOTOR OPERATED POT - Change speed using contact closures at TB-13A (DEC FREQ) and TB-13B (INC FREQ).

28



and  keys.

Table of Contents

14.0 CONTROL WIRING 14.1

GENERAL

14.1.1 KEYPAD CONTROL The drive can be controlled by the keypad or by control devices wired to the terminal strip. The drive will run from the keypad “out of the box”, requiring no connections to the terminal strip. Refer to Section 13.0 - KEYPAD CONTROL.

14.1.2 CONTROL WIRING VS. POWER WIRING External control wiring MUST be run in a separate conduit away from all other input and output power wiring. If control wiring is not kept separate from power wiring, electrical noise may be generated on the control wiring that will cause erratic drive behavior. Use twisted wires or shielded cable grounded at the drive chassis ONLY. Recommended control wire is Belden 8760 (2-wire) or 8770 (3-wire), or equivalent. Torque the control terminals to 2 lb-in (0.2 Nm). Be careful not to overtorque the control terminals, as this will cause damage to the terminal strip. This is not covered under warranty and can only be repaired by replacing the control board.

14.1.3 TB-2: CIRCUIT COMMON The TB-2 terminals are used as circuit common for the start/stop, forward/reverse, input select, local/remote,analog input, and analog outputfunctions. There are three TB-2 terminals available on the terminal strip, and they are all internally connected to each other on the main control board. If necessary TB-2 may be connected to chassis ground. NOTE: TB-2 MUS T be con nected to chassis gro und when usi ng serial communications.

14.1.4 SURGE SUPPRESSION ON RELAYS Current and voltage surges and spikes in the coils of contactors, relays, solenoids, etc, near or connected to the drive, can cause erratic drive operation. Therefore, a snubber circuit should be used on coils associated with the drive. For AC coils, snubbers should consist of a resistor and a capacitor in series across the coil. For DC coils, a free-wheeling or fly back diode should be placed across the coil. Snubbers are typically available from the manufacturer of the device.14.2 START/STOP AND SPEED CONTROL

14.2.1 REMOTE MODE SELECTION The REMOTE mode can be selected by one of two methods: 1. Program Parameter 30 - CONTROL to REMOTE, or: 2. Program CONTROL to BOTH, set the TB-13A or TB-13C function (see Parameter 47 or 49) to LOCAL SELECT, and DO NOT make a contact closure between TB-13A or TB-13C and TB-2 (making the contact closure will select LOCAL mode).

WARNING! If CONTROL is set to LOCAL, TB-1 is disabled andCANNOT be used as a STOP switch! Incorrect use of TB-1 may result in damage to equipment and/or injury to personnel! See Parameter 30 - CONTROL.

29

Table of Contents

WARNING! STOP (TB-1) and EXTERNAL FAULT (TB-13D) circuitry may be disabled if parameters are reset tofactory defaults! The drive must be reprogrammed after a RESET in order to insure proper operation (see Parameter 65 - PROGRAM). FAILURE TO DO SO MAY RESULT IN DAMAGE TO EQUIPMENT AND/OR INJURY TO PERSONNEL!

14.2.2 TWO-WIRE START/STOP CONTROL A two-wire start/stop circuit can be accomplished by one of three methods on the MC Series drive. Follow the appropriate procedure listed below: FORWARD ROTATION ONLY 1. Select REMOTE mode (see above). 2. Connect a jumper betweenTB-12A and TB-2 to provide a permanent START command to the drive. 3. Wire a normally open maintained contact between TB-1 and TB-2. Closing this contact will RUN the drive and opening this contact will STOP the drive. FORWARD and REVERSE ROTATION 1. Select REMOTE mode (see above). 2. Program Parameter 27 - RO TATION to FWD & REV to allow rotation in both directions. 3. Program Parameter 49 - TB13C to START REVERSE. This will force TB12A to act as START FORWARD. 4. Select the desired rotation by closing the appropriate terminal (TB-12A for forward, or TB-13C for reverse) to TB-2. This can be done with a toggle switch or equivalent circuit. 5. Wire a normally open maintained contact between TB-1 and TB-2. Close this contact to RUN the drive, and open this contact to STOP the drive.

14.2.3 ALTERNATE TWO-WIRE START/STOP CONTROL METHOD

WARNING! This method requires TB-13C to be set for RUN REVERSE, which will disable TB-1 as a STOP switch! Incorrect use of TB-1 may result in damage to equipment and/or injury to personnel! Refer to Parameter 49 - TB13C.

FORWARD ROTATION ONLY 1. Select REMOTE mode (see above). 2. Program Parameter 27 - ROTATION to FWD & REV. 3. Program Parameter 49 - TB13C to RUN REVERSE. This will force TB-12A to act as RUN FORWARD. 4. Wire a normally open maintained contact between TB-12A and TB-2. Close this contact to RUN the drive in FORWARD, and open this contact to STOP the drive.

30

Table of Contents FORWARD and REVERSE ROTATION with TWO RUN CONTACTS 1. Follow 1-4 above and also wire a normally open maintained contactbetween TB-13C and TB-2. Close this contact to RUN the drive in REVERSE, and open this contact to STOP the drive. FORWARD and REVERSE ROTATION with ONE RUN CONTACT 1. Follow 1-3 above and wire a normally open maintained contact between TB-2 and the common of a single-pole, double-throw toggle switch. Wire the poles of the toggle switch to TB-12A and TB-13C. Select the desired rotation with the toggle switch. Close the maintained contact to RUN, and open to STOP.

14.2.4 THREE-WIRE START/STOP CONTROL A three-wire start/stop circuit can be accomplished by one of two methods on the MC Series drive. Follow the appropriate procedure listed below: FORWARD ROTATION ONLY 1. Select REMOTE mode (see above). 2. Wire a normally closed momentary STOP contact between TB-1 and TB-2. Momentarily open this contact to STOP the drive. 3. Wire a normally open momentary START contact between TB-12A and TB-2. Momentarily close this contact to START the drive. FORWARD and REVERSE ROTATION with TWO START CONTACTS 1. 2. 3. 4.

Select REMOTE mode (see above). Program Parameter 27 - ROTATION to FWD & REV. Program Parameter 49 - TB13C to START REVERSE. Wire a normally closed momentary STOP contact between TB-1 and TB-2. Momentarily open this contact to STOP the drive. 5. Wire a normally open momentary START FORWARD contact between TB-12A and TB-2. Momentarily close this contact to START the drive in FORWARD. 6. Wire a normally open mom entary START REVERSE contact between TB-13C and TB-2. Momentarily close this contact to START the drive in REVERSE. NOTE: If the drive is operating in one direction, and is given the START command for the opposite direction, the drive will decelerate to 0 Hz and then accelerate back to the speed set point in the opposite direction. FORWARD and REVERSE ROTATION with ONE START CONTACT 1. Follow 1-4 above and wire a normally open momentary contact between TB-2 and the common of a single-pole, double-throw toggle switch.Wire the poles of the toggle switch to TB-12A and TB-13C. See the wiring diagram in Section 15.3.

31

Table of Contents 14.2.5 SPEED REFERENCE SIGNALS The drive allows for three analog speed reference inputs: a speed potentiometer (10,000 Ohm), 0-10 VDC, or 4-20 mA. SPEED POT

Connect the wiper to terminal TB-5A, and connect the high and low end leads to terminals TB-6 and TB-2, respectively.

0-10 VDC

Wire the positive to terminal TB-5A and the negative to terminal TB-2. TB-5A input impedance is 200 kilohms.

4-20 mA

Wire the positive to terminal TB-5B and the negative to terminal TB-2. TB-5B input impedance is 100 ohms.

14.2.6 SPEED REFERENCE SELECTION AUTO/MAN vs. LOCAL/REMOTE In the MC Series drive, AUTO/MAN refers to speed control, and LOCAL/REMOTE refers to START/STOP control. AUTOMATIC or MANUAL speed control selection is affected by whether the drive is in LOCAL or REMOTE mode. In LOCAL mode (keypad start/stop control), AUTOMATIC and MANUAL speed control is selected using Parameter 28 - AUTO/MAN. When AUTO/MAN is set to BOTH, the AUTO/MAN button on the keypad is active and is used to toggle between MANUAL (keypad or speed pot) and AUTOMATIC (0-10 VDC, 4-20 mA, or preset speeds) speed control. When set to MANUAL, speed control is governed by Parameter 29 - MANUAL, which selects either KEYPAD or 0-10 VDC (speed pot). When set to AUTOMATIC, one of the TB-13 input selects must be set to the desired speed reference, and that terminal must be closed to TB-2. The drive will then respond to the automatic speed reference. If one of the TB-13 input selects is set for a speed reference, and the contact closure is not made to TB-2, speed control will remain in AUTO mode, but the drive will respond to the keypad or speed pot, depending on Parameter 29 - MANUAL. Therefore, if the Form C relay or opencollector outputs are set to indicate AUTO/MAN mode, they will still indicate AUTO mode.In REMOTE mode (terminal strip start/stop control), speed control is only selected using the TB-13 input selects. For AUTOMATIC speed control, one of the TB-13 input selects must be set to the desired speed reference, and that terminal must be closed to TB-2. The drive will then respond to the automatic speed refer ence. If none of the TB-13 input selects are closed to TB-2, speed control will default to MANUAL mode, and the drive will respond to the keypad or speed pot, depending on Parameter 29 - MANUAL. This will cause the Form C relay or open-collector outputs to indicate MANUAL mode if set to indicate AUTO/MAN mode. 0 - 10 VDC and 4 - 20 mA INPUT SIGNALS TB-13A, TB-13B, and TB-13C can all be programmed to select 0-10 VDC or 4-20 mA input. PRESET SPEEDS TB-13A can be programmed to select SPEED #1, TB-13B to select SPEED #2, and TB-13C to select SPEED #3. Closing any two of these terminals to TB-2 will select SPEED #4. Refer to Parameters 1-4: SPEED #1 - #4 in Section 18.0 - DESCRIPTION OF PARAMETERS.

32

Table of Contents JOG The JOG function only works when the drive is in REMOTE mode, and only when the drive is in a STOP condition. TB-13B can be programmed to select either JOG FORWARD or JOG REVERSE. The jog speed is set by PRESET SPEED #2. Close TB-13B to TB-2 to JOG, and open the contact to STOP.

WARNING! When operating in JOG mode, the STOP key WILL NOT stop the drive. To stop the drive, the contact between TB-13B and TB-2 must be opened. MOP - MOTOR OPERATED POT TB-13A and TB-13B are used for this function, which sets the speed of the drive using contacts wired to the terminal strip. Program TB-13A to select DEC FREQ, and program TB-13B to select INC FREQ. Closing TB-13A to TB-2 will activate the DEC FREQ function, and will cause the speed set point to decrease until the contact is opened. DEC FREQ will operate when the drive is in RUN mode or STOP mode. Closing TB-13B to TB-2 will activate the INC FREQ function, and will cause the speed set point to increase until the contact is opened. INC FREQ will only operate when the drive is in RUN mode. NOTE: If TB-13A, TB-13B, and TB-13C are all programmed to select speed references, and two or three of the terminals are closed to TB-2, the higher terminal has priority and will override the others. For example, if TB-13A is programmed to select 0-10VDC, and TB-13C is programmed to select PRESET SPEED #3, closing both terminals to TB-2 will cause the drive to respond to PRESET SPEED #3, because TB-13C overrides TB-13A.

14.2.7 ANALOG OUTPUT SIGNALS There are two terminals that can supply analog output signals proportional to output frequency or load. Terminal TB-10A can provide a 0-10 VDC or a 2-10 VDC signal proportional to output frequency, and TB-10B can provide the same signals proportional to load. The 2-10 VDC signals can be converted to a 4-20 mA signal using a resistor in series with the signal such that the total load resistance is 500 Ohms. See Parameters: 42 - TB10A OUT, 43 - @TB10A, 44 - TB10B OUT, and 45 - @TB10B in Section 18.0 - DESCRIPTION OF PARAMETERS. NOTE: These analog output signals cannot be used with “loop-powered” devices that derive power from a 4-20 mA signal.

14.2.8 DRIVE STATUS OUTPUT CONTACTS The control board has one Form C relay at terminals TB-16, TB-17, and TB-18. Contacts are rated 2 amps at 28 VDC or 120 Vac. NOTE: Models rated above 30 Hp at 200/240 Vac and 60 Hp at 400/480 Vac have a second Form C relay at terminals TB-19, TB-20, and TB-21. There are also two open-collector outputs at terminals TB-14 and TB-15. The opencollector circuit is a current-sinking type rated at 30 VDC and 40 mA maximum. An external power supply (30 VDC max) must be used to power the open-collector outputs. The drive does not have a dedicated power supply for theopen-collector outputs. The Form C relay and the open collector outputs can be programmed to indicate any of the following: RUN, FAULT, /FAULT (INVERSE FAULT), LOCK (FAULT LOCKOUT), AT SPEED, ABOVE #3, I LIMIT (CURRENT LIMIT), or AUTO/MAN. See Parameters: 52 - TB14 OUT,53 - TB15 OUT, and54 - RELAY. Refer to Section 6.2.5 for a complete description of each of these status indications.

33

Table of Contents

15.0 MC1000 CONTROL WIRING DIAGRAMS 15.1

MC1000 TERMINAL STRIP

Shown below is the terminal strip on the main control board, along with a brief description of the function of each terminal. Wiring shown above the terminal strip indicates internal wiring on the main control board. FORM C RELAY The TB-2 terminals are internally tied together

1

2 5A 5B 6 10A 10B 2 12A 13A 13B 13C 13D1 4 15 2 RXA TXB

S T O P

C IR C U IT C O M M O N

0 -1 0 V D C S P E E D R E F E R E N C E IN P U T

4 -2 0 m A S P E E D R E F E R E N C E IN P U T

1 0 V D C S U P P L Y F O R S P E E D P O T

0 -1 0 O R 2 -1 0 V D C O U T P U T : F R E Q U E N C Y

0 -1 0 O R 2 -1 0 V D C O U T P U T : L O A D


S T A R T

T B -1 3 A F U N C T IO N S E L E C T

T B -1 3 B F U N C T IO N S E L E C T

T B -1 3 C F U N C T IO N S E E L C T

T B -1 3 D F U N C T IO N S E E L C T

O P E N -C O L L E C T O R O U T P U T

O P E N -C O L L E C T O R O U T P U T


C O M M U N IC A T IO N S

16 17 18

R S -4 8 5 S E R IA L

NOTE: The function of terminals TB-10A, TB-10B, TB-13A, TB-13B, TB-13C, TB-13D, TB-14, TB-15, TB-16, and TB-18 are dependent on the programming of certain parameters. In most cases, the name of the parameter matches the number of the terminal, allowing quick and easy programming of the terminals to suit the application. The exception is TB-16 and TB-18, which are governed by Parameter 54 - RELAY. A complete description of operating the drive in the REMOTE mode can be found in Section 14.2. The following diagrams provide a quick reference to wire the drive for the most common configurations.

34


TWO-WIRE START/STOP CONTROL

Shown below is the wiring diagram for a typical two-wire start/stop control scheme, using one maintained contact (such as that from a PLC) for RUN and STOP commands. Close the contact to RUN, and open the contact to STOP. Also shown is the wiring for a 0-10 VDC or 4-20 mA speed reference signal. The TB-2 terminals are internally tied together

1

2 5A 5B 6 10A 10B 2 12A 13A 13B 13C 13D1 4 15 2 RXA TXB

S T O P


0 -1 0 V D C IN P U T

4 -2 0 m A IN P U T


S T A R T R E V E R S E

S T A R T F O R W A R D

FWD

16 17 18

0-10 VDC or 4-20 mA SELECT (see Note 3)

REV (see Note 2)

MAINTAINED RUN/STOP CONTACT

NOTES: 1. Close TB-1 to TB-2 to RUN, and open to STOP. 2. If REVERSE direction is required, ROTATION must be set to FWD&REV, and TB-13C must be set to START REVERSE (refer to Parameters: 27 - ROTATION, and 49 - TB-13C). If REVERSE is not required, jumper TB-2 to TB-12A and eliminate the FWD/REV switch. 3. Program 13B,the or 13C select(refer the appropriate speed signal thatTB-13A, will control drivetospeed to Parameters 47,reference 48, and 49). When that TB-13 terminal is closed to TB-2, the drive will respond to the selected speed reference signal. In the diagram above, TB-13A is programmed to select either a 0-10 VDC or 4-20 mA signal. 4. If the contact closure is not made between TB-13A and TB-2 to select a speed reference, the drive will default to MANUAL speed control, which is determined by Parameter 29 - MANUAL.

35


THREE-WIRE START/STOP CONTROL

Shown below is the wiring diagram for a typical three-wire start/stop control scheme, using momentary contacts (such as push buttons) for START and STOP commands. Also shown is the wiring for a 0-10 VDC or 4-20 mA speed reference signal. The TB-2 terminals are internally tied together

1

2 5A 5B 6 10A 10B 2 12A 13A 13B 13C 13D 141 5 2 RXA TXB

S T O P


0 -1 0 V D C IN P U T

4 -2 0 m A IN P U T


FWD

MOMENTARY STOP CONTACT

S T A R T R E V E R S E

S T A R T F O R W A R D

16 17 18

0-10 VDC or 4-20 mA SELECT (see Note 3)

REV (see Note 2)

MOMENTARY START CONTACT

NOTES: 1. Momentarily close TB-12A to TB-2 to START, and momentarily open TB-1 to TB-2 to STOP. 2. If REVERSE direction is required, ROTATION must be set to FWD&REV, and TB-13C must be set to START REVERSE (refer to Parameters: 27 - ROTATION, and 49 - TB13C). If REVERSE is not required, wire the Start button directly to TB-12A and eliminate the FWD/REV switch. 3. Program TB-13A, 13B, or 13C to select the appropriate speed reference signal that will control the drive speed (refer to Parameters 47, 48, and 49). When that TB-13 terminal is closed to TB-2, the drive will respond to the selected speed reference signal. In the diagram above, TB-13A is programmed to select either a 0-10 VDC or 4-20 mA signal. 4. If the contact closure is not made between TB-13A and TB-2 to select a speed reference, the drive will default to MANUAL speed control, which is determined by Parameter 29 - MANUAL.

36


SPEED POT AND PRESET SPEED CONTROL

Shown below is the wiring diagram for a control scheme that utilizes a speed pot and PRESET SPEEDS for speed control, and either a two-wire or three-wire START/STOP circuit: The TB-2 terminals are internally tied together

1

2 5A 5B 6 10A 10B 2 12A 13A 13B 13C 13D 141 5 2 RXA TXB

S T O P


0 -1 0 V D C IN P U T

1 0 V D C S U P P L Y


S T A R T

P R E S E T S P E E D



16 17 18


SPEED POT (10 K)

NOTES: 1. Program the PRESET SPEEDS (Parameters 1-4) to the desired values. 2. Program TB-13A to select SPEED #1, TB-13B to select SPEED #2, and TB-13C to select SPEED #3 (refer to Parameters 47, 48, and 49). 3. To select a preset speed, close the appropriate terminal to TB-2. To select SPEED #4, close any two of the preset speed terminals to TB-2. 4. Speed pot control can be selected by one of two methods. If none of the preset speeds are selected (all TB-13 terminals are open), the drive will default to speed pot control if Parameter 29 - MANUAL is set to 0-10 VDC. The speed pot can also be selected if one of the TB-13 terminals is programmed to select 0-10 VDC and that terminal is closed to TB-2. 5. If REVERSE rotation is required, TB-13C cannot be used to select SPEED #3. TB-13C must be programmed to select RUN REVERSE or START REVERSE, leaving only TB-13A and TB-13B to select preset speeds.

37

Table of Contents

16.0 PROGRAMMING THE MC1000 DRIVE 16.1

PROGRAMMING THE PARAMETERS

The MC1000 keypad serves two purposes: operating the drive when in the LOCAL mode, and programming the parameters for particular applications. The keypad is shown below, along with the display that should appear when the drive is first powered up:

STOP

PROG RUN

ENTER

> 20.00 HZ

AUTO MAN

START

FWD

STOP

REV

To program the drive, the PROGRAM mode must be entered by pressing the PROG/ RUN button. If the password protection is disabled, pressing the PROG/RUN button will result in direct entry into the PROGRAM mode. If the password protection is enabled, the PASSWORD prompt will appear when an attempt is made to enter the PROGRAM mode. The PASSWORD prompt appears as follows:

PASSWORD

0000 CURSOR

To enter the password, use the UP and DOWN arrow keys to scroll to the password value, and then press the ENTER key. Note: The factory default password is 0019.

38

Table of Contents Once the correct password is entered, the PROGRAM mode will be entered and the first parameter will be displayed, which is Parameter 0 - LINE VOLTS. This is shown below: PARAMETER NAME

PARAMETER VALUE

LINE VOLTS

AUTO

CURSOR

To scroll through the parameters, use the UP and DOWN arrow buttons on the keypad. When the desired parameter is found, press the ENTER key to shift the cursor from the parameter name to the parameter value. In this example, the cursor shifts from LINE VOLTS to AUTO: PARAMETER NAME

PARAMETER VALUE

LINE VOLTS

AUTO CURSOR

The parameter value can then be changed using the UP and DOWN arrow buttons. If the parameter has a numerical value, the UP arrow will increase the value and the DOWN arrow will decrease the value. If the parameter has specific choices that can be selected, the UP and DOWN arrow keys will scroll through the list of possible settings. When the desired value or option is selected, press the ENTER key to store the new setting. If the new setting is not ENTERED, it will not take effect and the old setting will still be valid. If the PROG/RUN key is pushed while the cursor is highlighting the parame ter value, the value will change back to the srcinal setting (if it had been changed, but not ENTERED), and the cursor will shift back to the parameter name. Pressing PROG/ RUN will exit the mode. If theviewed, PROGRAM mode iswill entered again withinagain two minutes, the PROGRAM last parameter that was or changed, come up on the display. After two minutes has elapsed, the password will have to be entered again when attempting to access the PROGRAM mode.

39


PARAMETER ACCESS USING SPEED DIAL

SPEED DIAL is used to access parameters quickly using the parameter number. Once accessed, the parameter can be programmed as described in Section 16.1. SPEED DIAL is accessed by pressing the AUTO/MAN key while in the PROGRAM mode. This will activate the SPEED DIAL display as shown below:

- SPEED DIAL Once in SPEED DIAL, the UP and DOWN arrow keys will allow the operator to scroll through the parameter numbers. The display will continue to show SPEED DIAL while scrolling through the parameter numbers, as shown below:

#11

SPEED DIAL

When the desired parameter is reached, the SPEED DIAL display will be replaced by the parameter name:

#11

MAX FRQ

Once the desired parameter is displayed on the screen, press the ENTER key to display the parameter name and present setting. The parameter setting can now be changed by the method described in Section 16.1. Press the AUTO/MAN key to return to SPEED DIAL.

40

Table of Contents

17.0 PARAMETER MENU

PARAMETER MENU PARAM.

PARAMETER

RANGE OF

FACTORY

NUMBER

NAME

ADJUSTMENT

DEFAULT

0

LINEVOLTS

HIGH,LOW,AUTO

1

SPEED#1

MINFRQ-MAXFRQ

20.00Hz

2

SPEED#2

MINFRQ-MAXFRQ

20.00Hz

3

SPEED#3

MINFRQ-MAXFRQ

20.00Hz

4

SPEED#4

MINFRQ-MAXFRQ

20.00Hz

5

SKIP#1

0.00Hz MAX - FRQ

0.00Hz

6

SKIP#2

0.00Hz MAX - FRQ

0.00Hz

7

BANDWID

8

ACCEL

(NOTE 1)

30.0 SEC

9

DECEL

(NOTE 1)

30.0 SEC

10

MINFRQ

11 12

MAXFRQ DC BRAKE

13

DCTIME

0.0 999.9 - SEC

14

DYN BRAKE

OFF, ON

0.00 10.00 - Hz

0.00 MAX - FRQ MINFREQ-120.0Hz(NOTE2) (NOTE 1)

25180 - %(NOTE3)

AUTO

1.00Hz

0.50Hz 60.00Hz 0.0 VDC 0.0SEC OFF

16

CURRENT

17

MOTOR OL

18

BASE

19

FX BOOST

0.0 30.0 - %

(NOTE 1)

20

AC BOOST

0.0 20.0 - %

0.00 %

21

SLIP CMP

0.0 5.0 -%

22

TORQUE

CONSTANT, VARIABLE, CT / NOCMP

23

CARRIER

2.5,6,8,10,12,14kHz

25

START

NORMAL, POWER UP, AUTO RE-, RE-BRAKE

26

STOP

COAST,RAMP,RAMP2

27

ROTATION

100 25 -% 20.00-360.0Hz(NOTE2)

180% 100 % 60.00Hz

0.00 % CONSTANT 2.5kHz

FORWARD, REVERSE, FWD&REV, FWD@LOC

NORMAL COAST FORWARD

NOTE 1: REFER TO SECTION 18.0 - DESCRIPTION OF PARAMETERS NOTE 2: MAX LIMIT IS 650 Hz ON UNITS WITH HIGH FREQUENCY SOFTWARE NOTE 3: IFIS LINE VOLTS SET TO (OR SET TO "AUTO" AND THE INPUT VOLTAGE LOW), THEIS RANGE IS "LOW" 25 - 150%.

41

Table of Contents


PARAMETER

RANGE OF

FACTORY

NUMBER

NAME

ADJUSTMENT

DEFAULT

28

AUTO/MAN

AUTO,MANUAL,BOTH

BOTH

29

MANUAL

KEYPAD,0-10VDC

KEYPAD

30

CONTROL

LOCAL,REMOTE,BOTH

LOCAL

sp: HERTZ, RPM, % HZ, /SEC, /MIN, /HR, GPH, NONE 31

UNITS

sp: HERTZ

pid: %, PSI, FPM, CFM, GPM, IN, FT, /SEC, /MIN, /HR, F, C, MPM, GPH

32

HZ MULT

0.10 650.0 -

1.00

33

SPEEDDP

34

LOAD MLT

139 95 -%

35

CONTRAST

LOW,MED,HIGH

36 37

SLEEPTH SLEEPDL

0.00 360.0 - Hz 0.0300.0 SEC

38

SLEEPBW

39

TB5MIN

0.00-360.0Hz(NOTE2)

0.00Hz

40

TB5MAX

0.00-360.0Hz(NOTE2)

60.00Hz

41

AINFLTR

0.0110.0 - SEC

0.02SEC

42

TB10AOUT

NONE,0-10V,2-10V

43

@TB10A

0.00 360.0 - Hz

44

TB10BOUT

NONE,0-10V,2-10V

45

@TB10B

47

TB13A

NONE, 0-10VDC, 4-20MA, SPEED#1, LOC SEL, DEC FREQ

NONE

48

TB13B

NONE, 0-10VDC, 4-20MA, SPEED#2, INC FREQ, JOG FWD, JOG REV

NONE

49

TB13C

NONE, 0-10VDC, 4-20MA, SPEED#3, LOC SEL, RUN REV, STRT REV

NONE

50

TB13D

EXT FAULT EXT/FAULT, EXT CLEAR

EXT FAULT

XXXXX, XXX.X, XX.XX, X.XXX, .XXXX

FB@MINFB - @MAX

200 10 -%

XXXXX 100 % MED 0.00Hz 30.0SEC 0%

NONE 60.00Hz NONE 125 %

NOTE 2: MAX LIMIT IS 650 Hz ON UNITS WITH HIGH FREQUENCY SOFTWARE.

42

Table of Contents


PARAMETER

RANGE OF

FACTORY

NUMBER

NAME

ADJUSTMENT

DEFAULT

NONE, RUN, FAULT, /FAULT, LOCK, @ SPEED, ABOVE #3, I LIMIT, AUT/MAN, FLWR PR,

52

TB14 OUT

53 54

TB15 OUT RELAY

55

TB5BLOSS

57

SERIAL

58

ADDRESS

61

PASSWORD

0000 9999 -

0019

63

SOFTWARE

(VIEW ONLY) -

(N/A)

64

MONITOR

OFF, ON

ON

65

PROGRAM

MAINTAIN, RESET 60, RESET 50 (NOTE 4)

66

HISTORY

MAINTAIN,CLEAR

70

PIDMODE

74

PID FB

75

FB@MIN

-32768to32767

0.0%

76

FB@MAX

-32768to32767

100.00%

77

GAIN P

0.0 999.9 - %

5.0 %

78

GAIN I

0.0 10.0 - SEC

0.0 SEC

79 80

D GAIN PIDACC

0.0 10.0 - SEC 0.0 100.0 - SEC

0.0 SEC 30.0SEC

81

MINALRM

FB@MIN-FB@MAX

0.0%

82

MAXALRM

FB@MIN-FB@MAX

0.0%

98

LANGUAGE

99

FAULTHISTORY

MIN/MAX ALARM, INV MIN/MAX A, MIN ALARM, INV MIN ALARM, MAX ALARM, INV MAX ALARM, REVERSE, SLEEP, SPD = 0HZ

NONE

FAULT,SP#4,NONE

FAULT

DISABLED,W/TIMER,W/OTIMR

DISABLE

247 -1

30

RESET 60 MAINTAIN

OFF,NORMAL,REVERSE

OFF

TB-5A, TB-5B

TB-5A

ENGLISH (VIEW-ONLY)

(N/A)

NOTE 4: "RST HIGH" WILL APPEAR ON UNITS SET UP FOR HIGH FREQUENCY.

NOTE! If you are working with Software M108313 or ealier (see Parameter 63), parameters 69 and 70 are shown here as parameters 98 and 99.

43

Table of Contents

18.0 DESCRIPTION OF PARAMETERS 0

LINE VOLTS (LINE VOLTAGE)

This parameter calibrates the drive for the correct input voltage, and can be set to AUTO, HIGH, or LOW. When set to AUTO, the drive measures the DC bus voltage when power is applied and automatically calibrates itself according to the measured value (DC bus voltage is equal to input voltage multiplied by 1.4). This parameter can also be set “manually”, using the HIGH or LOW settings. For actual line voltages of 230/240 Vac (on 240/200 Vac models), 460/480 Vac (on 480/400 Vac models), or 575/590 Vac (on 590/480 Vac models), set this parameter to HIGH. Also use the HIGH setting for 240/120 Vac single-phase input models. Refer to the table below. For actual line voltages of 200/208 Vac (on 240/200 Vac models), 380/415 Vac (on 480/400 Vac models), or 460/480 Vac (on 590 Vac models), set this parameter to LOW. Refer to the table below.

INPUT LINE VOLTAGE SELECTION MODEL

M1100S

RATED INPUT VOLTAGE

INPUT PHASE

240/120Vac

1

220-240Vac

240/120Vac

1

110-120Vac

240Vac M1200(S)

M1400

M1500 1-4

240/200Vac

1

ACTUAL INPUT VOLTAGE

PARAM. SETTING

HIGH

220-240Vac

3

HIGH

220-240Vac

240200 / Vac

3

200-208Vac

LOW

480/400Vac

3

460-480Vac

HIGH

480400 / Vac

3

380-415Vac

LOW

590/480Vac

3

575-600Vac

HIGH

590480 / Vac

3

460-480Vac

LOW

SPEED #1- #4

(PRESET SPEEDS #1, #2, #3, AND #4)

PRESET SPEEDS are only active when the drive is in AUTO mode, and are activated via contact closures between terminal TB-2 and terminals TB-13A, TB-13B, and TB-13C. These terminals must be programmed as preset speed selects using Parameters 47 - 49: TB13A, TB13B, and TB13C. The preset speeds can only be set to values that are within the operating range defined by the minimum andmaximum frequency (see Parameters: 10 - MIN FREQ, and 11 - MAX FREQ). The following table shows how each preset speed is selected using the TB-13 terminals. The terms OPEN and CLOSED refer to the state of the TB-13 terminal relative to TB-2.

44

Table of Contents

PRESET ACTIVATION PRESET#

T1B- 3A

T1B- 3B

T1B- 3C

1

CLOSED

OPEN

OPEN

2

OPEN

CLOSED

OPEN

3

OPEN

OPEN

CLOSED

CLOSED

CLOSED

OPEN

CLOSED OPEN

OPEN CLOSED

CLOSED CLOSED

4

NOTE: SPEED #4 is selected if any two of the three TB-13 terminals are closed to TB-2. 5,6

SKIP #1 & #2

7

BAND WID

(SKIP SPEED #1 & #2) (SKIP BANDWIDTH)

These parameters are used to prevent thedrive from operating continuously at critical speeds, or frequencies, that cause excessive mechanical vibration of the driven equipment. The SKIP SPEEDS (Parameters 5 and 6) and the SKIP BANDWIDTH (Parameter 7) are used to define up to two speed avoidance ranges. The SKIP SPEED settings define the starting point of the speed range that is to be avoided, and the SKIP BANDWIDTH setting defines how far the speed range extends beyond SKIP SPEED. Setting the SKIP SPEEDS to .00 Hz disables this function. Example: The critical frequency is 21 Hz, and a bandwidth of 2 Hz is desired. Therefore, set SKIP #1 to 20 Hz and set SKIP BANDWIDTH to 2 Hz. This results in a speed range from 20 Hz to 22 Hz that the drive will not operate within continuously. If the drive were operating at 25 Hz and then commanded to operate at a speed within the range of avoidance, the drive would decelerate to 22 Hz and remain at that frequency until commanded to20 Hz or below. The drive would thendecelerate through the range of avoidance to the new frequency. Likewise, if the drive were operating at 18 Hz, and then commanded to operate at a speed within the range of avoidance, the drive would accelerate to 20 Hz and remain at that frequency until commanded to a speed of 22 Hz or above. The drive would then accelerate through the range of avoidance to the new frequency.

45

Table of Contents 8

(ACCELERATION TIME)

ACCEL

ACCEL sets the acceleration rate for all speed reference sources (keypad, speed pot, 4-20 mA, 0-10VDC, jog, and the preset speeds). The ACCEL setting isthe time to accelerate from 0 Hz to the BASE FREQUENCY (Parameter 18). The range of adjustment for ACCEL depends on horsepower. Refer to the following table:

ACCELERATION LIMITS 120 - 240 Vac Models

400 - 590 Vac Models

0.2520 - HP

RANGE OF ADJUSTMENT

120 - HP

25-30HP

0.13600 - SEC

25-60HP

4060 - HP

0.3-3600SEC

75-150HP

1.0-3600SEC

Example: If ACCEL is set to 30 seconds, and the BASE FREQUENCY is set to 60 Hz, the drive will ramp from 0 Hz to 60 Hz in 30 seconds. This is a linear function, therefore the drive would ramp up to 30 Hz in 15 seconds, etc. NOTE: The ability to accelerate a given load at a particular rate will be limited by the output power capability of the drive/motor combination. The acceleration of highinertia and high-friction loads may be affected by the current limiting characteristics of the drive. See Parameters: 16 - CURRENT, 19 - FX BOOST, and 20 - AC BOO ST for more information. 9

DECEL

(DECELERATION TIME)

DECEL sets the deceleration rate for all speed reference sources. The DECEL setting indicates the time to decelerate from BASE FREQUENCY to 0 Hz. As with Parameter 8 - ACCEL, this is a linear function. If the drive is set to COAST to stop, this parameter will have no effect when a STOP command is given. The range of adjustment for DECEL depends on horsepower, voltage, and whether Dynamic Braking (DB) is being used. Refer to the table below:

DECELERATION LIMITS HORSEPOWER / VOLTAGE RATING 120 - 240 Vac Models (NOTE 1)

480/400 Vac Models

R A N G E O F A D JU S T M E N T

590 / 480 Vac Models

WITHOUT DB (NOTE 2)

WITH DB

0.25-7.5HP 10-15HP

1-7.5HP 10-20HP

---1-7.5HP

0.3-3600SEC 0.5-3600SEC

0.1-3600SEC 0.1-3600SEC

20-30HP

25-60HP

10-20HP

1.0-3600SEC

0.2-3600SEC

40HP ----

-------

----

1.0-3600SEC

25-60HP

0.3-3600SEC

2.0-3600SEC

0.2-3600SEC

60HP

75HP

----

3.0-3600SEC

0.8-3600SEC

----

100-150HP

----

7.0-3600SEC

1.8-3600SEC

NOTE 1: 120/240 Vac units have the same limits as 240/200 Vac units. NOTE 2: The parameter value can be set below the minimum value shown, but the value shown is the operational limit of the drive. For example, if DECEL is set for 0.1 seconds on a 10 HP, 480 Vac drive without dynamic braking, the actual deceleration time would be 0.5 seconds.

46

Table of Contents If an attempt is made to decelerate a high-inertia load too quickly, the motor will regenerate voltage back into the drive. This will cause the DC bus voltage to rise, which can result in a HI VOLTS fault. In order to prevent faulting, the drive will enter DECEL FREEZE, which halts the deceleration until the DC bus voltage returns to a normal level. The drive will then begin to decelerate again, and if necessary, will enter DECEL FREEZE repeatedly to avoid faulting. If a very short deceleration time is programmed, DECEL FREEZE may not be able to compensate fast enough, resulting in a HI VOLTS fault. In applications where very short deceleration times are required on high-inertia loads, dynamic braking may be required. Consult the factory for more information on the Dynamic Braking option. 10 (MINIMUM FREQUENCY) MIN FRQ This parameter defines the lower limit of the drive’s speed range. MIN FRQ is used in conjunction with MAX FRQ (Parameter 11 below) to define the operating range of the drive. If MIN FRQ is set to a value above 0.0 Hz, the drive will ramp up from 0.0 Hz when given a start command. Once running, however, the drive will not operate below the MIN FRQ setting unless the rotation is changed, or a stop command is issued and the drive is programmed to ramp to a stop. If the MINIMUM FREQUENCY is set to 0.0 Hz, the drive may be operated in ZERO SPEED mode (drive is in RUN state, but there is no output to the motor). ZERO SPEED operation can be used in applications requiring the ability to start and stop the drive using only the selected speedorreference. will start when the speed reference is raised above 0 VDC 4 mA, and itThe will drive stop when the reference is lowered to 0 VDC or 4 mA. Note that the drive must be initially started using one of the normal start commands (keypad or terminal strip). 11

MAX FRQ

(MAXIMUM FREQUENCY)

This parameter defines the upper limit of the drive’s speed range. MAX FRQ is used in conjunction with MIN FRQ (Parameter 10 above) to define the operating range of the drive.

WARNING! Consult motor manufacturer before operating motor above rated frequency. Overspeeding the motor and/or driven equipment can cause damage to equipment and injury to personnel! NOTE: If the drive is equipped with the High Frequency Output option, the range of adjustment will be 1.00 - 650.0 Hz.

47

Table of Contents 12

DC BRAKE

(DC BRAKE VOLTAGE)

DC braking creates a braking torque by injecting DC voltage into the motor. This parameter sets the magnitude of that DC voltage. The point at which the drive applies DC braking to the motor depends on which STOP mode is programmed (either COAST or RAMP, see Parameter 26 - STOP). If the drive is set to COAST, DC braking is activated when the stop command is given. In this case, DC braking helps decelerate the motor. This is useful in applications where a quick deceleration is desired on a load that would normally take a long time to coast to a stop. If the drive is set to RAMP, DC braking is activated when the output frequency reaches 0 Hz. In this case, the drive decelerates the load to a near stop and then DC braking is used to stop and hold the motor. This is useful in applications where the load needs to be stopped in a certain position. Similar applications with highinertia loads utilize both dynamic braking and DC braking. The dynamic braking allows the high-inertia load to be decelerated quickly, while the DC braking stops the load in the desired position. Due to heat generated in the motor, DC braking should only be used in applications where the load is stopped infrequently. In high duty-cycle applications, dynamic braking is recommended because the heat is dissipated through external resistor banks, rather than in the motor. When used, DC BRAKE should be set to the lowest voltage that provides satisfactory operation in order to minimize motor heating. The maximum voltage available depends on the voltage rating of the drive. Refer to the table below:

MAXIMUM DC BRAKE VOLTAGE MODEL M1100 240 / 200 Vac

13

MODEL M1200 240 / 200 Vac

MODEL M1400 480 / 400 Vac

24VOLTS

24VOLTS

48VOLTS

DC TIME

(DC BRAKE TIME)

MODEL M1500 590 / 480 Vac

59VOLTS

This parameter determines the length of time that the DC braking voltage is applied to the motor. DC TIME should be set to the lowest value that provides satisfactory operation in order to minimize motor heating. NOTE: If this parameter is set to 999.9 seconds (the maximum value), the DC braking will be continuous. If it is set to .0 seconds, it is disabled. 14 DYN BRAK (DYNAMIC BRAKE) This parameter enables the dynamic braking circuit. Set this parameter to ON only if the optional dynamic braking circuit board and resistors are installed. Dynamic braking is used in applications where high-inertia loads need to be decelerated quickly. When this is attempted, the motor regenerates voltage back into the drive, causing the DC bus voltage to rise, eventually resulting in a HI VOLTS fault. With the dynamic braking option, the DC bus voltage is monitored, and when it reaches a certain level, a transistor is switched on that connects an external resistor bank across the DC bus. This allows the regenerated energy from the motor to be dissipated through the resistors as heat, which keeps the DC bus voltage below the trip level.

48


CURRENT

(CURRENT LIMIT)

This parameter sets the maximum allowable output current of the drive, which also determines the torque capability of the motor. For most applications, CURRENT is left at the maximum setting, which is 150% or 180% (of the drive’s output current rating), depending on whether the input voltage to the drive is low or high (see Parameter 0 - LINE VOLTS). The drive will enter current limit when the current draw of the motor exceeds the current limit setting. To respond to this condition, the drive will enter "frequency foldback", which commands the drive to decelerate in order to reduce the output current and regain synchronization with the motor. When the over current condition passes, the drive will return to normal operation and reaccelerate to the speed set point. However, if "frequency foldback" cannot correct the condition and the drive remains in current limit for too long, it will trip into an OVERLOAD fault. If the drive enters current limit while accelerating, the time required to reach the speed set point will be longer than the time programmed into ACCEL (Parameter 8). Regardless of the CURRENT setting, the drive is capable of delivering a maximum of 150% current for one minute, and 180% current for approximately 30 seconds, before tripping into an OVERLOAD fault. See Parameter 17 – MOTOR OL. 17

MOTOR OL

(MOTOR OVERLOAD)

The MC1000 Series is UL approved for solid state motor overload protection. Therefore, a separate thermal overload relay is not required for single motor applications. The MOTOR OVERLOAD circuit is used to protect the motor from overheating due to excessive current draw. The trip time for the MOTOR OVERLOAD setting is based on what is known as an “inverse I2t” function. This function allows the drive to deliver 150% of the rated output current for one minute, and even higher current levels for shorter periods of time. Once the overload circuit “times out”, the drive will trip into an OVERLOAD fault. The MOTOR OVERLOAD should be set to a value which is equal to the ratio (in percentage) of the motor full load current rating to the drive output current rating. This will result in an overload capacity of 150% of the MOTOR current rating for one minute. If this parameter is set to 100%, the motor will be allowed to draw 150% of the DRIVE output current rating for one minute. This distinction is important in cases where the motor full load current rating is significantly less than the drive output current rating, such as applications where the drive is oversized to meet torque requirements. A 5 Hp, 480 Vac operating a 3by HP motor a full load current Example 1: amps. rating of 4.8 Divide the drive motoriscurrent rating the drivewith output current rating: 4.8 / 7.6 = 63%. Entering this value will allow continuous operation at 4.8 amps, and will also allow the motor to draw 7.2 amps (150% of 4.8 amps) for one minute. If the setting is left at 100%, the motor could draw 11.4 amps (150% of 7.6 amps) for one minute before tripping the drive. The MC Series drive has two options for thermal overloa d protection.One depends on the speed of thedrive, and the otherdoes not. The diagram below illustrates the difference between “speed compensated” and “non-compensated” thermal overload protection. The “speed-compensated” thermal overload circuit offers additional protection from high load conditions at low speeds, where motor cooling is often less effective (e.g., motors with shaft-mounted fans). As seen on the diagram below, the drive reduces the allowable continuous output current when operating at frequencies less than 30 Hz.

49

Table of Contents Example 2: A 480 Vac, 20 HP drive is operating a motor at 10 Hz. From the diagram, a drive operating at 10 Hz can deliver about 75% of its output current rating continuously. A 480 Vac, 20 HP drive’s output current rating is 27 Amps. Therefore, the drive would be able to operate continuously at 20 Amps. The drive would also be able to deliver 150% of that value (30 Amps) for one minute before tripping into an OVERLOAD fault. The “speed compensated” thermal overload is the factory default and should be used in applications where the motor does not normally experience high loads at low speeds for extended periods of time. NON-COMPENSATED 100 S U O U IN T N O C M U M I X A M

) % ( T N E R R U C T U P T U O

80

EE SP

OM DC

PE

ED AT S N

60 40 20

10

20

30

40

50

60

FREQUENCY (Hz)

NOTE 1: The above diagram is based on a MOTOR OL setting of 100%. For lower MOTOR OL settings, reduce the % CURRENT values bythe same percentage. For example, if MOTOR OL is set to 75%, reduce the % CURRENT values by 25%. Therefore, the curve shifts down, but the shape of the curve remains the same. The “non-compensated” thermal overload circuit allows 100% current continuously, and 150% current for one minute, at all speeds. In the example above, the motor operating at 10 Hz without “speed-compensated” protection would be allowed to operate continuously at 27 Amps, and could draw 40.5 Amps for one minute before tripping. Without sufficient motor cooling, this can result in motor failure due to overheating. The “non-compensated” circuit is selected by setting Parameter 22 - TORQUE to CT/NOCMP. The “non-compensated” setting should only be used in applications where the motor is properly cooled at all speeds, or the motor manufacturer has approved the motor for full-load operation at low speeds. NOTE 2: The operation of the motor thermal overload circuit is affected by the setting of Parameter 34 - LOAD MLT.

50


(BASE FREQUENCY)

BASE

The BASE FREQUENCY determines the V/Hz ratio by setting the frequency at which the drive will output full voltage to the motor. For most applications the base frequency should be set to match the motor’s rated frequency. For example, if the drive is rated for 460 Vac output, and the BASE FREQUENCY is set to 60 Hz, the drive will maintain a constant ratio of 7.66 V/Hz (except when AC BOOST or FX BOOST are active, see Parameters 19 and 20) from 0 Hz to 60 Hz. This range is the region of constant torque. If the motor speed is increased past 60 Hz, the output voltage remains constant while the frequency increas es, resulting in a reduced V/Hz ratio. This range, from 60 Hz to about 90 Hz, is the region of constant horsepower. Above 90 Hz, horsepower begins todecrease as frequency increases. Refer to Section 6.1 - DESCRIPTION OF AC MOTOR OPERATION. 19 FX BOOST (FIXED BOOST) This parameter is usedin applications which require high starting torque.FX BOOST increases the output voltage at lower output frequencies (below 30 Hz for 60 Hz base frequency), in order to boost the torque capability of the motor. Refer to the diagram below. The factory default for FX BOOST depends on the horsepower rating. Refer to the table below:

FX BOOST FACTORY DEFAULT SETTINGS HP

0.25 1HP 1.5 HP 2-

FACTORY DEFAULT (ALL VOLTAGES)

5.30% 4.40 %

40HP 50 HP

FACTORY DEFAULT (240 / 200 VAC)

FACTORY DEFAULT (400+ VAC)

2.30%

1.20%

---

0.80 %

HP 3

3.60 %

HP 5

3.00 %

75 HP

7.5 HP

2.70 %

100 HP

---

1.90 %

10 HP

2.40 %

125 HP

---

1.90 %

15 HP

2.20 %

150 HP

---

1.80 %

20HP

2.00%

25HP

1.80%

30HP

1.60%

60 HP

HP

2.10 %

0.80 %

---

2.00 %

51


AC BOOST

(ACCELERATION BOOST)

AC BOOST is similar to FX BOOST,but is only active when the drive is accelerating. During acceleration, the output voltage is increased according to the setting of AC BOOST, which increases motor torque. Refer to the diagram below. AC BOOST, like FX BOOST, is used in applications with high-inertia loads. The diagram below illustrates how FX BOOST and AC BOOST alter the V/Hz ratio to increase motor torque. FX BOOST sets the boost at 0 Hz (approximately 15% in the example above), and as the output frequency approaches 30 Hz, the boost decreases to zero. 100 90

AC BOOST

80 ) % ( E G A T L O V T U P T U O

70 60 FX BOOST

50 40 30 20

CONSTANT V/Hz

10

10

20

30

40

50

60

OUTPUT FREQUENCY (Hz)

AC BOOST only functions during acceleration. In the diagram above, the drive is operating at 35 Hz and is then commanded to 50 Hz. The output voltage is increased by the AC BOOST setting (approximately 15% in the example above) during acceleration to the new speed set point. Once the new set point is reached, the output voltage returns to normal. 21

SLIP CMP

(SLIP COMPENSATION)

SLIP COMPENSATION is used to compensate for changes in motor speed (“slip”) which occur due to changes in load. In a standard AC induction motor, as the load on the motor increases, the motor current increases and the motor shaft speed decreases. By increasing the output frequency in response to the increased motor current, SLIP COMPENSATION is able to counteract the reduction in motor speed due to increased load. This parameter is useful in applications where precise speed regulation is needed, even under changing load conditions. The use of SLIP COMPENSATION can result in speed regulation of less than 1% of base speed in most applications. SLIP COMPENSATION is often set to 3%, which is the standard slip rating of most AC induction motors.

52


TORQUE

(TORQUE CURVE SELECTION)

This parameter is used to select whether the output of the drive follows a constant or variable V/Hz curve. The following selections are available: CONSTANT

Use for constant torque applications to optimize torque.

VARIABLE

Use for variable torque applications to optimize energy savings.

CT / NOCMP

Use for constant torque applications that require full overload capacity at low speeds (see Parameter 17 - MOTOR OL).

23 (CARRIER FREQUENCY) CARRIER This parameter sets thecarrier, or switching, frequency ofthe output IGBT’s. Higher switching rates result in less audible noise from the motor, but the efficiency of the drive decreases as the carrier frequency increases. Therefore, this parameter should be set to the lowest value which yields acceptable sound levels. Available settings are: 2.5 kHz, 6 kHz, 8 kHz, 10 kHz, 12 kHz and 14 kHz. NOTE 1: The 2.5 kHz carrier frequency setting is a variable carrier. The carrier frequency remains fixed at 1.5 kHz up to 25 Hz output frequency. Above 25 Hz, the carrier is a fixed multiple of 60 times the drive’s output frequency. For example, if the output frequency of the drive was set to 45 Hz, the carrier frequency would be 2.7 kHz (45 Hz x 60 = 2700 Hz). NOTE 2: The ability to operate a drive in the quiet (high carrier frequency) mode is dependent on the drive horsepower rating, driven load, drive enclosure, and the ambient temperature. At full ambient temperature, operation above 8 kHz requires derating the drive by multiplying the output current rating by the following factors: 0.94 at 10 kHz, 0.89 at 12 kHz, and 0.83 at 14 kHz. NOTE 3: If the drive is equipped with the High Output Frequency option, and MAX FRQ is set above 120 Hz, CARRIER will automatically change to 14 kHz, and the CARRIER parameter will disappear from the parameter menu. Operation at 14 kHz carrier frequency requires derating as shown in NOTE 2 above.

53


START

(START MODE)

WARNING! Automatic start of equipment may result in damage to equipment and/or injury to personnel! Automatic start shouldonly be used on equipment that is inaccessible to personnel. This parameter selects the starting method for the drive, and can be set for one of the following: NORMAL

The drive will start when the appropriate contact closure is made on the terminal strip (in REMOTE mode), or by pressing the keypad START key (in LOCAL mode). To start the drive in NORMAL mode, a start command must be issued at least two seconds AFTER input power is applied.

POWER UP

The drive will automaticallystart upon application of input power. The drive MUST be wired for a two-wire start/stop circuit (refer to Section 14.0 - CONTROL WIRING). The start command MUST be present when power is applied for this function to operate.

AUTO RE-

The drive will automaticallyrestart after a protective fault or upon application of input power. As with the POWER-UP option, a start command must be present for this function to operate.

RE-BRAKE

After a fault, the drive will apply DC braking equal to the DC BRAKE setting for 15isseconds then restart. is done to ensure the motor stopped and during the restartThis attempt, as the drive will not start into a spinning motor.

NOTE 1: POWER UP, AUTO RE-, and RE-BRAKE settings are only active when the drive is in REMOTE mode (see Parameter 30 - CONTROL). NOTE 2: After a fault, the drive will attempt to restart five times, and if unsuccessful, will shut down on aFAULT LOCKOUT. Every 15 minutes thatpasses will decrement the restart counter by one. Therefore, 75 minutes after a successful restart, the restart counter is fully reset, and the drive can once again attempt five restarts. NOTE 3: The drive WILL NOT restart after the following faults: CONTROL and PWR SAG. Also, if an OUTPUT fault occurs below 1.5 Hz, only one restart will be attempted, after a four minute delay. If unsuccessful, it will then trip into FAULT LOCKOUT, which will require a manual reset. This is done to protect the drive in case of a shorted motor. 26 (STOP MODE) STOP This parameter selects whether the motor will COAST to a stop, or RAMP to a stop, when the drive is given a stop command. COAST

When a stop command is given, the drive shuts off the output to the motor, allowing it to coast to a stop. The time required for the motor to stop is governed by the inertia of the load.

RAMP

When a stop command is given, the drive will decelerate the motor to a stop over a period of time according to Parameter 9 - DECEL. Once the output frequency reaches 0.0 Hz, there will be a 200 ms delay before the drive can be started again.

RAMP 2

Same as RAMP, but without the 200 ms start delay. This allows faster start/stop cycles for applications that require it.

54


(ROTATION DIRECTION)

ROTATION

WARNING! If TB-13C is programmed for RUN REVERSE, TB-1 is disabled and CANNOT be used as a STOP switch! This is true in LOCAL and REMOTE mode. Incorrect use of TB-1 may result in damage to equipment and/or injury to personnel! Refer to Parameter 49 - TB13C for more information. This parameter is used to limit the motor rotation direction to forward or reverse, or to allow rotation in both directions. The parameter can be set to one of the following: FORWARD

Rotation is allowed in the forward direction only. This selection disables the FWD/REV button on the keypad and TB-13C (REVERSE).

REVERSE

Rotation is allowed in the reverse direction only. This selection disables the FWD/REV button on the keypad and TB-12A (FORWARD). TB-13C must beprogrammed for either RUNREV or STRT REV for this function to operate in the REMOTE mode.

FWD&REV

Rotation is allowed in both directions. The FWD/REV button is enabled. Rotation can be changed from the keypad (LOCAL mode), or the terminal strip (REMOTE mode). In the REMOTE mode, TB-13C must be programmed for either RUN REV or STRT REV for this function to operate.

FWD@LOC

In LOCAL mode, rotation is allowed in the forward direction only.

In REMOTE mode, rotation is allowed in both directions. NOTE: If the rotation is changed while thedrive is running, the drive willdecelerate to 0 Hz, and then accelerate back up to the speed set point in the opposite direction. 28

AUTO / MAN

(AUTO / MANUAL SPEED CONTROL)

This parameter is used to select the method of speed control when the drive is in the LOCAL mode. The choices are explained below: MANUAL

The drive will accept a speed reference from the keypad (UP and DOWN ARROW keys) or a speed potentiometer (wired to TB-2, 5A, and 6). Parameter 29 - MANUAL below selects either keypad or speed potentiometer. The AUTO/MAN button on the keypad is disabled.

AUTO

The drive will accept a 0-10 VDC input signal on TB-5A and TB-2, a 4-20 mA input signal on TB-5B and TB-2, or one of the four PRESET SPEEDS. The programming ofTB-13A, TB-13B and TB-13C determines which AUTO reference is selected. The AUTO/MAN button on the keypad is disabled.

BOTH

The AUTO/MAN key on the keypad is enabled and can be used to toggle between MANUAL and AUTO control ONLY if the drive is in LOCAL mode.

NOTE: If the drive is in the AUTO mode, and a speed reference is not selected using TB-13A, TB-13B, or TB-13C, the speed reference source will default to the setting of Parameter 29 - MANUAL (KEYPAD or 0-10 VDC). 29

MANUAL

(MANUAL)

This parameter selects the speed reference source when the drive isset for MANUAL speed control (see Parameter 28 - AUTO/MAN above). Thespeed reference options are KEYPAD (UP and DOWN ARROW keys), or 0 - 10 VDC (from a speed pot wired to TB-2, 5A, and 6; or some other 0-10 VDC source).

55


CONTROL

(START/STOP CONTROL)

WARNING! If CONTROL is set to LOCAL, TB-1 is disabled and CANNOT be used as a STOP switch! Incorrect use of TB-1 may result in damage to equipment and/or injury to personnel!

WARNING! STOP (TB-1) and EXTERNAL FAULT (TB-13D) circuitry may be disabled if parameters are reset to factory defaults! The drive must be reprogrammed after a RESET in order to insure proper operation (see Parameter 65 - PROGRAM). FAILURE TO DO SO MAY RESULT IN DAMAGE TO EQUIPMENT AND/OR INJURY TO PERSONNEL! This parameter is used to select the source of the start/stop command and direction control. The following settings are available: LOCAL

START/STOP and FORWARD/REVERSE commands from the keypad only.

REMOTE

START/STOP and FORWARD/REVERSE commands from the terminal strip only.

BOTH

LOCAL operation if TB-13A or TB-13C is programmed for LOCAL SELECT and a contact closure is made from TB-13A or TB-13C to TB-2. If the contact closure is not made, the drive will be in REMOTE mode.

31

(SPEED/PID UNITS)

UNITS

UNITS sets the units of the output speed or PID display on the keypad. The following choices are available: Speed mode: HERTZ, RPM, %HZ, /SEC, /MIN, /HR, GPH, NONE PID mode:

%, PSI, FPM, CFM, GPM, IN, FT, /SEC, /MIN, /HR, F, C, MPM, GPH

NOTE: If one of the "pid" units is selected, but the drive is in Manual (open-loop) speed control mode or PID MODE is DISABLED, the displayed speed units will default HERTZ. If onemode, of the "speed" units isPID selected, butdefault PID MODE and thetodrive is in Auto the displayed units will to %. is ENABLED 32

HZ MULT

(HERTZ MULTIPLIER)

The HZ MULTIPLIER is used to scale the output speed indication on the display. If UNITS is set for HERTZ or % HZ, this parameter has no effect. Multiplying the output frequency by the HZ MULTIPLIER will yield the desired speed value on the display. Example: The desired speed units is RPM with a standard 60 Hz, 1800 RPM motor. Set UNITS to RPM and set HZ MULT to 30.00. This will result in a speed display of 1110 RPM for an output frequency of 37 Hz (37 Hz X 30 = 1110 RPM). Also, if there was a 100:1 gear reducer in the system, Parameter 33 - SPEED DP below could be set to XX.XX to represent the output of the gear reducer (11.10 RPM in the example).

56


SPEED DP

(SPEED DECIMAL POINT)

This parameter is used to move the decimal point location in the speed display. This parameter will not have any effect if UNITS is set to HERTZ or % HZ. The possible settings are: XXXXX, XXX.X, XX.XX, X.XXX, and .XXXX. Refer to Parameter 32 - HZ MULT above for an example on the use of SPEED DP. 34

LOAD MLT

(LOAD MULTIPLIER)

This parameter is used to scale the %LOAD display. If the drive output current rating is higher than the motor full load current rating, the drive will not display 100% load when the motor is at full load. Setting this parameter to the ratio (in %) of the drive output current rating to the motor full load current rating will scale the load display to show motor load instead of drive load. This will result in a display of 100% when the motor is at full load. The motor overload circuitry is also affected by this parameter. When the display reads 150% load, the drive will trip on OVERLOAD in one minute, regardless of the actual motor current. If this parameter is used to scale the display to show actual motor load, then Parameter 17 - MOTOR OL should be left at 100%. Likewise, if MOTOR OL has been set according to the motor full load rating, this parameter should be left at 100%. Changing both parameters will result in an OVERLOAD fault sooner than expected. The output signal at TB-10B is also affected by this parameter. When set to the ratio of current ratings as explained above, the output signal will be proportional to motor load instead of drive load. 35

CONTRAST

(LCD DISPLAY CONTRAST)

This parameter is used to adjust the contrast of the drive display and can be set to LOW, MED, or HIGH in order to obtain the most visible display. If the drive is mounted lower than eye level, a HIGH setting may make the display more visible. Likewise, if the drive is mounted higher than eye level, a LOW setting may make the display more visible. 36

SLEEP TH

(SLEEP THRESHOLD)

The MC1000 Series drive has a Sleep Mode function that allows the drive to cease operation when system demand falls below a preset level. This is to prevent the motor from operating at low speeds for long periods of time. It is commonly used along with the PID Set point Control feature, but can also be used in standard speed control mode. When the commanded speed falls below the SLEEP THRESHOLD setting for the defined SLEEP DELAY time (see Parameter 37 below), the drive will "go to sleep" and the motor will go to zero speed. The drive will remain "sleeping" until it is commanded to operate at a speed that is 2 Hz above the SLEEP THRESHOLD, at which point it will "wake up" and ramp the motor up to the commanded speed. NOTE 1: While the drive is in Sleep Mode, the Status portion of the display will read SLEEP. NOTE 2: If the drive's commanded speed goes below the SLEEP THRESHOLD, the SLEEP DELAY timer will start to count down. If the commanded speed equals or exceeds the SLEEP THRESHOLD before the SLEEP DELAY times out, the SLEEP DELAY timer will be reset. NOTE 3: If the drive is in a Stop state, and the commanded speed is below the SLEEP THRESHOLD, the drive will immediately go to sleep upon a Start command, bypassing the SLEEP DELAY.

57


SLEEP DL

(SLEEP DELAY)

This parameter sets the amount of time the drive must operate below the SLEEP THRESHOLD (see Parameter 36 above) before the drive "goes to sleep" and brings the motor to zero speed. Example: SLEEP THRESHOLD is set to 15 Hz and SLEEP DELAY is set to 60 seconds. If the drive operates below 15 Hz for 60 seconds, the drive will "go to sleep" and the motor will stop. The drive's display will indicate SLEEP, and the drive will remain "sleeping" until the drive commanded to a speed equal to greater than 17 Hz. At this point, the drive will "wake up" and ramp the motor up to the commanded speed. 38

SLEEP BW

(SLEEP BANDWIDTH)

This parameter allows the PID feedback signal to determine when drive should "wake up" when operating in Sleep Mode. In process systems that utilize Integral Gain (see Parameter 78), the drive may cycle in and out of Sleep Mode more often than desired, due to the Integral function of the PID algorithm. When SLEEP BANDWIDTH is used, the feedback signal must decrease or increase (depending on whether the system is normal or reverse-acting) by the programmed amount before the drive will "wake up". This parameter is set in PID units. Example: In a normal-acting system, the PID set point is 50 PSI, SLEEP THRESHOLD is set to 20 Hz, and SLEEP BANDWIDTH is set to 5 PSI. The drive will enter Sleep Mode when the commanded speed drops below 20 Hz for the time defined in SLEEP DELAY. The drive will wake up when the feedback signal drops below 45 PSI (50 PSI set point minus 5 PSI bandwidth = 45 PSI), even if the commanded speed is still below 20 Hz. NOTE: If SLEEP BANDWIDTH is set to 0, this function is disabled, and the drive will wake up when the commanded speed exceeds the SLEEP THRESHOLD plus 2 Hz, as described in Parameters 36 and 37. 39

TB5 MIN

(TERMINAL TB-5 INPUT)

TB5 MIN selects the output frequency of the drive that will correspond to the minimum analog speed reference input (0 VDC or 4 mA). This parameter is used in conjunction with Parameter 40 - TB5 MAX to define a speed range that corresponds to the analog speed reference input (0 - 10 VDC or 4 - 20 mA). 40

TB5 MAX

(TERMINAL TB-5 INPUT)

TB5 MAX selects the output frequency of the drive that will correspond to the maximum analog speed reference input (10 VDCor 20 mA). This parameter is used in conjunction with Parameter 39 - TB5 MIN to define a speed range that corresponds to the analog speed reference input (0 - 10 VDC or 4 - 20 mA). Example 1: The drive is required to operate from 0 to 60 Hz in response to a 0-5 VDC speed reference signal (rather than the “normal” 0-10 VDC). Because TB5 MAX is based on a 0-10 VDC (or 4-20 mA) signal, the drive will operate at half of the TB5 MAX value if it is given a 5 VDC signal. Therefore, setting TB5 MAX to 120 Hz will cause the drive to run at 60 Hz when it is given a 5 VDC speed reference signal. NOTE: The drive can be programmed for inverse operation so that as the speed reference increases, the drive speed will decrease , and as the speed reference decreases, the drive speed will increase.This is accomplished by setting TB5 MIN to the desired maximum output frequency, and TB5 MAX to the desired minimum output frequency.

58

Table of Contents Example 2: The drive is being controlled by a pressure transducer that provides a 4-20 mA signal proportional to duct pressure. The minimum frequency desired is 20 Hz, and the maximum is 60 Hz. Set TB5 MIN for 60 Hz, and TB5 MAX for 20 Hz. As the duct pressure rises, the output signal from the transducer will increase, causing the speed of the drive to decrease. This results in a decrease in duct pressure and a decreasing transducer signal. The drive responds to the decreasing signal by increasing speed, which again raises the duct press ure. In this way, the average duct pressure can be maintained at a certain level. If the acceleration and deceleration rates are set too fast however, the drive will react quickly to signal changes which will cause the drive speed to “hunt” up and down excessively. 41

AIN FLTR

(ANALOG INPUT FILTER)

This parameter adjusts the filter on the analog input terminals (TB-5A and TB-5B) to reduce the effect of any electrical noise that may be present on the analog input signals. This filter works in both PID mode and standard speed control mode. It should be set to the lowest value that yields acceptable performance, as setting it too high may cause the drive to react too slowly to signal changes. 42

TB10A OUT

(TERMINAL TB-10A OUTPUT)

The analog output signal at TB-10A is proportional to the output frequency of the drive. This parameter selects whether that signal is 0-10 VDC or 2-10 VDC. The 2-10 VDC signal can be converted to a 4-20 mA signal by connecting a resistor in series with the signal such that the total load resistance is 500 Ohms. If set to NONE, the function is disabled. NOTE: This output cannot be used with “loop-powered” devices that derive power from a 4-20 mA signal. 43

@ TB10A

(TERMINAL TB-10A SCALING)

This parameter scales the analog output signal at TB-10A. This setting is the output frequency that is indicated when the TB-10A output measures 10VDC. Example: The drive is part of a control system that requires a 0-5 VDC signal (rather than 0-10 VDC) that is proportional to 0-60 Hz output frequency. The output signal is linear, so setting this parameter to 120 Hz would yield 10 VDC at 120 Hz, and 5 VDC at 60 Hz. 44

TB10B OUT

(TERMINAL TB-10B OUTPUT)

The analog output signal at TB-10B is proportional to the drive load. This parameter selects whether that signal is 0-10 VDC or 2-10 VDC. The 2-10 VDC signal can be converted to a 4-20 mA signal by connecting a resistor in series with the signal such that the total load resistance is 500 Ohms. NOTE: This output cannot be used with “loop-powered” devices that derive power from a 4-20 mA signal. 45

@ TB10B

(TERMINAL TB-10B SCALING)

This parameter scales the analog output signal at TB-10B. This setting is the load (in %) that is indicated when the TB-10B output measures 10 VDC. Example: The drive is part of a control system that requires a 0-10 VDC signal to indicate 0-150% drive load. If this parameter were set to 150%, the drive would output 10 VDC at 150% load (and about 6.7 VDC at 100% load). NOTE: The output signal at TB-10B is affected by the setting of Parameter 34 - LOAD MLT.

59


TB13A

(TB-13A INPUT FUNCTION)

This parameter is used to select the function of terminal TB-13A. Closing TB-13A to TB-2 activates the TB-13A input function. The following functions can be selected: NONE

Disables the TB-13A function.

0-10VDC

Selects 0-10 VDC as the AUTO speed reference input. The 0-10 VDC signal is wired to TB-5A and TB-2.

4-20 MA

Selects 4-20 mA as the AUTO speed reference input. The

SPEED#1

4-20 mA signal is wired to TB-5B and TB-2. Selects PRESET SPEED #1 as the AUTO speed reference.

LOC SEL

Selects LOCAL mode when Parameter 30 - CONTROL is set to BOTH. Drive is in REMOTE mode if contact closure is not made.

DEC FREQ

Decrease frequency set point. Used with the MOP (motor operated pot) function. Refer to Section 14.2.6 - SPEED REFERENCE SELECTION.

48

TB13B

(TB-13B INPUT FUNCTION)

WARNING! When operating in JOG mode, the STOP key WILL NOT stop the drive. To stop the drive, the contact between TB-13B and TB-2 must be opened. This parameter is used to select the function of terminal TB-13B. Closing TB-13B to TB-2 activates the TB-13B function. The following functions can be selected: NONE

Disables the TB-13B function.

0-10VDC


4-20 MA

Selects 4-20 mA as the AUTO speed reference input. The 4-20 mA signal is wired to TB-5B and TB-2.

SPEED#2

Selects PRESET SPEED #2 as the AUTO speed reference.

INC FREQ

Increase frequency set point. Used with the MOP (motor operated pot) function. Refer to Section 14.2.6 - SPEED REFERENCE SELECTION.

JOG FWD

Jog in the forward direction. Active only when drive is STOPPED. The jog speed is set by Parameter 2 -SPEED#2.

JOG REV

Jog in the reverse direction. Active only when drive is STOPPED. The jog speed is set by Parameter 2 - SPEED#2.

49

TB13C

(TB-13C INPUT FUNCTION)

WARNING! If TB-13C is programmed for RUN REVERSE, TB-1 is disabled and CANNOT be used as a STOP switch! This is true in LOCAL and REMOTE mode. Incorrect use of TB-1 may result in damage to equipment and/or injury to personnel!

60

Table of Contents This parameter is used to select the function of terminal TB-13C. Closing TB13C to TB-2 activates the TB-13C input function. The following functions can be selected: NONE

Disables the TB-13C function.

0-10VDC


4-20 MA

Selects 4-20 mA as the AUTO speed reference input. The 4-20 mA signal is wired to TB-5B and TB-2.

SPEED#3 LOC SEL

Selects PRESET SPEED #3 as the AUTO speed reference. LOCAL SELECT - Selects LOCAL mode when Parameter 30 - CONTROL is set to BOTH. Drive is in REMOTE mode if contact closure is not made.

RUN REV

RUN REVERSE - Run in reverse direction . Require s a maintained contact closure - close to RUN in reverse direction, open to STOP. This will cause TB-12A to function as RUN FORWARD, also requiring a maintained contact to RUN in forward.

STRT REV

START REVERSE - Start in reverse direction. Requires a momentary contact closure to RUN in reverse direction. A momentary STOP contact must be wired between TB-1 and TB-2. Setting this parameter to START REVERSE causes TB-12A to function as START FORWARD, also requiring a momentary contact closure to RUN in forward.

50

TB13D

(TB-13D FUNCTION)

WARNING! STOP (TB-1) and EXTERNAL FAULT (TB-13D) circuitry may be disabled if parameters are reset to factory defaults! The drive must be reprogrammed after a RESET in order to insure proper operation (see Parameter 65 - PROGRAM). FAILURE TO DO SO MAY RESULT IN DAMAGE TO EQUIPMENT AND/OR INJURY TO PERSONNEL! This parameter selects the function for TB-13D. EXT FAULT

Sets TB-13D as a normally open EXTERNAL FAULT contact. Close TB-13D to TB-2 to trip the drive into an EXTERNAL FAULT.

EXT / FAULT

Sets TB-13D as a normally closed EXTERNAL FAULT contact. Open TB-13D to TB-2 to trip the drive into an EXTERNAL FAULT.

EXT CLEAR

Sets TB-13D as a normally open FAULT RESET. Close TB13D to TB-2 to clear a fault.

NOTE: When set to CLEAR, TB-13D becomes the only terminal that can be used to clear a fault (TB-1 will not work). However, the keypad STOP key can still be used to clear faults.

61


TB14 OUT

(TB-14 OPEN COLLECTOR OUTPUT)

This parameter sets the open-collector output indication for terminal TB-14. The following conditions can be selected: NONE

This setting disables the output.

RUN

The relay energizes when the drive is given a START command, and remains energized until: a STOP command is given and the output frequency has decelerated to 0.5 Hz, the drive has “tripped”, or the input voltage is removed. Note that this relay indicates only that the drive is in the RUN mode. It does not necessarily indicate that the motor is turning.

FAULT

The relay energizes when input voltage is applied to the drive and remains energized until the drive “trips” into a fault condition, or input voltage is removed.

/ FAULT

INVERSE FAULT - The relay energizes when the drive “trips” into a fault condition, and remains energized until the fault condition is cleared.

LOCK

FAULT LOCKOUT - This relay is used when the drive is programmed to automatically restart after a fault. The relay energizes when input voltage is applied to the drive and remains energized until the drivehas faulted and unsuccessfully attempted five restarts, or input voltage is removed.

@ SPEED

AT SPEED - The relay energizes when the drive reaches the speed set point. To avoid a “chattering” relay (energizing and de-energizing), due to small fluctuations in speed, the relay will remain energized as long as the actual speed is within + 3 Hz of the speed set point.

ABOVE #3

ABOVE SPEED #3 - The relay energizes when the output frequency exceeds the SPEED #3 value, and de-energizes when the output frequency returns to a value lower than the SPEED #3 value. See Parameter 3 - SPEED #3 in Section 18.0 - DESCRIPTION OF PARAMETERS.

I LIMIT

CURRENT LIMIT - The relay energizes when the drive is operating in current lim it. Once the current limit relay is energized, it remains energized for a minimum of 500ms, regardless of whether thethe drive is still in current limit. the end of the 500ms interval, relay will de-energize if theAt drive is no longer in current limit. See Parameter 16 - CURRENT in Section 18.0 - DESCRIPTION OF PARAMETERS.

AUT/MAN

AUTO/MANUAL MODE - The relay energizes when the drive is in the AUTOMATIC mode, and de-energizes in the MANUAL mode. Refer to Section 14.2.5 - SPEED REFERENCE SELECTION.

FLWR PR

FOLLOWER PRESENT - The relay energizes when the analog input reference signal at TB-5B is greater than 2 mA, and deenergizes if the signal falls below 2 mA.

REVERSE

The relay energizes when Reverse direction is selected, and de-energizes when Forward direction is selected.

62

Table of Contents MIN/MAX ALARM

The relay energizes when the feedback signal (in PID mode) or the speed reference signal (in open-loop speed mode) is within the limits set by MIN ALARM and MAX ALARM (Parameters 81 and 82), and de-energizes when the signal falls below the MIN ALARM setting or exceeds the MAX ALARM setting.

INV MIN/MAX A

INVERSE MIN/MAX ALARM - The relay de-energizes when the feedback signal (in PID mode) or the speed reference signal (in open-loop speed mode) is within the limits set by MIN ALARM and MAX ALARM (Parameters 81 and 82), and energizeswhen the signal falls below the MIN ALARM setting or exceeds the MAX ALARM setting.

MIN ALARM

The relay de-energizes when the feedback signal (in PID mode) or the speed reference signal (in open-loop speed mode) equals or exceeds the MIN ALARM setting (Parameter 81), and energizes when the signal falls below the MIN ALARM setting.

INV MIN ALARM

INVERSE MIN ALARM - The relay energizes when the feedback signal (in PID mode) or the speed reference signal (in openloop speed mode) equals or exceeds the MIN ALARM setting (Parameter 81), and de-energizes when the signal falls below the MIN ALARM setting.

MAX ALARM

The relay de-energizes when the feedback signal (in PID mode) or theorspeed signal (in open-loop speed mode) is and less than equalreference to the MAX ALARM setting (Parameter 82), energizes when the signal exceeds the MAX ALARM setting.

INV MAX ALARM

INVERSE MAX ALARM - The relay energizes when the feedback signal (in PID mode) or the speed reference signal (in open-loop speed mode) is less than or equal to the MAX ALARM setting (Parameter 82), and de-energizes when the signal exceeds the MAX ALARM setting.

SLEEP

The relay energizes when the drive is in SLEEP MODE. See Parameters 36 - 38.

SPD = 0HZ

The relay energizes when there is no output to the motor, for any reason, such as: drive is in STOP mode, drive is in RUN mode but the speed command is 0 Hz, drive is in SLEEP mode,

drive has tripped into a fault, etc. The open-collector output circuit is a current-sinking type rated at 30 VDC and 40 mA maximum. An external power supply (30 VDC max.) must be used to power the open-collector outputs. The drive does not have a dedicated power supply for the open-collector outputs. 53

TB15 OUT

(TB-15 OPEN COLLECTOR OUTPUT)

This parameter sets the open-collector output indication for terminal TB-15. It has the same functionality as Parameter 52 - TB14 OUT above. 54

RELAY

(RELAY FUNCTION)

The control board has one set of FORM C relay contacts at TB-16, 17, and 18 that can be programmed for the same indications as the open-collector outputs described in parameter 52.

63

Table of Contents The FORM C contacts at TB-16, 17, and 18 are rated 2 amps at 28 VDC or 120 Vac. Control wiring diagrams show relays in the rest state (coils NOT energized). NOTE: Models rated above 30 Hp at 200/240 Vac and 60 Hp at 400/480 Vac have a second Form C relay at terminals TB-19, TB-20, and TB-21. This relay is controlled by Parameter 52 - TB14 OUT. 55

TB5B LOSS

(LOSS OF FOLLOWER ACTION)

This parameter selects the action taken by the drive if the follower signal is lost at TB-5B. This function is only active if the follower signal is 4-20 mA. The signal is considered lost if it falls below 2 mA. FAULT

The drive will trip into a FOLLOWER fault condition.

SP #4

The drive will go to SPEED #4 (Parameter 4).

NONE

The drive will go to the programmed minimum speed.

57

SERIAL

(SERIAL COMMUNICATIONS)

This parameter is used to activate serial communications. When using this feature, the drive can communicate with a personal computer (PC), programmable logic controller (PLC), or other external device that utilizes RS-485 serial communicati ons for control. The serial interface may be used to read present parameter settings (uploading to the control device), write new parameter settings (downloading from the control device), monitor present drive activity, and control drive activity. The following settings are available: DISABLE

Serial communication function is disabled.

W / TIMER

Enables serial communications with a watchdog timer. If there is no serial activity (read or write) for more than 10 seconds, serial control will turn off and the drive will stop.

W / O TIMR

Enables serial communications without a watchdog timer. However, after 10 seconds of no serial activity, serial control can be turned off by issuing a STOP command from any source (keypad, terminal strip) other than the serial link.

NOTE 1: The keypad STOP button is always active, regardless of what method (LOCAL, REMOTE, orSERIAL) is being used to control the drive.The remote STOP input (TB-1) may also be active, depending on how the drive is programmed. NOTE 2: If a RESET command (Parameter 65 - PROGRAM) is issued through the serial link, this parameter will not default back to DISABLE. However, explicitly setting this parameter to DISABLE through the serial link will cut off communication with the drive. If developing an application for serial communications, refer to the RS-232/RS-485 Modbus Communications Protocol Specification. 58

ADDRESS

(SERIAL ADDRESS)

This parameter is used with the serial communications feature, and is intended for use in a multiple drive network (RS-485). The serial link will support drives with addresses from 1 up to 247.

64


PASSWORD (PASSWORD NUMBER)

This feature limits access to the programmable parameters for added security. The correct password must be entered in order to change the parameters. Pressing the PROG/RUN button on the keypad will activate the PASSWORD prompt. If the correct password is entered, the PROGRAM MODE is entered and parameters can be changed. If the wrong password is entered, the drive will flash ERROR: INCORRECT and then return to the PASSWORD prompt to allow another attempt at entering the correct password. If the ENTER key is pressed while PASSWORD reads 0000, the MONITOR MODE will be entered (if Parameter 64 - MONITOR, is set to ON), which will allow the parameters to be viewed (except for PASSWORD), but not changed. NOTE 1: The factory default value is 0019. NOTE 2: If PASSWORD is set to 0000, the function is disabled. Pressing the PROG/RUN key will result in direct entry into the PROGRAM mode without having to enter a password. 63

SOFTWARE (SOFTWARE VERSION)

This parameter displays the software code and revision number of the control board software. This information is useful when contacting the factory for programming or troubleshooting assistance. This is a “view-only” parameter, and cannot be changed. 64

MONITOR

(MONITOR MODE)

This parameter is used to enable (ON) or disable (OFF) the MONITOR MODE function. The functionality is explained below: ON

Pressing the PROG/RUN key will call up the PASSWORD prompt. If the ENTER key is pressed while the password value reads 0000, the MONITOR MODE is entered and parameters can be viewed (except for PASSWORD), but not changed.

OFF

Pressing the PROG/RUN key will call up the PASSWORD prompt. If the ENTER key is pressed while the password value reads 0000 (or any other incorrect value), it will be treated as in incorrect password and the display will flash ERROR: INCORRECT, and then return to the PASSWORD prompt to

65

PROGRAM

allow another attempt at entering the correct password. (PROGRAM FACTORY DEFAULTS)

WARNING! STOP (TB-1) and EXTERNAL FAULT (TB-13D) circuitry may be disabled if parameters are reset to factory defaults! The drive must be reprogrammed after a RESET in order to insure proper operation.

FAILURE TO DO SO MAY RESULT IN DAMAGE TO EQUIPMENT AND/OR INJURY TO PERSONNEL!

65

Table of Contents This parameter is used to reset the programmable parameters back to the factory default settings. This parameter has four possible settings: MAINTAIN

Maintain parameter settings as they are.

RESET 60

Resets parameters to factory defaults for 60 Hz base frequency.

RESET 50

Resets parameters to factory defaults for 50 Hz base frequency.

RST HIGH

Resets parameters to factory defaults for 650 Hz base frequency. This option will only appear if the drive is equipped with the High Frequency Output option.

When a factory reset is performed, the following terminals are affected: TB-1 will be disabled as a STOP input because Parameter 30 - CONTROL will default to LOCAL. TB-13A, 13B, and 13C will be disabled because Parameters 47, 48, and 49 will default to NONE. If TB-13C was set to RUN REVERSE, TB-12A will default to a momentary START contact. TB-13D will default to a normally open EXTERNAL FAULT contact because Parameter 50 - TB13D will be reset to EXT FAULT. NOTE: This parameter will display RESET 60, RESET 50 or RST HIGH until a change is made to one or more of the parameter settings. Once a parameter is changed, the display will change to MAINTAIN. 66 (CLEAR FAULT HISTORY) HISTORY This parameter is used to clear the previous faults in the FAULT HISTORY. When set to CLEAR and the ENTER key is pushed, the display will change to MAINTAIN, and the FAULT HISTORY will display NO FAULT for each of the eight fault histories. 70

PID MODE

(PID MODE SELECT)

This parameter activates the PID function, and selects whether the PID control will be direct or reverse acting. Refer to Section 19.0 - MC1000 PID SET POINT CONTROL. The following options are available: OFF

Disables the PID function to allow “standard” drive operation.

NORMAL

Enables the PID function for direct acting systems. An increase in the feedback variable will cause a decrease in motor speed.

REVERSE

Enables the PID function for reverse acting systems. An increase in the feedback variable will cause an increase in motor speed.

used to compensate for reverse acting feedback NOTE: The REVERSE selection is not devices. If a reverse acting feedback devic e is used, program Parameters 75 and 76 - FB @ MIN and FB @ MAX as described inSection 19.1 - FEEDBACK DEVICES. When PID is enabled, and the drive is in REMOTE and AUTO mode, the drive will operate in a CLOSED LOOP fashion, responding to the feedback signal in order to maintain the process set point. In this case, the set point reference can be a 0-10 VDC or 4-20 mA signal, or the keypad. The SPEED REFERENCE SOURCE indication in the CONTROL display will indicate VDC (0-10 VDC), IDC (4-20 mA), or AKB (keypad), depending on the set point reference.

66

Table of Contents When PID is enabled, and the drive is in LOCAL and AUTO mode, the drive will also operate in a CLOSED LOOP fashion. However, in this case, the only set point reference available is the keypad, andthe SPEED REFERENCE SOURCE indication in the CONTROL display will indicate AKB. When PID is enabled, and the drive is in MANUAL and LOCAL or REMOTE mode, the drive will operate in an OPEN LOOP fashion, responding directly to speed commands from the keypad only. The SPEED REFERENCE SOURCE indication in the CONTROL display will indicate MKB. When PID is disabled, the drive will operate in an OPEN LOOP mode, responding directly to speed commands from either the keypad (MANUAL mode) or an analog input signal or preset speed (AUTO mode). 74

PID FB

(PID FEEDBACK SOURCE)

This parameter selects the terminal to be used for the feedback signal, and can be set to TB-5A or TB-5B. TB-5A is used for 0-10 VDC signals, and TB-5B is used for 4-20 mA signals. NOTE: The MC1000 has only one analog input of each type, so the same type of signal cannot be used for feedback and set point reference. For example, a 4-20 mA signal from a transducer could not be used as a feedback signal if the set point is being controlled by a 4-20 mA signal from a PLC. 75

FB @ MIN

(MINIMUM FEEDBACK VALUE)

This parameter should be set to the value of the process variable that corresponds to the minimum transducer feedback signal (0 VDC or 4 mA). 76

FB @ MAX

(MAXIMUM FEEDBACK VALUE)

This parameter should be set to the value of the process variable that corresponds to the maximum transducer feedback signal (10 VDC or 20 mA). NOTE: If a reverse acting feedback device is being used, FB @ MIN should be set to the maximum process variable value, and FB @ MAX should be set to the minimum process variable value. 77

P GAIN

(PROPORTIONAL GAIN)

This parameter setting represents the speed command output (in % of maximum speed) that results from each 1% of error (1% of the feedback range; FB @ MAX minus FB @ MIN). Example: If P GAIN is programmed for 5%, and the error (difference between set point and feedback) is 10%, the speed command output of the Proportional term is 50% (10 x 5 = 50) of maximum speed. 78

I GAIN

(INTEGRAL GAIN)

This parameter setting represents the ramp rate of the speed command output (in % of maximum speed per second) that results from each 1% of error. Example: If I GAIN is programmed for 0.5 seconds, and the error is 5%, the rate of rise of the speed command output of the Integral term is 2.5% (0.5 x 5 = 2.5) of maximum speed per second. 79

D GAIN

(DIFFERENTIAL GAIN)

This parameter setting represents the speed command output (in % of maximum speed) that results from each 1% per second change in the error.

67

Table of Contents Example: If D GAIN is programmed for 5 seconds, and the error is increasing at 2% per second, the speed command output of the Differential term is 10% (5 x 2 = 10) of maximum speed. NOTE: Differential gain is used as a “shock-absorber” to dampen overshoots in fast-acting systems. However, it can be very sensitive to “noise” on the feedback signal and to digitizing errors, so it must be used with caution. 80

PID ACC

(PID ACCEL/DECEL)

This parameter sets the acceleration and deceleration rate of the set point reference into the PID unit. When the set point changes, this function will “filter” the input to the PID unit by ramping the set point reference from the previous value to the new value. This will help prevent overshoots that can occur when the PID control attempts to respond to step changes in set point, resulting in smoother operation. If PID ACC is set to 0.0 seconds, it is effectively disabled. 81

MIN ALRM

(PID MINIMUM ALARM)

This parameter setting represents the value that the feedback signal (in PID mode) or speed reference signal (in open-loop speed mode) must fall below to activate the MIN ALARM output (see Parameters 52, 53, and 54). 82

MAX ALRM

(PID MAXIMUM ALARM)

This parameter setting represents the value that the feedback signal (in PID mode) or speed reference signal (in open-loop speed mode) must exceed to activate the MAX ALARM output (see Parameters 52, 53, and 54). NOTE 1: The MIN/MAX ALARM function can be used to start and stop the drive based on the level of the speed reference signal or PID feedback signal. This is done by wiring a 2-wire start/stop circuit through the drive's Form C relay or opencollector output, and setting the Form C relay or open-collector output for MIN/MAX (see Parameters 52, 53, and 54). When the signal drops below the MIN ALARM setting, the relay or open-collector output will de-energize, which opens the start contact and stops the drive. When the signal is equal to or greater than the MIN ALARM setting, the relay or open-collector output will energize, which closes the start contact and starts the drive. The drive must be in REMOTE mode to use the MIN/MAX function to start and stop the drive. NOTE 2: When using the MIN and MAX ALARM functions in open-loop speed mode (PID is disabled), parameter 74 - PID FB must still be set to match the speed reference signal being used. 98

LANGUAGE

(LANGUAGE SELECTION)

The MC Series drive can support other languages with the addition of an optional LANGUAGE EEPROM chip installed in socket U11 on the control board of the drive. If the EEPROM is not present, the default language will be ENGLISH. Also, this parameter is not affected when the parameters are reset using Parameter 65 - PROGRAM. Therefore, if a language other than ENGLISH is selected, it will remain in effect after a RESET. 99

FAULT HISTORY

The FAULT HISTORY stores the previous eight fault conditions that caused the drive to trip. The information stored here is view-only, it cannot be altered. The FAULT HISTORY can be used to determine if there is a pattern, or trend, to the faults, which may indicate a problem in the system. Refer to Section 19.0 - TROUBLESHOOTING for more information on faults.

68

Table of Contents The FAULT HISTORY indicates the number of the fault (number 1 is the most recent fault), the fault message, and the status of the drive at the time of the fault. An example is shown below: FAULT NUMBER

FAULT MESSAGE

3 OVERLOAD

DRIVE STATUS

RUN

In the example above, the third fault log is being viewed, which is an OVERLOAD fault that occurred while the drive was in a RUN state

69

Table of Contents

19.0 MC1000 PID SET POINT CONTROL PID Set point Control allows the MC1000 to maintain a process set point, such as PSI or CFM, without using an external controller. When PID is activated, the MC1000 will operate in a closed-loop fashion, automatically adjusting the motor speed to maintain the set point. PID set point control requires feedback from the process in order to compare the process variable “value” o t the set point. The difference betweenthe process variable “value” and the set point is called the error. The MC1000 will increase or decrease the motor speed in an attempt to minimize the error. By constantly adjusting the motor speed, the PID control will drive the process toward the set point. Refer to the PID block diagram below: P I

SET

Motor

Error

Speed Command

D

Process

Process Variable Feedback (transducer)

19.1

FEEDBACK DEVICES

A transducer or transmitter is required to monitor the process variable and provide feedback to the PID unit in order to compare the process variable feedback to the set point. A transducer outputs a signal corresponding to a fixed range of the process variable. A transmitter provides offset and gain adjustments to allow the output signal to be adjusted to correspond to different ranges of the process variable. Typical output signals for transducers and transmitters are: 0-5 VDC, 0-10 VDC, or 4-20 mA. The feedback device must be externally powered, as the drive does not have a power supply for such devices. Program Parameter 74 - PID FB (PID FEEDBACK SOURCE) for the appropriate terminal (TB-5A or TB-5B), and connect the feedback device as described below: POT

The positive signal wire (wiper) is connected to TB-5A, and the “high” lead is connected to TB-6.

0-5, 0-10 VDC

Connect the positive signal wire to TB-5A.

4-20 mA

Connect the positive signal wire to TB-5B.

The common, or negative signal wire, is connected to TB-2 (circuit common). Feedback devices can be direct or reverse acting. A direct acting device outputs a signal that increases as the process variable increases. A reverse acting device outputs a signal that decreasesas the process variable increases. The programming of Parameters 75 - FB @ MIN and 76 - FB @ MAX depend on the type of feedback device being used. When using a direct acting transducer, Parameter 75 - FB @ MIN should be set to the value of the process variable feedback corresponding to the minimum feedback signal (0 VDC or 4 mA), and Parameter 76 - FB @ MAX should be set to the value of the process variable feedback corresponding to the maximum feedback signal (5 or 10 VDC, or 20 mA).

70

Table of Contents Example 1: A 0-100 psi transducer outputs a 4 mA signal at 0 psi and 20 mA at 100 psi. Program Parameter 75 to 0.0 PSI, and Parameter 76 to 100.0 PSI (This assumes that Parameter 31 - UNITS is set to pid PSI, and Parameter 33 - UNITS DP is set to XXX.X). For a reverse acting transducer, set Parameter 75 - FB @ MIN to the maximum process variable feedback value, and set Parameter 76 - FB @ MAX to the minimum process variable feedback value. In other words, Parameter 75 is set higher than Parameter 76. See the example below: Example 2: A 0-100 psi transducer outputs a 20 mA signal at 0 psi and 4 mA at 100 psi. Program Parameter 75 to 100.0 PSI, and Parameter 76 to 0.0 PSI (This assumes that Parameter 31 - UNITS is set to pid PSI, and Parameter 33 - UNITS DP is set to XXX.X).

19.2

THE SYSTEM - DIRECT AND REVERSE ACTING

The entire system can also be direct or reverse acting. In a direct acting system, an increase in motor speed causes an increase in the process variable. This is equivalent to requiring an increase in motor speed in response to a decreasing process variable feedback. In a reverse acting system, an increase in motor speed causes a decrease in the process variable. This is equivalent to requiring an increase in motor speed in response to an increasing process variable feedback. Examples of direct and reverse acting systems are described in the next section.

19.3

PID CONTROL - DIRECT AND REVERSE ACTING

The PID Set point Control software can be direct or reverse acting, and must be set to match the system. This is accomplished with Parameter 70 - PID MODE. When set to NORMAL (for direct acting systems), the PID unit will command an increase in motor speed if the process variable feedback decreases, and a decrease in motor speed if the process variable feedback increases. When set to REVERSE (for reverse acting systems), the opposite is true. NOTE: The REVERSE setting for Parameter 70 - PID MODE is not used to compensate for reverse acting feedback devices. If a reverse acting feedback device is used, program Parameters 75 and 76 as described above. An example of a direct acting system is one that maintains duct pressure. Duct pressure is the process variable that is monitored by the feedback device. As duct pressure rises, motor speed needs to be decreased to maintain the pressure. A direct acting PID control will command a decrease in motor speed in response to an increasing process variable feedback. An example of a reverse acting system is one that maintains water temperature in a cooling tower. Water temperature is the process variable that is monitored by the feedback device. As the water temperature rises, motor speed needs to be increased to lower the temperature of the water. A reverse acting PID control will command an increase in motor speed in response to an increasing process variable feedback.

71


SET POINT REFERENCE SOURCES

The set point reference input can be one of the following: 1. Keypad 2. 4-20 mA signal at TB-5B 3. 0-10 VDC signal at TB-5A 4. Potentiometer signal at TB-5A In order to use TB-5A or TB-5B for a set point input, one of the terminals must be programmed for the appropriate signal. Closing the TB-13 terminal to TB-2 will then select that signal as the set point reference. If the contact closure is not made to TB-2, the set point reference source will default to the keypad. See Parameters 47 - TB13A, 48 - TB13B, and 49 - TB13C. Remote set point reference inputs at TB-5A and TB-5B can only be used if that terminal is NOT being used for the process feedback signal from a transducer. The MC1000 has only one analog input of each type, so the same type of signal cannot be used for transducer feedback and set point reference. For example, a 4-20 mA signal from a transducer could not be used as a feedback signal if the set point is being controlled by a 4-20 mA signal from a PLC.

19.5

TUNING THE PID CONTROL

Once the PID control is set up correctly, it needs to be tuned in order to maintain the process set point. First, set the Integral and Differential Gains to zero, and increase the Proportional Gain (Parameter 77) until the system becomes unstable , then lower the gain until the system stabilizes again. Set the Proportional Gain about 15% less than that value that stabilizes the system. If only Proportional Gain is used, and the system is operating in a steady-state condition (set point is fixed and process variable has settled to a fixed value), there will always be a certain amount of error in the system. This is called the steady-state error. Integral Gain (Parameter 78) is used to force the steady-state error to zero by increasing the output speed command with respect to time. Over time, the error will be forced to zero because the Integral term will continue to change the speed command, even after the Proportional term reaches steady state and no longer affects the speed command. The Integral Gain affects the rate of rise of the output speed command from the Integral term. Small amounts of Integral Gain can cause large changes in PID performance, so care must be taken when adjusting Integral Gain. Too much Integral Gain will result in overshoots, especially if large step changes in error occur. Typically, Proportional and Integral Gain are all that is needed to fine-tune the system. However, it may be necessary to use Differential Gain (Parameter 79) to further stabilize the system, especially when quick responses are required. The Differential term responds to the rate of change of the error, not the actual error itself. Differential Gain acts like a “shock-absorber” to dampen overshoots that can occur when the PID tries to react quickly to changes in error or set point. This allows fast PID response, with reduced risk of becoming unstable due to overshoots. The Differential term is very sensitive to electrical noise on the feedback signal and to digitizing errors, so it must be used with caution. The other parameter setting that affects the response of the PID control is Parameter 80 - PID ACC. This sets the acceleration (and deceleration) rate of the set point reference into the PID unit. When the set point changes, this function will “filter” the input to the PID unit by ramping the set point reference from the previous valu e to the new value. This will help prevent overshoots that can occur when the PID control attempts to is respond to step changes set point,disabled. resulting in smoother operation. If PID ACC set to 0.0 seconds, it is in effectively

72


MC1000 DISPLAY IN PID MODE

When the drive is in PID mode, the DRIVE STATUS portion of thedisplay will indicate actual output frequency (in Hertz) instead of RUN, and the right side of the display will indicate PID SET POINT, % LOAD, or PID FEEDBACK. The ENTER key is used to toggle between the different displays. Examples of the possible displays are shown below: DRIVE STATUS

PID SET

42.53 HZ

35.0 PSI PID UNITS

DRIVE STATUS

42.53 HZ

PERCENT LOAD

57% LOAD PID FEEDBACK

DRIVE STATUS

42.53 HZ

33.7 PSI PID UNITS

In the examples above, the drive is running at 42.53 Hz to maintain the PID SET POINT of 35.0 psi. Pressing the ENTER key displays % LOAD, which is 57%. Pressing ENTER again displays the PID FEEDBACK from the process, which is 33.7 psi. When the PID SET POINT and PID FEEDBACK displays are entered, the display will flash SET POINT or FEEDBACK before displaying the value to indicate which display is being viewed.

73

Table of Contents

20.0 TROUBLESHOOTING The table below lists the fault conditions that will cause the drive to shut down, as well as some possible causes. Please contact the factory for more information on troubleshooting faults. NOTE: The drive will not automatically restart after a PWR SAG or a CONTROL fault. Also, if an OUTPUT fault occurs below 1.5 Hz, the drive will only attempt one restart, after a four minute delay. If unsuccessful, it will then trip into FAULT LOCKOUT, which will require a manual reset. This is done to protect the drive in case of a shorted motor.

FAULT MESSAGES

FAULT OUTPUT

DESCRIPTION

POSSIBLECAUSES

Output transistor fault: Output cur- Phase to ground short. rent exceeded 200% of drive rating. Phase to phase short. FX or AC BOOST set too high. Bad transistor module (IPM).

LO VOLTS

Low DC Bus Voltage fault: DC bus Low line voltage. voltage below 60% of normal.

HI VOLTS

High DC Bus Voltage fault: DC bus High line voltage. voltage above 120% of normal. Overhauling load. DECEL rate is set too fast.

HI TEMP

Temperature fault: Internal drive temperature too high.

Ambient temperature too high. Fan failure (if equipped).

OVERLOAD

Current Overload fault: Output cur- Drive undersized for the rent rating exceeded for too long. application. Problem with motor and/or driven equipment.

PWR TRAN

Power Transient fault: Low line voltage.

AC line dipped or sagged.

Power fault: tolerance. Control board voltageSag is below

Erratic AC line.

A new control board has been installed that is different from the previous version.

Perform a factory reset using Parameter 65-PROGRAM. This will update the software and allow the fault to be reset

PWR SAG

LANGUAGE

Language fault: Selected language Defective language EEPROM. not present Language EEPROM (U11) removed after programming.

74

Table of Contents

FAULT MESSAGES

F A UL T

DESCRIPTION

POSSIBLECAUSES

EXTERNAL

External fault: TB-13D is open or closed to TB-2, depending on setting of Parameter 50 - TB13D.

Check setting of Parameter 50-TB 13D Check devices wired between TB13D and TB-2.

DB ERROR

Dynamic Brake fault: overload. DB circuit has sensed a resistor

The DB duty cycle is too high, causing the resistors to overheat.

CONTROL

Control Board fault: New software Perform a factory reset using has been installed that is different Parameter 65-PROGRAM. from the previous version. This will update the software and allow the fault to be reset.

INTERNAL INTERN (#)

Internal fault: The microprocessor has sensed a problem.

Electrical noise on control wiring. Defective microprocessor.

FOLLOWER

Loss of Follower fault: 4-20 mA signal at TB-5B is below 2 mA.

Parameter 55 - TB5B LOSS is set to FAULT.

Blank display or The power supply has shut down. repeatedly flashes This can be the result of clogged or failed heatsink fans. TESTING (drive will not run)

75

Check heatsink fans (if equipped). Clear any obstructions. If they are not clogged, contact the AC Tech Service Department.

Table of Contents

21.0 USER SETTING RECORD

PARAMETER MENU: USER SETTING RECORD PARAM. NUMBER

PARAMETER NAME

FACTORY DEFAULT

0

LINE VOLTS

AUTO

1

SPEED #1

20.00 Hz

2

SPEED #2

20.00 Hz

3

SPEED #3

20.00 Hz

4

SPEED #4

20.00 Hz

5

SKIP #1

.00 Hz

6

SKIP #2

.00 Hz

7

BAND WID

8

ACCEL

30.0 SEC

9

DECEL

30.0 SEC

1.00 Hz

10

MIN FRQ

.50 Hz

11

MAX FRQ

60.00 Hz

12

DC BRAKE

.0 VDC

13

DC TIME

SEC .0

14

DYN BRAKE

OFF

16

CURRENT

180 %

17

MOTOR OL

18

BASE

19

FXBOOST

(NOTE1)

20

AC BOOST

0.00%

21

SLIP CMP

0%

22

TORQUE

23

CARRIER

100% 60.00 Hz

CONSTANT 2.5 kHz

NOTE 1: Refer to section 18.0 - description of parameters.

76

USER SETTING

Table of Contents


PARAMETER NAME

FACTORY DEFAULT

25

START

NORMAL

26

STOP

COAST

27

ROTATION

FORWARD

28

AUTO/MAN

BOTH

29

MANUAL

KEYPAD

30

CONTROL

LOCAL

31

UNITS

sp: HERTZ

32

HZ MULT

1.00

33

SPEED DP

XXXXX

34

LOAD MLT

100%

35

CONTRAST

36

SLEEP TH

.00 Hz

37

SLEEPDL

30.0SEC

38

SLEEP BW

0%

39

TB5 MIN

.00 Hz

40

TB5 MAX

60.00 Hz

41

AIN FLTR

0.02 SEC

42

TB10A OUT

NONE

43

@TB10A

44

TB10B OUT

45

@TB10B

125%

47

TB13A

NONE

48

TB13B

NONE

49

TB13C

NONE

50

TB13D

EXT FAULT

MED

60.00 Hz NONE

77

USER SETTING

Table of Contents


PARAMETER NAME

FACTORY DEFAULT

52

TB14 OUT

NONE

53

TB15 OUT

NONE

54

RELAY

NONE

55

TB5B LOSS

57

SERIAL

DISABLE

58

ADDRESS

30

61

PASSWORD

0019

63

SOFTWARE

(N/A)

64

MONITOR

ON

65

PROGRAM

66

HISTORY

MAINTAIN

70

PID MODE

OFF

74

PID FB

TB-5A

75

FB @ MIN

0.00 %

76

FB @ MAX

100.00 %

77

GAIN P

5.00 %

78

GAIN I

0.0 SEC

79

GAIN D

0.0 SEC

80

PID ACC

30.0 SEC

81

MIN ALRM

0.0 %

82

MAX ALRM

0.0 %

98

LANGUAGE

ENGLISH

99

FAULTHISTORY

FAULT

RESET60

(N/A)

78

USER SETTING

Table of Contents

A C Technology Corporation 630 Douglas Street, Uxbridge MA 01569 Sales: 800 - 217 - 9100, FAX: 508 - 278 - 7873 Service: 508 - 278 - 9100 ext 125, FAX: 508 - 278 - 6620 www.actech.com Document: M101T


7.0 Recommended Spare Parts Stock Redler India Private Limited recommends purchasing and holding in reserve the following replacement parts to reduce any downtime that might occur due to component failure. Having these replacement parts on hand would allow for the equipment to return to operational status with minimal downtime. For a price quote or to place an order, call the Parts Department at (080) 3040-3705/706/707 extension 650 or fax to (080) 3040-3708. The quantities shown in the list below reflect spare parts required for one feeder conversion. Description

Part No.

Qty.

DT_9 Controller

V000754.B09

1

Keyboard/Display Assembly

V000755.B09

1

Speed Sensor

FE11705

1

Variable Frequency Drive

V003033.B06

1

Motor

FE14364

1

Novmber 2013 1272-0000 Revision 0

7.0 Recommended Spare Parts Stock Redler India Private Limited


Novmber 2013 1272-0000 Revision 0

DT9 manual.pdf

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