8H110343 8H112343 Feeding controller - Congrav® OP1 1.

Manual

Operating unit OP1

Device: Congrav® OP1

Software:
Interface: -
Document: 8H112343
Rev.: 1.2
Date: 06-12-11
- Copyright as per DIN 34 –
 ManualOperating unit OP1

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 ManualOperating unit OP1

TABLE OF CONTENT

1 Introduction 4
1.1 Congrav® OP1 4
1.2 Group of users of the documentation 5
1.3 Safety note 5
1.4 Signs used in the operating instructions 5
1.5 Revision index 6

2 Connection of the OP1 7

2.1.1 Activation of the OP1 operation 7
2.2 Dimensions of the OP1 8

3 The operation of the OP1 9

3.1 The front keyboard of the OP1 9
3.2 The display of the OP1 11
3.3 The operation of the OP1 12

4 The assignment of the H-type software parameters 13

5 Configuration parameters for the ISC-CM 16

5.1 Parameters for the I/O configuration 16
5.2 Parameters for testing the I/O of the ISC-CM 19
5.3 Index 20

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1 Introduction
1.1 Congrav® OP1

Congrav® OP1, called OP1 in this manual, is an operating and display unit
for the control and the monitoring of the feeding operation of a feeder. For
this purpose, the OP1 is equipped with an operating element (keyboard)
and a display element (display).

As far as the feeding operation of a feeder is concerned, the OP1 is a

passive operating/display unit and not a feeding controller.

The OP1 is not equipped with the internal software and the hardware
equipment required for the control and monitoring functions of the feeding
operation. For this, the OP1 will have to be connected to a suitable feeding
controller. This feeding controller offers the necessary software and
hardware functions and is operated and configured via the OP1.
At present, the connection of the OP1 is supported by the following feeding
controllers:
„ Feeding controller ISC-CM
„ Feeding controller Congrav® CB

The functions of the OP1 change as a function of the feeding controller, to

which the OP1 is connected. For this reason the documentation of the OP1
is structured as follows:
„ The present description deals with the key functions and the menu
structure of the OP1. The menu structure permits to call up and to
administer the parameters of the feeding controller. The assignment
(feeding controller parameters ÅÆ menu structure) is described by
means of the assignment list.
„ The parameters of the feeding controller are described in the
"Description of the software parameters". This is a separate
documentation and is part of the OP1 documentation.
„ The operator’s manual completes the OP1 documentation. It describes
the essential operating functions of the OP1.

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1.2 Group of users of the documentation

The OP1 description has been conceived for trained and authorised
specialist staff. It describes the selection of menu levels that contain
parameters, the functions of which must only be changed by specialist staff.
Some parameters have to be enabled by the input of a password. The
necessary passwords are only indicated in the present manual and are thus
reserved for the specialist staff.

A change of the feeding parameters will change the behaviour of the

feeding controller. An incorrect modification of the parameters by
untrained specialist staff will have a negative impact on the safety of the
Attention!
feeding operation.

1.3 Safety note

The parameters indicated in the menu structure of the OP1 are defined by
the feeding controller and its software. Parameter modifications must only
be carried out by trained and authorised specialist staff that is familiar with
the parameter functions and the parameter configurations. The parameter
Attention!
functions and the parameter configurations are described in the
"Description of the software parameters".

1.4 Signs used in the operating instructions

The following signs are used in the operating instructions to point out
important notes:

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

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

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

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

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

The notes and indications have to be observed for the earthing of the
device and the connected mechanical and electrical assemblies. The
correct and complete earthing is a requirement for the operation of the
device.

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 ManualOperating unit OP1

Before any work on the feeding device, the feeding device has to be
disconnected from the electrical power supply and protected against
unauthorised reconnection.

With mounted motors the correct direction of rotation of the motor is

marked by means of a red arrow. Make sure that the motor rotates in the
correct sense. A wrong sense of rotation might lead to operational failures.

This sign marks additional information or references to other sources of

information.

1.5 Revision index

Revision 1.0

Basic version of the documentation.

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2 Connection of the OP1

The connection of the OP1 to the feeding controller is made by means of a
6-pole jack. This connection provides
„ the serial connection (RS422) of the OP1 with the feeding controller for
the data exchange and
„ the supply (DC 24V) of the OP1

For the connection of the OP1 you can order a preconfectioned cable set
from the manufacturer. Pin assignment:

Pin 1 RxB Æ Reception OP1 +

Pin 2 RxA Æ Reception OP1 -
Pin 3 TxB Æ Transmission OP1 +
Pin 4 TxA Æ Transmission OP1 -
Pin 5 DC 24 V
Pin 6 GND 24V

2.1.1 Activation of the OP1 operation

There are two possibilities for the activation of the OP1:

„ The operation is activated by means of a higher-level operating unit
(e.g. Congrav® RC4, host system). With this possibility, the feeder can
be operated via the higher-level operating unit in case of a failure of the
OP1.
„ The OP1 is employed as master operating unit. In this case the OP1 is
activated by making the connection with the feeding controller. With
this possibility it is absolutely required to install a hardware emergency
cut-out. This has the purpose to stop the feeder in case of a possible
failure of the serial connection.

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2.2 Dimensions of the OP1

Legend:
A Front view
B Side view
C Top view
D Rear view

File: OP1_Maße
Rev.: 1.0
Date: 04-06-14
by: Donsbach
Fig. 1: Dimensions of OP1

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3 The operation of the OP1

This chapter describes the operation and thus the operating element
"keyboard". The functions of the keyboard are also determined by the
software of the connected feeding controller. Therefore, the functions of the
keyboard might change as a function of the software type.

3.1 The front keyboard of the OP1

The figure shows the front views of the

OP1 with the keyboard and the display. As
far as the software of the connected
feeding controller is concerned, the keys of
the keyboard can be subdivided into 2
groups.
„ keys the function of which is
independent of the software and
„ keys the function of which depends on
the software of the feeding controller.
The software type permits to distinguish
the software of the feeding controller. At
present, we distinguish the following
software types:

HGC Software for the control of loss-in-weight feeders (H), weigh-belt

feeders (G) and Coriolis Mass Flow Scale/CP-FlowMeter (C).
N Loss-in-weight batching
A Gain-in-weight batching

Key function is independent of the software type of the feeding controller

ALARM RESET – resets the current alarm

MENU – opens the menu of the parameter administration

CURSOR UP – calls the previous parameter/menu item

CURSOR UP – calls the next parameter/menu item

CLEAR - cancels the last number of the numeric parameter input

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ENTER – validates the numeric parameter input

activates the selected menu item/parameter
validates the defined parameter setting

The keys of the numeric keyboard are employed for numeric inputs.

Key function is a function of the software type of the feeding controller

START H starts the feeding operation

G starts the feeding operation
C starts the flow measurement
N -
A -

LED start key Meaning

Red one start condition is not fulfilled
Red flashing an alarm cut-out has occurred
Green feeding has started
- feeding has stopped
Orange flashing feeding enable is interlocked

STOP H stops the feeding operation

G stops the feeding operation
C stops the flow measurement
N -
A -

STEP H setpoint, actual value, weight, speed, throughput

G setpoint, actual value, belt load, speed, throughput
(actual
C actual value, weight, throughput
values)
N -
A -
Each activation of the STEP-key calls up an actual value according to the indicated order.
If you select the throughput in the 2nd. Display line, it can be cancelled by the input "0" + ENTER.

Xs H setpoint kg/h, setpoint %

G setpoint kg/h, setpoint %
(setpoints)
C setpoint kg/h
N -
A -
With several setpoint types each activation of the Xs-key calls up a setpoint according to the indicated
order.
Active setpoint types are determined by the active mode. Inputs into an inactive setpoint
type are taken over. However, they do not influence the active operation.

Refill H manual start of the refill operation

G -
C -
N -
A -

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Auto- H auto-taring of the loss-in-weight feeder

G selection of the auto-tare operation mode
tare
C selection of the auto-tare operation mode
N -
A -

SAMPL H start sampling

G start sampling
E
C -
N -
A -

3.2 The display of the OP1

The OP1 is equipped with a 2 x 40 LCD-display. The

display shows the actual status of the feeding operation
and the parameterisation.
The display has the following functions:

1st display line (2)

Indicates the designations of the parameters and of the menus. If you call
up the actual values (STEP-key), the name and the value of the selected
actual value will be displayed.

2nd display line (3)

The actual parameter values and inputs are indicated in the 2nd display
Parameter
line.
In general, alarms and missing start conditions are indicated in the 2nd
display line. The format of the display permits to identify the type of alarm.
Alarms
flashing + stopped == feeding error with alarm cut-out
constant + stopped == start condition is missing
constant + started == error without alarm cut-out
The STEP-key permits to select the actual values. Pushing of the key
CURSOR-DOWN activates the 2nd display line, so that the actual values of
nd
the 2 display line can be selected by means of the STEP-key. Pushing of
st
Actual the key CURSOR-UP reactivates the 1 display line.

values
Special function "Throughput reset"

If you select the actual value "throughput" in the 2nd display line, it can be
cancelled by the input "0" + ENTER.

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Mode display (1)

The mode display delivers further information for the operator, the mode
display is visible in the left corner of the first display line and is made up of
2 digits. There are three different representations of the mode display:

normal: feeding has stopped

inverted: feeding has started
flashing: an alarm has occurred

Please see the "Description of the software parameters" for a description

of the alarm report, missing start conditions and mode displays.
Attention!

3.3 The operation of the OP1

The OP1 offers different modes of operation. They differ as far as the call
and the activation are concerned.

Parameter inputs
We distinguish two types of parameter input, namely the numeric input and
the predefined selection of the parameter value. Both types are identical,
the only exception is the parameter input/selection.
„ Select the parameter by means of a cursor-key, so that it is indicated in
the 1st display line.
„ Push the ENTER-key
„ Enter the new numeric value or select a predefined value by means of
the cursor-keys.
„ Validate the new value with the ENTER-key.

Selection of a menu level

„ Push the MENU-key.

„ Select the desired mode with the cursor-keys.
„ Activate the menu with the ENTER-key.
„ Within the menu the parameters can be selected by means of the
cursor-keys.

Return from the menu level

„ Next-higher menu level: MENU-key

„ Quit the menu level: Xs-, STEP-key

Key functions

Important control and operating functions can be activated directly by

pushing of the corresponding key (e.g. STOP-key).

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4 The assignment of the H-type software parameters

This chapter describes the parameter assignment lists of the OP1 for a feeding controller
with an H-software type. The H-type software permits to monitor and to control the loss-in-
weight feeders.
The table lists the sub-menus "mode", "feeding parameters", "code", "weigh-feeder
parameters“ and "alarm cut-out" with the corresponding parameters. The column
"reference" indicates the name of the corresponding chapter in the "Description of the
software parameters" as reference for the parameter function.

Submenu Included parameters Reference chapter

01 Mode 01 Gravimetric feeding GF Modes Æ Gravimetric feeding
02 Volumetric feeding VF (see above) Æ Volumetric feeding
03 Check. max. output CM (see above) Æ Check. max. output
04 Discharge (see above) Æ Discharge
05 Gravimetric discharge (See above) Æ Gravimetric discharge
06 Volumetric regulation (See above) Æ Volumetric regulation
07 Volumetric setting (See above) Æ Volumetric setting
02 Feeding parameters 01 Controller 1 P-term Feeding parameter Æ PID-controller
02 Controller 1 I-term (See above) Æ PID-controller
03 Controller 1 D-term (See above) Æ PID-controller
04 Control adaptation (See above) Æ Control adaptation
05 Grav. calc. max. output (see above) Æ Grav. calc. max. output
06 Bulk density (See above) Æ Bulk density
07 Checking max. output (See above) Æ Check. max. output
08 Volumetric output (See above) Æ Volumetric output
09 Decade switch Drive controller Æ decade switch
03 Code 01 Code input
The following menu items with their parameters can only be displayed and not
changed. For a configuration it is required to enable the system by means of a code
input. There are 2 different enable steps. Each step is enabled by a code of its own.

Code input 0133

This code input permits to enable all subsequent menu points with their parameters. A
configuration/modification of the parameters is only possible if the system is stopped.

Code input 0873

This code input permits to enable all subsequent menu points with their parameters.
Moreover, some modifications can be carried out while the feeding operation is
started.

Mode change: Gravimetric feeding ÅÆ volumetric feeding

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Gravimetric feeding ÅÆ discharge

Volumetric feeding Æ discharge
Parameter changes: Bulk density, check. max. output, decade switch

Submenu Included parameters Reference chapter

04 Feeder parameter 02 Weighing range Weight reading
03 Max. output Adaptation
04 Underload Weight reading
05 Overload Weight reading
06 Coarse tare Weight reading
07 Average values Feeding parameter
08 Throughput divisor Adaptation
09 Speed minimum Drive control
10 Speed maximum Drive control
11 Control difference Feeding parameter
12 Alarm cut-out time Feeding parameter
13 Type of interlocking Adaptation
14 Indic. of actual value Adaptation
15 Lever factor Weight reading
16 Hopper volume Refilling
17 Fill. level minimum Refilling
18 Fill. level maximum Refilling
19 Window/K1/Filter Weight reading
20 Digital speed Drive control
21 Maximal refill time Refilling
22 Refill optimize Refilling
23 Stabilization time Refilling
24 Sampling time Adaptation
25 AV cut-out time Feeding parameter
26 PID contr. access time Feeding parameter
27 Control automatic Feeding parameter
28 Filter limits Feeding parameter
29 Adapt. of actual value Adaptation
30 Adapt. of manip.variable Drive control
31 Adapt. of actual val. VR Adaptation
32 Start delay time VR Feeding parameter
05 Alarm cut-out 01 Speed minimum Alarm reports
02 Speed maximum Alarm reports
03 Control difference negative Alarm reports
04 Control difference positive Alarm reports
05 Overload Alarm reports
06 Underload Alarm reports
07 Refill fault Alarm reports
08 Anti-vibration Alarm reports

Submenu Included parameters Reference chapter

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06 Setup 01 Analogue control Configuration

02 Interlocking/stop Configuration
03 Start operation Feeding parameter
04 Setpoint ramp Feeding parameter
05 Setpoint threshold Feeding parameter
13 Simulation Test functions
14 Service mode Test functions
16 RAM delete Deletes the working memory of the device

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5 Configuration parameters for the ISC-CM

The menu items "07 I/O-configuration" and "08 Test program" permit to
configure the hardware components of the feeding controller ISC-CM and
to test their function. Thus, they become specific for the feeding controller
ISC-CM.

5.1 Parameters for the I/O configuration

01 Speed input

This parameter configures the signal form for the speed-reading on the
ISC-CM. The speed-reading is monitored and processed by the software
(belt-feeder).
Analogue: Analogue speed (0-10VDC or 2-10VDC)
Frequency Speed as frequency signal (max. 10kHz). The frequency reading is
configured by means of the calibration parameter "digital speed".
Motion No reading (software bridge), the manipulated variable is displayed as
monit.: speed.

An ISC-CM-A offers an analogue input. This is employed for the analogue

speed reading, if
ƒ the analogue speed (speed = 2) and
Attention!
ƒ no analogue load cell (load cell type ≠ 3) has been selected.

02 Load cell type

The indication of the load cell type permits to activate the corresponding
weight reading.
IDL: IDL/F-, ED60- or MD-load cell (serial weight signal)
AED: AED-module (serial weight signal)
EMS: Analogue weight signal, 0-10VDC or 2-10VDC

For the gravimetric feeding process it is required to measure the weight,

thus the ISC-CM can compute the feed rate/time unit. As a rule, the weight
is measured by the load cells. The supported load cell types are directly
connected to the ISC-CM.
At present, the following load cell types are supported:

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Type Signal Description

IDL/F TTL Digital one-wire-load cell with digital filter technique.
IDL/F 2 RS422 Digital one-wire-load cell with digital filter technique. Supplies a
serial weight signal.
ED60 Frequency Digital two-wire-load cell with digital filter technique.
MD_ Frequency Digital two-wire-load cell with digital filter technique.
AED RS422 Serial connection module for an EMS-load cell. The mV load cell
signal is processed by a digital filter technique and converted into a
serial signal.

EMS DC Analogue mV-load cell with the communication module BT0296 for
0-10V a signal range 0-10VDC.
Throug DC Analogue throughput measuring instrument (e.g. Micro Motion) that
hput 0-10V supplies a 0-10VDC standard signal. These measuring instruments
are employed for the mode "volumetric regulation".

Condition for the analogue weight reading:

An analogue input that is configured accordingly is available.
An ISC-CM-A offers an analogue input. It is employed for the analogue
weight signal, if
Attention!
ƒ the analogue load cell (load cell type = 3) and
ƒ no analogue speed (speed ≠ 2) has been selected.

03 WZ RS422/485

Signal form of the serial weight signal for the load cell types 1 and 2.

04 Drive control

A suitable drive controller is connected to the ISC-CM for the control of the
feed drive of the weigh-feeder.

Input Signal Description

FC RS485 ISC-FC frequency converter for a threephase drive.
VC RS485 ISC-VC vibration amplitude controller with vibration amplitude
feedback for a vibrating conveyor.
Analogu DC 0-10V Drive controller is driven by means of an analogue manipulated
e variable.

A controller by another manufacturer can only be connected in analogue

manner, if the ISC-CM-A is equipped with a corresponding analogue
output. Examples for devices with an analogue connection:

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Type Signal Description

806273E DC 0-10V Drive controller for a d.c. drive.
RMS2 DC 0-10V Vibration amplitude controller without vibration amplitude
feedback for a vibrating conveyor as feed drive.
FC-Vx.x DC 0-10V Frequency converter for a threephase drive.

05 St RS422/485

Selection of the interface type of the drive controller. Standard solution for
an ISC-operation: RS485

06 Analogue input

Permits to configure the signal range of the analogue input of the ISC-CM-
A to DC 0-10V or DC 2-10V.
Off: Analogue input of the ISC-CM-A is deactivated
0 -10V: DC 0-10V
2 -10V: DC 2-10V

07 Analogue output

Permits to configure the signal range of the analogue output of the ISC-CM-
A to 0-20mA or 4-20mA.
Off: Analogue output of the ISC-CM-A is deactivated
0 -20mA: 0 -20mA
4 -20mA: 4 -20mA

08 DE ISC-CM

This parameter configures the digital input on the ISC-CM.

Off: Interlocking
On: Start/Stop
The digital input reacts to a change of edge. With a rising edge of the input
signal the feeding operation will be started and with a falling edge of the input
signal it will be stopped.

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5.2 Parameters for testing the I/O of the ISC-CM

Submenu Included parameters Reference

Test program 01 Display Permits to test the display, so that display errors
become visible.
02 DI/DO - test Test functions Æ Test of the digital inputs/outputs
Permits to display and to test the digital inputs/outputs
of the ISC-CM. The feeding controller ISC-CM offers 1
digital input (interlocking) and 2 digital outputs (enable,
refill).
If the test mode has been activated, the input "1"
permits to activate the digital output 1 (= enable) and
the input "3" permits to activate the digital output 2 (=
refill).

The display and the input take into

consideration the function of the digital
inputs/outputs.

03 AI/AO - test Test functions Æ Test of the analogue inputs/outputs

Permits to display and to test the analogue
inputs/outputs of the ISC-CM-A. The feeding controller
ISC-CM-A offers 1 analogue input and 1 analogue
output.
04 Load cell Test functions Æ Status display load cell
05 Frequency converter 1 Test functions Æ Status display drive controller

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5.3 Index

A K
Activation OP1 · 7 Keyboard · 9
Alarms · 11 O
C Operation of the OP1 · 12
Connection of the OP1 · 7 P
D Parameter assignment lists H-software ·
Description: OP1 · 4 13
Dimensions of the OP1 · 8 Pin assignment OP1 · 7
Direction of rotation of the motor · 6 R
Directory · 2 Revision index · 6
Display of the OP1 · 11 S
E Signs used in the operating instructions · 5
Earthing of the device · 5 Supply voltage OP1 · 7
F T
Front keyboard · 9 Testing of the I/O of the ISC-CM · 19
G The operation of the OP1 · 9
Group of users · 5 Throughput reset · 11
H W
Hardware configuration ISC-CM · 16 Warning signs · 5
I
I/O configuration ISC-CM · 16

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