Operating Instructions for the Freqency Control Units for
Contents
1. SA3 VC96A110 Za VC96B PWM Power Board 0 uP Board Display 04 Ke 063 Power Circuit 02 5 E CS A CCAA AA AAA NAN ehh hy 10 A kK gt ng 1 H 4 d 4 d H d A N M I ZS PE LCD100 i gt SB3 163 123455678 9101112131415161718 E UC SB100 L LAU LEE EELLLLLI 12 LR AO EMC Filter d 1 gt or 027037 047 05 VC96D 27 1 0 Board A Keyboard Optional SA1 SA2 A is y 014 02 01102 sB Za xo xo xo WO03 i Lib EEA M 01 02 03 04 05 06 1 2 3 4 5 6 T 8 9 10 11 12 HH soz SIS SISTI IS STIS gt 1 E a EZ 2 x lt wo2 IREZ Z 3353 38332 3 9560 2 2 2 gt es Fuse F1 Ses u El E Set 3353 bd E AATR d wo4 wos SERE Z 2 E842 I H o Q Oo G X01 AAA X02 S 01 02 os os 05 oc oil eel 031 oaf osl S r 3 3 El DC 3 el E E wo1 O 2V EE E AE ET 9 AMO CL 37332 S y o XN RE LU d max 24V 50mA 7W PN SC 3 A max Mains Load L DS Plug 0 20mA When replacing a blown fuse a 4 0 A delayed should be used Rhein Nadel Automation GmbH MA RNA Ww Seite 25 Steuergerate Schwingantriebe ESR 2000 CD Rhein Nadel Automation GmbH Reichsweg 19 42 D 52068 Aachen Tel 49 0241 5109 159 Fax 49 0241 5109 219 Internet www rna de Email vertrieb rna de Rhein Nadel Automation GmbH Zweigbetrieb L denscheid Nottebohmstra e 57 D 58511 L denscheid Tel 49 02351 41744 Fax 49 02351 45582 Email werk luedenscheid rna de2. Rhein Nadel Automation GmbH Zweigbetrieb Ergolding Ahornstra e 122 D 84030 Ergolding Tel 49 0871 72812 Fax 49 0871 77131 Email werk ergolding rna de Rhein Nadel Automation GmbH Zweigbetrieb Ohrdruf Suhler Stra e 2a D 99885 Ohrdruf Tel 49 03624 312214 Fax 49 03624 312215 Email werk ohrdruf rna de CH HSH Handling Systems AG Wangenstr 96 CH 3360 Herzogenbuchsee Tel 41 062 95610 00 Fax 41 062 95610 10 Internet www rna de Email info handling systems ch RNA AUTOMATION LTD Hayward Industrial Park Tameside Drive Castle Bromwich GB Birmingham B 35 7 AG Tel 44 0121 749 2566 Fax 44 0121 749 6217 Internet www rna uk com Email rna rna uk com CED Vibrant S A Pol Ind Famades C Energia Parc 27 E 08940 Cornella Llobregat Barcelona Tel 34 093 377 7300 e Fax 34 093 377 6752 Internet www vibrant rna com Email info vibrant rna com CAN RNA Automated Systems Inc P O Box 560 Paris Ontario Canada N3L 3T6 Tel 1 905 3368429 Fax 1 905 3191252 Email sales rna can com VT BA ESR25 GB 30 04 03 Rhein Nadel Automation GmbH Seite 26 Steuerger te Schwingantriebe ESR 2000
3. Up Down Multicalibration pter gt Multicalibration Yes gt Yes lt Up Down Frequency Contrl Enter gt Frequency Contrl Auto Manual 25 150Hz Auto__57 5 Hz gt Auto lt 57 5 Hz Up Down Change Password Change Password Up Down Exit Main Menu 4 Enter Menu option Auto calibration The menu option Auto calibration activates the automatic calibrating procedure The ESR2x adapts itself to the con nected feeder To start the automatic calibration mode select Active and press the enter key to confirm See Section 3 4 Menu option 100 speed The maximum speed with which the feeder will operate is set here The feeder is switched on with the key ON OFF and the desired maximum speed can then be set If the feeder impacts mechanically press the ON OFF key immediately to switch off Reduce the set value by approx 5 1096 then switch the feeder on again to check that it no longer impacts If maximum voltage or current limit message is displayed the maximum permissible loading value for the solenoids has been reached In this case just let the feeder run whereby the ESR2x will automatically reduce the current and voltage to acceptable values Let the feeder run until the alarm no longer appears for at least 10 seconds Menu option 1096 speed The minimum speed with which the feeder shall operate can be set here The components should move very slowly Switch on the feeder
4. commissioning the sensor amplifier can be activated and the delay times as well as the soft start stop times can be set The vibration feeder can now be switched on with the ON OFF key After calibration the drive is running at the set 10 speed After pressing the enter key the speed can be adjusted to the desired feed rate e g 70 After making the adjustment press the enter key to save the value to memory The control unit is then in the main menu see also Section 3 1 3 Rhein Nadel Automation GmbH Seite 22 Key t tits tb Display contents 10 Speed XXXX Return Speed 1094 Switched Off Speed 10 Switched On Speed gt 70 lt Switched On Speed 70 Switched On Steuergerate Schwingantriebe ESR 2000 Input The input for external signals permits switch on and switch off of the feeder system by simple means without power drive Two inputs are available for this enable disable function bi Enable via the level sensor connection the advantage is that no intervention is required on the control unit Enable via the electrically floating input on the internal terminal strip option used mainly when the sensor input is already engaged for level monitoring The following holds for both applications Enable signal can be given as closing of a contact or as a voltage level signal The connect up to the sensor connector is described in detail on the wiring diagrams The input on the internal
5. conversion made Resonance frequency not found This error is connected with the calibration process and appears when the ESR2x cannot find the resonance frequency of the feeder Remedy 1 Check that the feeder can vibrate freely and that it contains no components Then try making a new calibration 2 Make a new calibration and ensure that the current limit is set to the value specified in Table 3 or possibly slightly higher If the current limit is set higher than the specified value bear in mind that the vibration solenoids may suffer damage Resonance maximum not found This error is connected with the calibration process and appears when the ESR2x cannot make optimum adjustment of the frequency with respect to the feeder Remedy 1 Check that the feeder can vibrate freely and contains no components then try making a new calibration 2 Make a new calibration and increase the current limit setting slightly e g by 2 5 If the current limit is set higher than the value specified in Table 3 bear in mind that the vibration solenoids may suffer damage Overmodulation protection This is not a fault but only a notification that the ESR2x is trying to generate a voltage higher than available on the 230 V mains input side The ESR2x will automatically limit the output voltage to a safe value and the message will then Rhein Nadel Automation GmbH Seite 14 Steuerger te Schwingantriebe ESR 2000 disappear of its own accord This limita
6. e n Normal Key m ITOW operation they a E x Key can be pressed to access the in dividual menu op Enter Key M Down Ar row Key the arrow keys e Inthe Activated menu option they are used to select the desired value or op erating state tions in both directions e Inthe menu option CHANGE PASS Rd WORD the code number is entered with MA RNA Gy Enter key The enter key is pressed to ac EJ tivate the individual menu op tions and to acknowledge the set parameters The set value is saved by pressing the enter key In this way the ESR retains its setting values even when it has been switched off After com pleting a setting the enter key should always be pressed to save programmed values To make a setting for example the speed first of all select the corresponding menu option with the arrow keys then press the enter key to activate this menu option The speed setting is marked with gt lt e g gt 57 lt This marking indi cates that the value can now be changed with the arrow keys e g to gt 68 lt When the desired change has been made press the enter key to acknowledge it This saves the new value to memory The arrows will now disappear leaving the value 68 Certain error messages must always be acknowledged with the enter key These messages concern serious errors such as Short circuit protection active and others Other error messages disappear automatically when the error con dition no longer exis
7. is connected to the mains voltage in accordance with the safety instructions the display first of all shows ESR2X here stands for the device type and X XX for the software version The main menu appears after 5 seconds Pressing the Up arrow key accesses On pressing the enter key the password for the calibration menu can be entered with the Up arrow key standard password 2000 Then switch to the calibration menu The display now shows Activate the menu option with the enter key Pointed brackets enclosing the changeable parameter indicate this Pm The parameter can now be changed with the arrow keys In this case to Press the enter key to start the automatic calibration process First of all the current magnitude guidance value from Table 8 and Table 9 must be set here with which the connected feeder is to be operated This protects the feeder against current overload The actual value must be set with the arrow keys Then press Enter to start the calibration The calibration process stops if a fault condition appears during calibration or it can be stopped manually by pressing the ON OFF key The former calibration data are then restored and used First of all the offset adjustment is made for the voltage measuring circuit This takes approx 12 seconds to complete Then the offset adjustment is made for the current measuring circuit This takes max 20 seconds to complete Rhein Nadel Automation GmbH Se
8. saved to memory on exit from this menu option The control unit can automatically control the vibration amplitude and the frequency only when movement of a certain magnitude is taking place If the feeder is running so slowly during the 10 speed adjustment that the frequency becomes unstable the frequency limits found may be incorrect 2 Very high loading with heavy articles The consequence is that the frequency has dropped by 20 due to the heavy loading The alarm can therefore appear in the case of heavy loading of the feeder which increases the total weight of the feeder system by more than 20 3 A broken or loose spring Remedy 2 None The feeding speed will possibly be reduced to some extent if the loading further increases Alarm messages will then also appear Maximum voltage RMS current limit etc 3 Recalibrate the 10 speed thereby making sure that the feeder is running stable before exit from this menu option 4 Check the springs replace and retention them as may be necessary Vibration restricted This alarm appears when the ESR2x is unable to maintain the desired speed vibration ampli qual tude without overloading the vibration solenoids 4 Rhein Nadel Automation GmbH Seite 15 Steuerger te Schwingantriebe ESR 2000 This alarm message appears when the feeder speed is less than half of the set speed but the feeder is receiving full current This is not necessarily a fault it could be caused by excessive loading of t
9. terminal strip is accessible through a PG9 screw fitting on the front of the casing As shown in Fig 5 a voltage level signal can be applied or a contact can be closed for enable Observing correct polarity the contact can also be replaced by a switched transistor conduction path e g an opto coupler An external voltage source is not required for this purpose The control unit recognises a voltage between 10 and 24 V DC between the terminals 4 and 5 as enable signal For enable signal by closing a contact the connecting line length must not exceed two metres Optional input board A PC board is available as an optional accessory device for connecting external equipment devices or for coupling several ESR2X to a complete feeder system This connectors PC board provides An alarm output the input for external enable and also two status signals of the ESR2X namely Ready for operation and Operating With these signals and the external enable signals several ESR2X control units can be coupled for monitoring the level status of an extensive feeder system The feeders can also be switched directly by a PLC system or similar facility via the external enable input The alarm output can drive a lamp or other device requiring up to 7 W power See the connections diagram in Fig 6 Rhein Nadel Automation GmbH Seite 23 Steuergerate Schwingantriebe ESR 2000 Sensor connection The sensor input is disabled in the factory settings This makes test r
10. LK N6G 2 5 45 60 Hz red To facilitate distinguishing of the vibration frequency RNA equips the feeders with differently coloured connecting cables Table 7 Connecting cables Cable colour Mains frequency operation 50 60 Hz 100 120 Hz 90 120 Hz Observe the maximum values for the load current and the solenoid gap otherwise there is a danger of destruction of the vibration feeder and or the control unit Commissioning The operating parameters for a feeder delivered with control unit ESR2x have already been adjusted in the factory to suit the feeder All settings have been archived in the RNA factory and can be called for After conversion replacement of the control unit or mechanical modification of the feeder system there is a danger of damaging springs vibrators configuration elements or the transfer device when commissioning the feeder Setting the control unit for use with a vibratory feeder If the vibration feeder impacts very loud metallic hammering noise during commissioning Switch off the control unit immediately On Off key In the case of commissioning without taking these precautions specified above there is a danger of destruction of the feeder system or parts thereof Warranty becomes void in this case Before the control unit can regulate amplitude and frequency it must be calibrated for the actually connected feeder This is necessary for initial commissioning after me
11. NNAI Ww Operating Instructions for the Freqency Control Units for Vibrator Drives ESR 25 ESR 28 Rhein Nadel Automation GmbH Rhein Nadel Automation GmbH Seite 1 Steuergerate Schwingantriebe ESR 2000 Contents 1 Re Vue RR TE 3 1 1 Guer le Beete EE 3 1 2 Which control unit for which RNA feeder eccccecccceeeeeeeeeeaeceeeeeeeseceacaeeeeeeeeesensanaeeeeeeeeetenaees 3 1 37 Tute Le EE 5 1 4 Technical data di eur Has eM devel Meo es 5 2 Safety Eadem 5 3 Cormimissioning Instr UiCtoris 4 oett Pe hortante et perdo e I ot ente roe Eget hie etri plius 6 3 1 Operator Controle er Gb ec re std coke eoe ep ete lee ete eb on ate telle dete ab Ae id 6 Sd elt RE 6 SE ba ee Le TEE 7 9 1 1 2 Arrow keys Up 7 DOWD s eee re DO e ad repe RR ipn 7 3 1 1 3 Enter Key oec ea e REG DUE GRE 7 3 1 2 Menu Structure ESR 2 7 3 773 Mam Meri 1 td LM Lei de dee Edd ede dedos ee 8 IMA Menu option Speed tic toe e dne ce etae da 8 3 1 3 2 Menu option Measuring Values eene 8 3 1 3 3 Menu option TGervice A 8 93 1 4 Control Menu etit e eee libet ts egt arr eek rota dep Ad R esca d tule 9 3 1 4 1 Menu option Calibration No Software version 1 07 13 3 1 4 2 Menu option Input relevant only when the optional PC board is fitted 10 3 1 4 3 Menu options Start delay input and Stop delay input relevant only when the optional PC board is Tied 10 SS A EE 10 e a RE SEE SEE TEE Me
12. R2x greatly increases the voltage to achieve the set speed e g when the feeder is heavily loaded or when it is started very rapidly Remedy None Load disconnected This message appears when it has been forgotten to connect a feeder or in the case of a cable breakage or if the connected feeder is very small in relation to the current limit setting Remedy 1 Disconnect the connected feeder and examine the cable for faults therein 2 Make a new calibration and thereby ensure that the current limit is set to the value specified in Table 3 or slightly lower Temperature error The temperature on the heat sink is now greater than 80 C Remedy 5 1 Switch off the feeder with the ON OFF key 2 Make sure that airflow past the heat sink is unimpeded 3 Remove dust and dirt deposits from the cooling fins High temperature The temperature on the heat sink is now greater than 70 C Remedy 1 Make sure that airflow past the heat sink is unimpeded 2 Remove deposits of dust and dirt from the cooling fins Frequency error The resonance frequency of the feeder has now reached an outer frequency limit This can have several causes 1 Poor calibration of the 10 speed During calibration of the 10 speed the ESR2x finds the outer limits of the permissible frequency range It is therefore important that the feeder is running stable and has been running stable for at least 10 seconds before exit from this menu option The limits are
13. be obtained with smallest possible current drain This typically takes about 10 seconds to complete but may require up to 1 minute It is important to ensure that the feeder can vibrate freely and is Compensation for mag not touched during this part of the calibration procedure netic saturation After successful calibration the data is saved to memory and used in future Tl The following message appears in the display after completion of the calibration DC Servo Offset X XXX A Impedance Meas Phase adjustment XXX X The following display appears on pressing the enter key Here the maximum speed is set with which the feeder shall operate Switch on the feeder with the ON OFF key and set the desired maximum speed with the arrow keys He Description Key 100 Speed gt XXXX lt Rhein Nadel Automation GmbH Seite 20 Steuerger te Schwingantriebe ESR 2000 If the feeder impacts with a loud hammering metallic noise switch off immediately with the ON OFF key and reduce the set value by about 5 10 Then switch on the feeder again to check that it no longer impacts If the maximum voltage or current limit message is dis played the maximum loading value for the solenoids has been reached Let the feeder run whereby the ESR2X will automatically reduce the current and voltage to safe val ues Let the feeder run until no more alarm messages have appeared for at least 10 seconds Press the enter key to switch to the me
14. carried out only by a trained electrician or by untrained persons under the leadership and supervision of a trained electrician in accordance with the regulations for electrical engineering All safety and danger warning signs on the machine plant must be observed The electrical equipment of a machine plant must be inspected and checked regularly Defects such as loose connections or damaged cables must be remedied immediately Steuerger te Schwingantriebe ESR 2000 Before opening the unit disconnect the mains plug and wait for at least 5 minutes The dangerous voltage in the intermediate circuit decays slowly after disconnection from the mains supply voltage Failure to pay attention to this entails danger to life Before commencing operation make sure that the safety grounding line power earth PE is intact and installed at the connecting point Only test instruments approved for this purpose may be used for checking the safety grounding conductor Commissioning Instructions The connecting cable between the control unit and the vibration feeder must be shielded and the shield must be connected to the safety grounding line at both ends The maximum permitted cable length is 2 metres gt gt gt Before connecting up to the mains input voltage and switching on the control unit it is essential to check the following points Are all plug connections secure i Is PROPER INTENDED USAGE ensured B Does the mains voltage spec
15. chanical modification of the feeder e g a change in the fitted springs or after the feeder has been replaced completely Use the calibration menu to make these calibrations see Section 3 1 5 It is important to ensure throughout the calibration procedure that the feeder can vibrate freely and that it contains no articles which could affect the vibration Rhein Nadel Automation GmbH Seite 17 Steuerger te Schwingantriebe ESR 2000 Table 8 Current limit setting guidance values for RNA vibration feeders Vibration feeder measured Max Guidance value for Recommended control Type of drive current A load current the current limit unit type A in A SRC N 16022 04 oe o5 ESR25 06 ESR25 1 8 SRB 250 2 Pos 12 10 IS E ESR25 5 5 4 SRB 400 2 1 5 i Table 9 Current limit setting guidance values for RNA linear feeders Linear feeder measured Max Guidance value for Recommended control Type of drive current A load current the current limit unit type GL 01 SLL 400 When calibrating the control units for a new feeder enter the current limit in the calibration menu see Section 3 4 1 The values specified here are for guidance only The current limit can also be set higher for heavy pots or linear feeders However it should never be set higher than the maximum permissible load current Rhein Nadel Automation GmbH Seite 18 Steuergerate Schwingantriebe ESR 2000 Description Key When the control unit
16. cumstances is it permissible to set the current limit higher than the specified maximum tolerated load current for the particular feeder The basic unit for the variants ESR 25 0 6 and ESR 25 1 8 is the standard control unit ESR 25 Conversion to a lower current region requires modification of the hardware of the control unit and changes of the factory settings therefore conversions should always be made in the RNA factory If you have any questions relating to the ESR control please contact the electrical engineering department of the company Rhein Nadel Automation in Aachen Mr Heinrichs is your contact Tel 0241 5109 207 Fax 0241 5109 219 Email RNA RNA DE In the UK contact RNA AUTOMATION LTD Birmingham Mr John Stanton is your contact Tel 0121 749 2566 Fax 0121 7496217 Email RNA RNA UK COM Rhein Nadel Automation GmbH Seite 4 Steuergerate Schwingantriebe ESR 2000 EC conformity The control unit complies with the following regulations EC EMC Directive 89 336 EEC EC Low voltage equipment directive 73 23 EEC Applied harmonised standards EN 60335 1 EC EMC Directive EN 50081 2 EC EMC Directive EN 50082 2 Conformity is ensured only when our installation instructions are observed as set forth in Section 3 Technical data Table 3 Technical data A EE 230 V 6 10 50 60 Hz 5 x 20mm 4 A slow It 72 0 210 V 25 150 Hz 5 53 A Key programmable 12 24 V DC or contact 0 05 to 10 seconds 0 005 to 10 s
17. e Stop command appears under the menu option Speed xxx in the main menu when the enable input is activated as Stop 3 1 4 3 Menu options Start delay input and Stop delay input Relevant only when the optional PC board is fitted The time delay between receiving a start stop signal at the Enable input and start stop of the feeder can be set here individually in the range 0 9999 ms 3 1 4 4 Menu option Sensor The feeder can be switched on and off with a 24 V signal at the Sensor input For example this signal can be derived from a photocell that monitors whether an output track is full This menu option provides the choices to make the input Inactive Active 24 Volts or Active O Volts Inactive The input signal is ignored and the input always has status switched on Active 24 Volts A signal level of 24 Volts at this input stops the feeder A signal of 0 V starts it again Active 0 Volt A signal level of O V at this input stops the feeder 24 Volts starts it again The message High level appears under the menu option Speed xxx in the main menu when the enable input is activated as Stop 3 1 4 5 Menu options Start delay Sensor and Stop delay Sensor The time delay between receiving a start stop signal at the Sensor input and the feeder starting or stopping can be individually set here in the range 0 0000 ms 3 1 4 6 Menu options Soft start and Soft stop Soft start prod
18. e deett da qe ptr teet c deb i edet 24 Tables Table 1 Which frequency control unit for which RNA vibration feeder ssssssessss 4 Table 2 Which frequency control unit for which RNA linear feeder oooocccconnocccccnnoccccnononcncnonancncnnnncccnnnnncnnnnns 4 Table 3 Technical data RERO E NERONE RAN OMM 5 Table 4 Alarm messages dE re A A duum ec 13 Table 5 RNA vibration feeder operating parameters sse ener enne nene 16 Table 6 RNA linear feeder operating parameters eene enne enne 17 Table 7 Connecting Cables nere ee a t E D HP odo dn oed 17 Table 8 Current limit setting guidance values for RNA vibration feeders ssssse 18 Table 9 Current limit setting guidance values for RNA linear feeders AA 18 Technical Data Function description The control units of the ESR2X family are devices for power control of RNA vibration and linear feeders The device generates a mains independent output voltage with variable frequency The microprocessor continually senses the vibration amplitude and the resonance frequency from the behaviour of the vibration solenoids This means that no additional sensor is required for actual value determination a patent application has been made for this method The controller holds the vibration amplitude constant at the selected value regardless of the actual loading The frequency of the operating current is controlled by a phase locked loop PLL so that the feeder always operates under
19. econds XS2 Pin 4 HIGH gt 16 V LOW lt 8 XS2 Pin 2 24 VDC Pin5 0 maximum 50 mA 0 000 to 10 seconds 24V 50mA 0 40 C 172 x 220 x 169 mm according to EMC directive IP 54 Maximum of 8 Key 1 Convertible to 115 V 6 10 50 60 Hz 2 Self limiting internally selectable for 1 38A 0 59A 0 14A 3 Optional when ESC 06 board is fitted Safety Instructions ESR 28 230 V 696 1096 50 60 Hz 5 x 20mm 4 A slow l t 72 0 210 V 25 150 Hz 8 5A Key programmable 12 24 V DC or contact 0 05 to 10 seconds 0 005 to 10 seconds XS2 Pin 4 HIGH gt 16 V LOW lt 8 XS2lPin 2 24 VDC Pin 5 0 Volt maximum 50 mA 0 000 to 10 seconds 24V 50mA 0 40 C 172 x 220 x 169 mm according to EMC directive IP 54 Maximum of 8 It is always necessary to read and understand the safety instructions This ensures preservation of valuable material and avoids impairment of health Steps must be taken to ensure that all persons working with this control unit are familiar with the safety regulations and observe them The device described in this manual is a control unit for operating RNA vibration and linear feeders The limit values specified in the technical data must be observed Attention A A Rhein Nadel Automation GmbH Seite 5 This warning triangle designates safety instructions Failure to heed this warning can lead to severe injuries or death Work on electrical equipment of the machine plant may be
20. he feeder with heavy articles An other possible reason why the feeder cannot vibrate freely is that a spring is broken or loose The air gap of a solenoid might be clogged with dirt This alarm message can also appear when heavily loaded feeders are started very rapidly It then takes some time un til the feeder reaches the desired speed although it is receiving full current Remedy 1 Reduce the loading of the feeder 2 Set the soft start time and possibly the stability to a higher parameter value This has no adverse effect on the start up because the loading is here limiting the starting speed 3 Check that the feeder can vibrate freely 4 Check the springs Replace and retention them as may be necessary and clean the air gap of the solenoids Maximum voltage This is not a fault but a notification that the ESR2x is now giving out the maximum voltage approx 230 V of which it is capable The reason for this message may be that the ESR2x has greatly increased the voltage in order to achieve the set speed when the feeder is heavily loaded or in the case of very rapid start up of the feeder Remedy None This message automatically disappears again when the loading is reduced Preparations required before applying power to the control Vibration feeders and linear feeders must be operated properly in accordance with the instructions in order to prevent damage of their mechanical construction Therefore the electrical operati
21. ification on the control unit agree with the local mains voltage p Operation of the control unit may commence only when all the above questions can be answered unambiguously with YES The following devices are installed on the control unit for operator control and for making connections Mains power switch Operator control and display section Mains input cable with grounded plug Plug connector for connecting the feeder device Sensor connector for fill level blockage monitoring Blind plug PG9 for additional wiring To avoid damage to the feeder at commissioning time of the control unit the following basic settings have been programmed in the factory Vibration amplitude 1096 Output frequency 100 Hz Soft start approx 0 3 seconds Sensor input disabled The feeder will vibrate very slowly after switch on XX AR Operator control Keyboard The keyboard consists of the display window and the four keys ON OFF Enter Arrow Up and Arrow Down See Fig 1 Rhein Nadel Automation GmbH Seite 6 Steuerger te Schwingantriebe ESR 2000 Key ON OFF The ON OFF key is used chiefly to switch the current for the feeder on and off In connection with auto calibration see Section 3 4 1 the WW Fig 1 Overview of the keys ON OFF key is used as an escape i key it switches off the current for the feeder and aborts the calibration process Arrow keys Up Down The arrow keys have several functions
22. ite 19 Display contents Vibrator Controller ESR 2X Ver X XX Speed 10 Switched Off Service Password 0000 Auto calibration Inactive Auto calibration gt Inactive lt Auto calibration gt Activated lt Current limit XXXX A Voltage Offset X XXX V Current Offset X XXX V Steuergerate Schwingantriebe ESR 2000 Description Key Display contents A check is then made whether connection to the feeder Last test exists This takes max 5 seconds to complete X XXXA XXXXV Next the offset adjustment is made for the DC servo circuit This ensures that no DC current component flows in the feeder because it could cause unstable vibration and disturb the regulating circuits The DC servo offset adjustment requires 2 to 50 seconds to complete The impedance of the feeder is now measured 8 seconds Then the ESR2X searches for the resonance frequency of the feeder This typically requires 20 seconds to complete but may in some cases take up to 2 minutes It is important to ensure that the feeder can vibrate freely during this part of the calibration procedure and that it is not touched Resonance Search Magnetic saturation of the solenoids is now compensated XXX X Hz This typically takes 20 30 seconds to complete but may require up to 5 minutes The ESR2X is then ready to operate the feeder close to resonance However first of all it must optimise its operating point so that maximum amplitude can
23. le to set the Stability parameter somewhat higher e g to 70 80 Menu option Multicalibration This menu option should be selected if multi programming is required Up to eight different programs can be stored Menu option Frequency control The frequency control option can be used to control the frequency of the feeder manually Automatic amplitude control is lost when manual frequency control is selected First select between automatic and manual frequency control The frequency can then be adjusted manually with the arrow keys when manual frequency control has been activated Menu option Change password A new password can be entered here for access to the calibration menu The standard password is 2000 If the currently valid password has been forgotten making a memory reset can reset it Warning This also deletes all calibration data for all stored programs Menu option Exit Activate this menu option to return to the main menu The control unit automatically returns to the main menu if no key has been pressed during the last 2 minutes Rhein Nadel Automation GmbH Seite 12 Steuergerate Schwingantriebe ESR 2000 Alarm messages and other displays Various alarm messages and other notifications can appear in the display under certain circum stances The alarm messages have an order of priority If more than one alarm is active only the one with highest priority is displayed The priority of some alarm messages is tha
24. mit is set to the value specified in Table 3 or slightly lower Rhein Nadel Automation GmbH Seite 13 Acknowledge necessary Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No Yes Yes Yes No No No Alarm output Continuously on Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Continuously on Flashing Flashing Continuously on Flashing Flashing Flashing Steuergerate Schwingantriebe ESR 2000 NV memory error This error is self diagnostic and appears only when there is a fault in non volatile NV memory The ESR2x can con tinue operation but it will possibly not retain all calibration data after power supply mains voltage is switched off In this case new Calibration is necessary after power supply is switched off Remedy Call customer service DAC offset error This error is self diagnostic and comes only in connection with the calibration process when there are so serious faults present in the control loop that the automatic offset adjustment is unable to compensate them Remedy 1 Make a new calibration 2 Call customer service Offset error voltage measurement This error is self diagnostic and comes only in connection with the calibration process when there are so serious faults present in the measuring circuits that the automatic offset adjustment cannot compensate them Remedy 1 Make a new calibration 2 Call customer service Offset er
25. ng conditions must be adjusted to suit the vibrating system The following table shows the variation ranges for the entire RNA range of devices within which safe operation is possible A prerequisite condition for constant and stable running performance is uniform distribution of weight on the feeder bowl top balance Balanced loading of the spring package is shown in detail in the operating instruction manual for the vibra tion feeder Table 5 RNA vibration feeder operating parameters Vibration feeder Max load Max air gap Frequency range Body colour of the Type of drive current Amps on solenoid mm solenoid 0 6 0 5 90 120 Hz black 1 2 0 5 90 120 Hz black 1 2 0 5 90 120 Hz black 26 1 2 90 120 Hz black 2 8 1 2 90 120 Hz black 3 8 2 8 45 60 Hz red 4 3 1 2 90 120 Hz black 5 7 28 45 60 Hz red 5 3 1 5 90 120 Hz black SRC N 630 1 5 SRC N800 1 8 5 2 3 45 60 Hz red 2 8 45 60 Hz red Rhein Nadel Automation GmbH Seite 16 Steuergerate Schwingantriebe ESR 2000 Table 6 RNA Linear feeder operating parameters Linear feeder Max load Max air gap Frequency range Body colour of the Type of drive current Amps on solenoid mm solenoid SLL 400 os A 90 120 Hz black SLL 800 14 In Pd red siL804 1600 J14 In l 45 60Hz red SU 804 em 28 l3 45 60Hz red SLF 1000 2 5 45 60 Hz red GL 01 loo 110 90 120Hz black 12 90 120 Hz black SLK N6 2 5 45 60 Hz red S
26. nsnsssnennnnnnnennnnennnnnennnennnnn nennen 14 3 2 1 6 Offset error PWM modulation nnne 14 3 2 1 7 DC servo circuit not functioning ssssseeee eem enn 14 3 2 1 8 Resonance frequency not found sssssssssseeeeenm nennen 14 3 2 1 9 Resonance maximum not found 14 3 2 1 10 Overmodulation protection ssssssssssssssseseeeneeeeenen nnne 14 3 2 1 11 Peak current Tu EE 15 3 2 1 12 RMS current limit cocoa iaa ii a ana 15 3 2 1 13 Load discontiected 2 idad iia ibas 15 93 2 1 14 Temperature ET 15 3 2 4 15 High temperature E 15 3 2 1 16 De ee 15 3 2 1 17 Vibration restricted a a cece eee aa a n ea aa E E aa aae aaaea Naaa atua i 15 3 2 1 18 Maximum Voltage EE 16 3 3 Preparations required before applying power to the Control 16 Rhein Nadel Automation GmbH Seite 2 Steuergerate Schwingantriebe ESR 2000 3 4 Commissioning ctp e e Ringe 17 3 4 1 Setting the control unit for use with a vibratory feeder sssssseee 17 O ee 23 3 6 Qptional input board xiii in Ri EEN 23 KREE 24 4 ESR 25 DIMENSIONS ame masia 24 5 Connection Diagram 22 5 d EE dE OH pena o PU aia EE 25 Illustrations Figure 1 Main men ated ars cases eade eae eee eodd oce covet adi daa nee 8 Figure 2 Control menu ce hrec e tente nds rei n deae Fehler Textmarke nicht definiert 2 Figure 3 Calibration menu sc eee tt reete n eb e ete te eet ie eds 11 Figure 4 Sensor C nniection o en A et
27. nu is not stated here Rhein Nadel Automation GmbH Seite 7 Steuergerate Schwingantriebe ESR 2000 Main menu Fig 1 Main menu Menu Control value Control range Display 10 100 0 E 0 cd KEE Enter oct PE Status display ON OFF HIGH LEVEL LOW gt play play LEVEL STOP COMMAND Up Down y 537A 358V AIR 35 0 C Up Down 4459W 976Hz Enter HEATSINK 40 0C Password 1 39 Control menu A Up Down y p SERVICE Enter ENTER Ne Password 2 gt Calibration menu A L PASSWORD ERROR Password 3 __ Factory settings Menu option Speed The speed can be set to values in the range of 10 to 100 when this menu option is activated i e when the currently valid value is marked with angular brackets gt 100 lt The speed setting determines the vibration amplitude in a completely linear manner Menu option Measuring values The measured values for current voltage power and frequency as well as the actual temperature in the casing and on the heat sink are shown in the display Menu option Service This menu option provides access to the other menus On activation with the enter key each individual digit of the desired password can be changed The activated digit is marked by the flashing cursor Rhein Nadel Automation GmbH Sei
28. nu option Here the minimum speed is set with which the feeder shall operate Set typically such that the components just move at this speed setting It is important to ensure that the feeder is running stable on exit from this menu option with the enter key This is necessary because the automatic adjustments of alarm limits and operating conditions are saved to memory on exit from this menu option During this calibration alarm displays such as frequency errors may appear because the values for maximum and minimum frequency are being changed too A genuine fault is present only if the alarm persists for a considerable time Attention The control unit can regulate the amplitude and frequency only when movement of a certain magnitude is taking place Therefore it can happen that a persistent error message such as a frequency error appears when the vibration amplitude is very small The set value must then be increased until the feeder is vibrating audibly or visibly Thereafter the value can be reduced again but thereby taking care that movement of the articles on the feeder remains visible Rhein Nadel Automation GmbH Seite 21 10 Speed gt XXXX lt Steuergerate Schwingantriebe ESR 2000 Description After completing the adjustments press the enter key to save the settings to memory The display contents become Press the Up arrow key three times Press the enter key to return to the main menu After successful
29. nu options Start delay Sensor and Stop delay Sensor 10 3 1 4 6 Menu options Soft start and Soft erop 10 3 1 4 7 Menu option Level aam 10 3 1 4 8 Menu option Alarm delay A 10 3 1 4 9 Menu option Display light mmm mnn 10 3 1 4 10 Menu option Display Iongouage mmm enn 10 3 1 4 11 Menu option Change password sssssssssssssssseseeeemeeenen enne 10 3 1 4 12 Menu option EXIU en E e ehe e ene aaa 10 3 1 5 Calibration Menu A d tenet eR e D eee gees 11 3 1 5 1 Menu option Auto calibration esssssssssseseeeenenem een 11 3 1 5 2 Menu option 10096 speed 11 3 1 5 3 Menu option 1096 speed 11 3 1 5 4 Menu Option Stability 222442 Haan 12 3 1 5 5 Menu option Multicalibration Software version 1 07 16 3 1 5 5 Menu option Frequency Control 12 3 1 5 6 Menu option Change password sssssssssssssssseseeeeeeeeenenen nnne 12 321 5 Menu opti ri E 12 3 2 Alarm Messages and other Displays enne ener enne nnns 13 3 2 1 Explanation of the Alarm Messages nennen nnns 13 3 2 1 1 Short circuit protection active sssssssssssssseeeenemeenenen nnns 13 3 2 1 2 1NV MEMORY error oe oe e e de n e dedo tie ede ee dade RR dade 14 3 2 1 3 DAC offset etrOr del eeh o deat qe dae eed dede roe donas qud aA 14 3 2 1 4 Offset error voltage measurement sssssssesssseeeeenn enn 14 3 2 1 5 Offset error current measurement 444440u
30. optimum conditions i e close to resonance The control system self adapts to the actual feeder by means of an automatic calibrating procedure This calibration must be carried out when a particular feeder is connected for the first time This makes it possible to eliminate the cumbersome procedure of mechanical tuning more or less springs in the drive Up to eight individual programs can be stored allowing fast change over times for different components or bowl tops With these control units vibration feeders can be operated on supply mains grid systems with various mains frequencies without requiring new adjustment of the feeders The device is self protecting Neither the solenoids of the feeder nor other components can be overloaded The operating parameters are monitored continuously In the case of large deviations the monitoring function issues corresponding alarm messages before serious consequences could arise This will detect a broken spring or loose nut before damage is incurred The solenoids of the vibration feeders are driven sinusoidal with width modulated pulses giving steady running behaviour of the feeder The control unit is equipped with a sensor input for connecting customary fill level sensors with PNP NPN output or a signal contact The sensor connection is a 5 pin DIN connector The sensor signal starts or stops the connected feeder with time delays that can be programmed separately for each signal transition The soft star
31. ror current measurement This error is self diagnostic and comes only in connection with the calibration process when so serious faults are pre sent in the measuring circuits that the automatic offset adjustment cannot compensate them Remedy 1 Make a new calibration 2 Call customer service Offset error PWM modulation This error is self diagnostic and comes only in connection with the calibration process when so serious faults are pre sent in the modulation circuit that the automatic offset adjustment cannot compensate them Remedy 1 Make a new calibration 2 Call customer service DC servo circuit not functioning This fault is self diagnostic and comes only in connection with the calibration process when the DC servo circuit is un able to keep the DC current 0 A Remedy 1 Make a new calibration if necessary with a somewhat higher setting of the current limit If this is unsuccessful call customer service Bear in mind that if the current limit is set to a value higher than the limit specified for the vibration solenoids the latter may suffer damage 2 If the feeder is very small in relation to the maximum current of the ESR2x i e the current specified in Table 3 is less than of the maximum output current of the ESR2x see Table 1 the ESR2x can be set internally to a more suitable current value This increases the accuracy of all measuring circuits and reduces their measuring errors Call customer service to get this
32. t 0 32000 ms A Up Down y DISPLAY LIGHT Enter gt DISPLAY LIGHT ON OFF ON gt ON lt A Up Down y DISPLAY LANGUAGE DISPLAY LANGUAGE ENGLISH 4 Enter gt gt ENGLISH lt DANISH GERMAN ENGLISH A Up Down y CHANGE PASSWORD Enter gt CHANGE PASSWORD XXXX gt XXXX lt A Up Nown EXT Enter gt MAIN MENU Rhein Nadel Automation GmbH Steuergerate Schwingantriebe ESR 2000 Seite 9 3 1 4 1 Menu option Calibration No Relevant for software version 1 07 and greater The stored parameters for up to eight programs are selected with this menu Press the Enter key to activate the menu then press the Up or Down keys to select the required program number The data must be programmed us ing the Calibration Menu Do not select a program number that does not contain valid data 3 1 4 2 Menu option Input Relevant only when the optional PC board is fitted The feeder can be switched on and off with an external source 24 V signal e g from a PLC system via the Input connection This menu option provides the choices to make the input Inactive Active 24 Volts or Active O Volts Inactive The input signal is ignored and the input always has status switched on Active 24 Volts A signal level of 24 Volts at this input stops the feeder A signal of 0 V starts it again Active O Volt A signal level of O V at this input stops the feeder 24 Volts starts it again The messag
33. t and soft stop times are separately programmable Which control unit for which RNA feeder The load current of the feeder which is to be driven determines the correct choice of control unit The load current is affected by four factors e Operating frequency Rhein Nadel Automation GmbH Seite 3 Steuergerate Schwingantriebe ESR 2000 e Size of the air gap e Load voltage e Weight of the superstructure bowl top linear rail The following table shows typical guidance values as averages of measurements made in our production factory Table 1 Which frequency control unit for which RNA vibration feeder Vibration feeder Measured Max permitted Guidance value for Recommended Type designator of current A load current current limit control unit RNA drive A in A Type SRC N 160 2 ESR 25 0 6 ESR 25 1 8 E memo os 32 57 53 e E Table 2 Which frequency control unit for which RNA linear feeder Linear feeder Measured max permitted Guidance value for Recommended Type designator of current A load current current limit control unit the RNA drive in A Type GL 01 ESR 25 0 6 SLL 400 0 4 ESR 25 1 8 a s 99 e The Current limit is entered in the calibration menu when calibrating the control units for a new feeder see Section 3 4 1 The values tabulated here are for general guidance only The current limit can be set higher for heavy bowl tops or linear rails Under no cir
34. t they remain in the dis E play until the operator acknowledges the alarm by pressing the enter key Alarm messages with this priority level will also produce an alarm signal at the alarm output of the options board This provides the possibility for indicating the alarm with an alarm lamp or other alarm device Table 4 Alarm messages Priority e e a af af af af Alarm text Short circuit protect active NV Memory error DAC offset error Offset error voltage meas Offset error current meas Offset error PWM modulation DC Servo circuit Not functional Resonance freq Not found Resonance max Not found Overmodulation protection Peak current limit RMS current limit Load disconnected Temperature error High temperature Frequency error Vibration restricted Max voltage Explanation of the alarm messages Short circuit protection active Short circuit protection becomes active when the current exceeds twice the value of the maximum RMS current In this case the ESR2x instantly switches off the output voltage to protect its output stage against overload The alarm message remains on the display until it is acknowledged by pressing the enter key This alarm appears if a genuine short circuit is present at the output of the ESR2x or if the connected feeder is much larger than the current limit setting permits Remedy 1 Switch off the feeder and examine the cable for faults 2 Make a new calibration ensuring that the current li
35. te 8 Steuergerate Schwingantriebe ESR 2000 Control Menu Fig 2 Control Menu Control Value Control Range Dis nl tog Software Ver 1 07 i i Calibration No Calibration No Enter 9 A gt 1 lt Un p INPUT INPUT INAKTIVE AKTIVE HIGH AKTIVE 4 Enter gt Ak own gt AKTIVE Only relevant if option ESC06 is mounted START BELAY Enter gt START DELAY 0 9999 ms INPUT 300 ms INPUT gt 300 ms lt Only relevant if option ESC06 is mounted A Up Down y STOP DELAY Enter gt STOP DELAY 0 9999 ms INPUT ms INPUT gt 0ms lt Only relevant if option ESC06 is mounted A Up Down y SENSOR SENSOR AKTIVE 4 Enter gt gt AKTIVE INAKTIVE AKTIVE HIGH AKTIVE A Up Down y START DELAY START DELAY SENSOR 300ms P SENSOR gt 300 ms lt 0 2293 mS A Up Down Up Down Y STOP DELAY STOP DELAY SENSOR 300 ms Enter SENSOR gt 300 ms lt oc iiu A Up Down y SOFT START Enter gt Ba 50 9999 ms 500 ms gt 500 ms lt A Up Down y SOFT STOP SOFT STOP 500 ms Enter gt gt 500 ms lt 5 9999 ms A Up Down y INAKTIVE E Enter gt E LOW CONST LOW FLASH HIGH CONST i 2 HIGH FLASH Up Down y ALARM DELAY ALARM DELAY 1000 ms Enter gt gt 1000 ms l
36. the alarm is activated at the alarm output Under normal conditions of level monitoring the signal at the level sensor input continually changes between 24 V and 0 V but an alarm signal is desired only if components have been missing or there have been too many for a considerable time 3 1 4 9 Menu option Display light The display illumination back light can be switched on and off here 3 1 4 10 Menu option Display language A selection of one of the available languages can be made here e g German Danish and English 3 1 4 11 Menu option Change password A new password can be entered here for access to the control menu The standard password is 1000 If the active password has been forgotten making a Memory Reset can reset it Refer to section 3 1 2 Warning This will delete all calibration data for all stored programs 3 1 4 12 Menu option Exit This menu option must be chosen to return to the main menu The control unit automatically returns to the main menu if no key has been pressed for 2 minutes Rhein Nadel Automation GmbH Seite 10 Steuerger te Schwingantriebe ESR 2000 Calibration menu Fig 3 Calibration menu Menu Control Value Control Range Display Auto Calibration Enter gt Auto Calibration Auto Calibration Inactive Inactive Inactive Up Down 100 Speed 100 Speed 2000 21500 Up pe 10 Speed 10 Speed 0 10000 Up Down Stability Stability 0 100 lt q Bme SC pee Up Down
37. tion is reset to zero each time the control unit is switched on with the ON OFF key wherefore a new message can appear and new limiting can start The message may appear if the ESR2x increases the voltage to much in order to achieve the set speed for example when the feeder is heavily loaded or in the case of rapid start up of the feeder Remedy None Peak current limit This is not a fault but a message that the output current to the feeder is more than 75 greater than the current limit setting The ESR2x automatically reduces the maximum output voltage to a safe value and then this message disap pears again of its own accord This limiting is reset to zero every time the control unit is switched on with the ON OFF key The message can then appear again and a new automatic limitation can be made This message can be produced when the ESR2x greatly increases the voltage in order to achieve the set speed for example when the feeder is heavily loaded or when it is started very rapidly Remedy None RMS current limit This is not a fault but a message that the output current to the feeder is 1 greater than the set current limit The ESR2x automatically limits the maximum output voltage to a safe value and this message then disappears again This limiting is reset to zero every time the control unit is switched on with the ON OFF key This message can then appear again and a new limitation can start This message can be produced when the ES
38. ts Menu structure ESR 2x The menu structure consists of 4 separate menus e Main menu e Control menu e Calibration menu e Factory settings Passwords are used to access the menus Each menu is designed as a scrolling list from which the individual options list items can be selected with the arrow keys To change the value of the parameter associated with a menu option press the Enter key to mark the currently selected parameter with gt lt The parameter value can then be changed with the arrow keys Press Enter to confirm the new choice of value and return to the scrolling list of menu options At the same time the new setting is saved into the non volatile memory A password must be known to obtain access to the individual submenus When in a submenu the password can be changed except for the menu Factory settings which has a fixed password To reset all changed values except for the factory settings switch off the mains voltage press in and hold in the two arrows keys Up and Down then switch the mains voltage on again The standard password for the control menu is 1000 The standard password for the calibration menu is 2000 Both these values can be changed within their respective menus and both are restored to their standard values on making a reset as described above The menu Factory settings contains device specific data that may be changed only by instructed personnel Therefore the password for this me
39. uces a timed ramp up of vibration amplitude after the power supply is switched on or external enable or level sensor enable If this time is set too short the vibrator solenoids will impact Heavy devices tend to overshoot due to their own dynamic response if vibration build up is too rapid Stopping the feeder device normally should not be delayed but a delay may be necessary in some cases to avoid in correct orientation of the components on the feeder if stopped too abruptly The time setting determines how long the build up of vibration from 0 to 100 or decay from 100 to 0 will take For example if the Soft start time is set to 1000 ms the feeder will take 1 second to build up the vibration amplitude from 096 to 10096 3 1 4 7 Menu option Level alarm The conditions which will produce an alarm signal at the alarm output can be set here available only when the control unit is equipped with the options board and whether the alarm shall be a continuous signal or an intermittent signal flashing The available possibilities are Inactive Low Cont Low flash High Cont High flash If the sensor alarm is set such that alarm will be issued for Low level the status message Low level will also appear under the menu item Speed xxx in the main menu 3 1 4 8 Menu option Alarm delay Here the time delay can be set which will elapse between receiving a signal at the sensor input which will produce an alarm until
40. uns and set up possible without problems To activate the input program a switch on delay in the control menu The sensor input at pin 4 of X02 has strong hysteresis in its response behaviour in order to ensure disturbance free operation Fig 4 Sensor connection 24 Volt max 50mA IT Sensor input k O Volt connection A g Wels a L9 CH 1 eg GC E m 1 4 1 E es ES Optical Sensor contact without amplifier ESR 25 Dimensions 1 EE 1 he a 4 1 E 2 ES 2 Magnetic sensor 2 wire NAMUR Opticalr Sensor Sender and reciever separately For more information on this or any other RNA product please contact RNA AUTOMATION LTD Unit 13 Hayward Industrial Park Tameside Drive Castle Bromwich Birmingham B35 7AG Tel 0121 749 2566 Fax 012 749 6217 Email RNA RNA UK COM Rhein Nadel Automation GmbH Seite 24 Allround sensor Steuergerate Schwingantriebe ESR 2000 Connection Diagram ESR 25 ESR 28
41. with the ON OFF key and leave it switched on throughout the procedure for adjusting this pa rameter It is particularly important to make sure that the feeder is running stable on exit from this menu option with the enter key This is because the automatic adjustments of alarm thresholds and operating conditions are saved to mem ory on exit from this menu option Alarms such as frequency errors can appear during this calibration This is because the values for maximum and minimum frequency are changed during this calibration A genuine fault is present only if the alarm persists for a con siderable time more than 1 minute Attention The control unit can adjust the vibration amplitude and frequency only when motion of a certain magnitude is present Therefore it is possible that a persistent error display such as a frequency error may appear when the vi bration amplitude is very small The set value must then be increased until an audible or visible vibration of the feeder is present The value can then be reduced again taking care that the vibration does not stop completely After complet ing the adjustment press the enter key to save the set values to memory Rhein Nadel Automation GmbH Seite 11 Steuerger te Schwingantriebe ESR 2000 Menu option Stability This menu option should be selected if the feeder shows strong overshoot on starting or if the speed setting produces fluctuating vibration amplitude In such cases it is advisab
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