Manual

Congrav® L/M 3

Subject:
Congrav® L/M 3
Category:
Feeding controller
Software:
LM 3 NA V1.32
Document:
7h114309.doc
Revision: 1.4
Date: 05-06-27

- Copyight as per DIN 34 –

 Manual Congrav® L/M 3 NA V_._

Addresses

Germany and international:

Brabender Technologie KG Service:

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

Great Britain:

Brabender Technologie Ltd Service:

3 Tanning Court : ++44-1925 244002
Howley FAX: ++44-1925 245 451
E-mail: [email protected]
Warrington
Cheshire WA1 2HF
: ++44-1925 244002
FAX: ++44-1925 245 451
E-mail: [email protected]
Web: http://www.brabender-technologie.com

North America:

Brabender Technologie Inc. Service:

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

Brabender Technologie, 2005-06 Page 2 of 112

 Manual Congrav® L/M 3 NA V_._

Guide through the document

Chapter 1 Information on the manual

Indications on the manual, revision index

Chapter 2 Description of the device

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

Brabender Technologie, 2005-06 Page 3 of 112

 Manual Congrav® L/M 3 NA V_._

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

2 Description of the device 14

2.1 The intended purpose 15
2.2 Residual danger 15
2.3 The software L/M 3 NA 16
2.3.1 The batch modes 17
2.3.1.1 The mode B1 or A1: Coarse-fine-feeding 17
2.3.1.1.1 The sequence of a coarse/fine-feeding operation 18
2.3.1.1.2 List of necessary parameters 20
2.3.1.2 The mode C2 or A2: ART-feeding 21
2.3.1.2.1 ART-feeding: the sequence of operations 22
2.3.1.2.2 Staying below/exceeding of the defined feeding time 23
2.3.1.2.3 List of necessary parameters 24
2.3.2 Important operating states 24
2.3.2.1 Refilling with loss-in-weight batching 24
2.3.2.2 Refilling during a batch: Partial batch operation 25
2.3.3 The discharge of a hopper scale 26
2.3.3.1 Manual discharge 26

3 General notes 28
3.1 Mains supply 28
3.2 The external 24VDC-supply 28
3.3 Cable types to be employed 28
3.4 Safety notes 29
3.4.1 Safety instructions for work on the Congrav® L/M3 29
3.4.2 Safety instructions for mounting 29
3.4.3 Safety instructions for cabling 30
3.4.4 Safety instructions for the operation, the manipulation 30
3.4.5 Specifications based on the software NA 31
3.5 The software development up to version V1.31 31
3.5.1 Software version LM3 NA V1.10 31
3.5.2 Software version LM3 NA V1.20 31
3.5.3 Software version LM3 NA V1.30 31

4 Hardware description 33
4.1 Congrav L/M3: the types 33
4.2 The display and the front keyboard 33

Brabender Technologie, 2005-06 Page 4 of 112

 Manual Congrav® L/M 3 NA V_._

4.2.1 The integrated front keyboard and its functions 33

4.2.2 Composition and menu structure of the display 35
4.3 Parameter modifications 36
4.3.1 The numeric input 36
4.3.2 The selection of fixed parameter sets 36
4.3.3 Parameter modifications are not taken over, if 36
4.4 Overview of the slots of Congrav® L/M3 37
4.4.1 Overview: the possible connections 39
4.5 The basic execution of Congrav® L/M3 40
4.5.1 The plug-in card L/M3-MSIO 40
4.5.1.1 XS1.1: The connection of the host computer 40
4.5.1.2 XS1.3: The connection of a modem 40
4.5.2 The DS-controller 41
4.5.2.1 The I/O-module for the DS-controller 41
4.5.2.1.1 The I/O-module-DS-LM3-R1 and ..-R2 42
4.5.3 The hardware components of the DS-controller 44
4.5.3.1 The digital inputs and outputs 44
4.5.3.2 The serial interfaces of the DS-controller 44
4.6 The optional extension of Congrav® L/M3 45
4.6.1 The plug-in card CDIO 45

5 Mounting and commissioning 47

5.1 Connection plan of a loss-in-weight feeder 48
5.1.1 Connections of Congrav® L/M3 49
5.2 Start-up, switching on the Congrav® L/M3 50

6 F100: Installation configuration 52

6.1 F110: Installation modes 52
6.2 Host computer operation 52
6.3 Text switch 52
6.4 Interlocking/stop 53
6.5 Date and time 53

7 F200: Printer configuration, reset of memory contents 55

7.1 Printer functions 55
7.2 F210: How to clear memory contents 56

8 F300: Setpoint input and selection 58

8.1 Installation setpoints 58
8.2 Component setpoints 58
8.3 Selection 58
8.4 Alarm stop 59

9 F400: Actual values and reset of throughputs 61

9.1 F430: Reset throughputs 61

Brabender Technologie, 2005-06 Page 5 of 112

 Manual Congrav® L/M 3 NA V_._

10 The component operation 63

10.1 The header of the component pages 63
10.2 Kxx0: The component control 63
10.3 The operating functions 63
10.3.1 Start 63
10.3.2 Stop 63
10.3.3 Alarm reset 64
10.3.4 Refill 64
10.3.5 Reset 64
10.3.6 Start tare 64
10.3.7 The actual value display in the right column 64
10.4 Kxx1 Product parameters 64
10.4.1 Auto-tare: 64
10.4.2 Checking max. output 65
10.4.3 Bulk density 65
10.4.4 Coarse maximum 65
10.4.5 Decade switch 65
10.4.5.1 The setting of the decade switch 66
10.4.6 Mode 66
10.5 Kxx2 The feeding parameters 67

11 F500: Alarm reports and start conditions 70

11.1 Alarm reports 70
11.2 Missing start conditions 72
11.2.1 Missing start conditions 72
11.2.2 Further reports 72
11.3 Error code for an operation with a serial drive controller 73
11.3.1 Serial frequency converter FC-V_ 73
11.3.2 Vibration amplitude controller DRS2 73
11.4 Kxx5: The alarm configuration 74

12 The hardware configuration 76

12.1 The configuration of the digital/serial inputs/outputs 76
12.1.1 The digital I/O of the DS-controller 76
12.1.2 Description of the functions: the digital inputs and outputs 77
12.1.3 Configuration of the interfaces of the DS-controller 78
12.1.3.1 Configuration of the load cell 78
12.1.3.2 Configuration of the drive controller 80
12.1.3.3 Definition of the signal range for the analogue I/O 80
12.1.4 The digital inputs and outputs of LM3-CDIO 81
12.1.5 The digital inputs and outputs of the analogue card 82
12.1.6 The analogue inputs and outputs of the analogue card 82
12.2 Configuration of the host computer operation 83
12.2.1 The host interface on the MSIO-card 83

13 The calibration program 85

Brabender Technologie, 2005-06 Page 6 of 112

 Manual Congrav® L/M 3 NA V_._

13.1 The feeder parameters 86

13.2 Explanation of the functions of the feeder parameters 87
13.2.1 CP01 – Feeder type 87
13.2.2 CP02 – Weighing range 87
13.2.3 CP03 - max. batch output 87
13.2.4 CP04 – Underload 87
13.2.5 CP05 - Overload 87
13.2.6 CP06 – Coarse tare 88
13.2.7 CP07 - Average values 88
13.2.8 CP08 - Throughput divisor 88
13.2.9 CP09 - Speed minimum 88
13.2.10 CP10 – Speed maximum 88
13.2.11 CP11 – Control difference 89
13.2.12 CP12 - Alarm cut-out time 89
13.2.13 CP13 - Type of interlocking 89
13.2.14 CP14 - Indication of actual value 89
13.2.15 CP15 – Lever factor 89
13.2.16 CP16 - Hopper contents 89
13.2.17 CP17 - Filling level minimum 89
13.2.18 CP18 – Filling level maximum 90
13.2.19 CP19 - Window/K1/Filter IDL/F, AED 90
13.2.20 CP20 – Digital speed 90
13.2.20.1 Standard motion monitoring 90
13.2.20.2 Motion monitoring for the FlexWallplus-feeder 90
13.2.20.3 Digital speed reading 90
13.2.20.4 Recommended inputs 91
13.2.21 CP21 - Maximum refill time 91
13.2.22 CP22 – Refill time 91
13.2.23 CP23 - Stabilisation time 91
13.2.24 CP24 - AV-cut-out time 91
13.2.25 CP25 – Anti-vibration 92
13.2.26 CP26 – Actual value adaptation 92
13.2.27 CP27 – Weight mode 92
13.2.28 CP28 – Refill mode 92
13.2.29 CP29 – Setpoint mode 92
13.2.30 CP30 – Batch stabilisation time 92
13.2.31 CP31 – Coarse delay 93
13.2.32 CP32 - Switch-over time coarse/fine 93
13.2.33 CP33 – Derivative action correction 93
13.2.34 CP34 – Switch-over kg / % 93
13.2.35 CP35 – Fast mode 93
13.2.36 COP36 – Tolerance mode 93
13.2.37 CP37 – Feeding tolerance+ 94
13.2.38 CP38 – Feeding tolerance- 94
13.2.39 CP39 – Setpoint factor 94
13.2.40 CP40 – Feeding time factor 94
13.3 Additional parameters 95

Brabender Technologie, 2005-06 Page 7 of 112

 Manual Congrav® L/M 3 NA V_._

13.3.1 AP01 - 03 PID-controller 95

13.3.2 AP05 – Recipe stabilisation time 95
13.3.3 AP06 - Valve closing time 95
13.3.4 AP07 – Max. discharge time 96
13.3.5 AP08 – Discharge tolerance 96
13.3.6 AP09 – Time discharge aid 96
13.3.7 AP10 – Discharge mode 96
13.3.8 AP11 – Batch mode 97
13.3.9 AP12 – Recipe release 97
13.3.10 AP13 – Discharge auto 97
13.3.11 AP14 – Derivation mode 97
13.3.12 AP19 - Drive control 2 min. 97
13.3.13 AP20 - Drive control 2 max. 97
13.3.14 Notes on AP19 and AP20 98

14 Hardware test functions 100

14.1 F140: Test of I/O-periphery (installation) 100
14.2 Kxx3: Status display of I/O-periphery 101
14.3 Kxx4: Test functions and simulation 102
14.3.1 The simulation mode 102
14.3.2 Testing of the inputs/outputs (component) 102

15 Glossary 104

16 Appendix 110
16.1 Technical data 110
16.2 Electromagnetic compatibility 111
16.3 Spare parts list 111
16.4 List of the possible mode displays 112

Brabender Technologie, 2005-06 Page 8 of 112

 Manual Congrav® L/M 3 NA V_._

TABLE OF ILLUSTRATIONS
Figure 2-1: Construction principle of gain-in-weight and loss-in-weight feeding 16
Figure 2-2: The sequence of a coarse/fine-feeding operation 18
Figure 2-3: Batch evaluation 19
Figure 2-4: Chronological representation of an ART-feeding with post-feeding 22
Figure 2-5: Batch evaluation 23
Figure 4-1: The rear view of Congrav® L/M3 for 4 weigh-feeders …. 37
Figure 4-2: The possible connection of a loss-in-weight feeder 39
Figure 4-3: IO-module-DS-LM3 R_ 42
Figure 4-4: Terminal plan I/O-module-DS-LM-R_ 43
Figure 4-5: Pin functions of the digital-I/O of the LM3-CDIO 45
Figure 5-1: Dimensions of panel cut-out and fixing of Congrav® L/M 3A 47
Figure 5-2: Mounting dimensions of Congrav® L/M3 B 47
Figure 5-3: Example for the connection of a loss-in-weight batching system 48
Figure 12-1: Overview weighing systems and weight signals 79

Brabender Technologie, 2005-06 Page 9 of 112

 Manual Congrav® L/M 3 NA V_._

1 Introduction
1.1 The structure of the manual

The present manual deals with

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

1.2 Supplementary documentation

Appendix with wiring examples for different standard peripheral

equipment
Manual of the corresponding host computer procedure

1.3 Group of users of the manual

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

1.4 Signs and warnings used in the manual

The following signs are used in the manual 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

Brabender Technologie, 2005-06 Page 10 of 112

 Manual Congrav® L/M 3 NA V_._

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

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

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

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

electrical power supply and protected against unauthorised
reconnection.

This sign marks additional information or references to other sources of

information.

1.5 Terms and abbreviations employed

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

following abbreviations are employed in the manual:

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

1.6 Index of revisions

Revision 1.0
Basic version of documentation

Brabender Technologie, 2005-06 Page 11 of 112

 Manual Congrav® L/M 3 NA V_._

Revision 1.1
Change the limit values for the calibration parameter CP19.

Revision 1.2
Correction of the terminal plan. The relays for the customer use have
the specification 250 VAC/5A (page 43)
Correction of the table on page 44. The relays K1’-K6’ are for the
use “on-site”. The relays K1-K6 are for the internal use.
Correction of the terminal plan on page 48. Change the terminal 72,
73 to 27, 28 (Relay K6 for internal use)

Revision 1.3
Correction of the terminal plan. The terminals for the relay K1 – K6
have been change (page 43).

Revision 1.4
Correction of the connection plan (figure 5.3).

Brabender Technologie, 2005-06 Page 12 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 2

DESCRIPTION OF THE DEVICE

This chapter gives a short description of the device, including

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

Brabender Technologie, 2005-06 Page 13 of 112

 Manual Congrav® L/M 3 NA V_._

2 Description of the device

The Congrav® L/M3 is part of the feeding controller program.
Congrav® L/M3 is a so-called multi-feeding controller. If it is equipped
with the software NA it supports the connection of a maximum of 8
weigh-feeders of different types (N- or A-type). It has the following main
functions:
Operating the weigh-feeders. The Congrav® L/M3 permits the
parameterisation and the control of the individual weigh-feeders.
The Congrav® L/M3 receives the data of the weigh-feeders and
controls their feeding operation.

Definition weigh-feeders:
A weigh-feeder is a feeder that permits to weigh the hopper
contents. Loss-in-weight feeders are employed for loss-in-weight
batching and hopper scales are employed for gain-in-weight
batching. Attention!
The term “weigh-feeder“ does not designate the feeding devices that
feed into the hopper scale. The number of feeders is not limited by
the DS-controller but by the number of available digital outputs.

The connection of the hardware of the weigh-feeders. The so-

called I/O-modules permit to connect the weigh-feeders, the
connection between these modules and the Congrav® L/M3 is
provided by pre-confectioned cables.
The connection of the weigh-feeders to a superset host system.
This may possibly require an optional extension card, e.g. a bus-
module for a ProfiBus DP-connection.
For the manual operation the front face of Congrav® L/M3 is equipped
with an LCD display and a foil-covered keyboard.

The software determines the functions of the individual keys and of the
display contents. The knowledge of the functions is absolutely required
for a correct operation of Congrav® L/M3. Important

This manual deals with the software type NA (L/M3 NA V_._). It permits
the Congrav® L/M3 to control the discontinuous feeding of weigh-
feeders (N) and hopper scales (A).
The electrical connection of the Congrav® L/M3 to the weigh-feeders, to
the mains supply etc. is provided on the rear side of Congrav® L/M3.
The Congrav® L/M3 is based on the technology of plug-in cards that
permits to dimension the hardware to the special needs of Congrav®
L/M3.

Brabender Technologie, 2005-06 Page 14 of 112

 Manual Congrav® L/M 3 NA V_._

2.1 The intended purpose

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

has been conceived for the operation/control of a maximum of 16
machines, the so-called weigh-feeders. The Congrav® L/M3 functions as
operating and control unit for the weigh-feeders,
if the weigh-feeders are equipped for the gravimetric feeding
applications,
the weight signals of the weigh-feeders of Congrav® L/M3 can be
read in,
the Congrav® L/M3 and the weigh-feeders are correctly
interconnected and
the Congrav® L/M3 is correctly equipped with the necessary plug-in
cards according to the application.
The possibilities for the use of the Congrav® L/M3 are determined by the
standard and the optional I/O-periphery. The functions of the I/O-
periphery are determined by the software employed by the Congrav®
L/M3.
An operation of Congrav® L/M3 is only allowed under observance of the
technical data and the specifications for the connection. The Congrav®
L/M3 is designed for the integration in a control cabinet, control panel or
similar. The integration and the use of the Congrav® L/M3 is only
allowed under respect of the EN 60204, the valid specifications on the
personal protection (e.g. BGVR), the EMC-directive and the valid state of
the art.
The user has to respect the intended purpose, as the manufacturer does
not accept liability for damage arising from the non-observance.

2.2 Residual danger

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

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

Operating errors are operating conditions that do not correspond to the

operating instructions of the software employed.

Brabender Technologie, 2005-06 Page 15 of 112

 Manual Congrav® L/M 3 NA V_._

2.3 The software L/M 3 NA

The software LM3 NA is a batch-software with two different batch-feeding

types.
loss-in-weight batching (N-type) and
gain-in-weight batching (A-type)

Both types of batch feeding have their basic principle in common,

however, they have different approaches, i.e. construction and sequence.

Feed the product quantity ΔF from hopper A into hopper B. Basic principle

Congrav L/M3

Gain-in-weight batching Loss-in-weight batching

6 5 66 67 6 8 6 9 7 0 7 1 7 2 73 7 4 7 5 7 6 7 7 7 8 79 80 81 82 83 8 4 8 5 8 6 8 7 88 8 9 9 0 9 1 9 2 9 3 9 4
3 5 36 37 3 8 3 9 4 0 4 1 4 2 43 4 4 4 5 4 6 4 7 4 8 49 5 0 51 52 5 3 5 4 5 5 5 6 5 7 58 5 9 6 0 6 1 6 2 6 3 6 4
16 1718 19

IO-Modul-DS-LM3 R1

TA
65 66 67 68 6 9 7 0 7 1 7 2 73 7 4 7 5 7 6 7 7 7 8 79 80 81 8 2 83 8 4 85 8 6 8 7 88 8 9 9 0 9 1 9 2 9 3 9 4

3 5 36 37 3 8 3 9 4 0 4 1 4 2 43 4 4 4 5 4 6 4 7 4 8 49 50 51 52 53 5 4 5 5 5 6 5 7 58 5 9 6 0 6 1 6 2 6 3 6 4

TB
16 1718 19

2 0 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 29 30 3 1 3 2 3 3 3 4
IO-Modul-DS-LM3 R1

RA
8 9 1 0 1 1 12 1 3 1 4 15

RB
TA
TB
TA

RA
TB

RB
2 0 2 1 2 2 2 3 24 2 5 2 6 2 7 2 8 29 30 3 1 3 2 3 3 3 4

8 9 1 0 1 1 12 1 3 1 4 1 5
RA
RB

TA
TB
RA

6 7
RB

4 5
1 2 3
6 7
4 5

K1 K2 K3
K6
1 2 3

K4 K5
K1 K2 K3

K6
K4 K5

A F1
F2

Feeder command Feeder command

Weight sensing

F2
ΔF = F2 - F1
F1

Weight sensing B Hopper

Scale

Figure 2-1: Construction principle of gain-in-weight and loss-in-weight feeding

Gain-in-weight batching (A-V) Loss-in-weight batching (N-V)

The principle:
With A-V the gain in weight in hopper B With N-V the loss in weight in the hopper
that is due to the feeding operation of that is due to the feeding operation is
feeder A is measured and monitored. measured and monitored. Therefore, a
Therefore, the hopper is weighed by loss-in-weight feeder is employed.
means of a feeder (hopper scale). ΔF = F2 – F1
ΔF = F2 – F1

Brabender Technologie, 2005-06 Page 16 of 112

 Manual Congrav® L/M 3 NA V_._

The construction:
The construction consists of two systems The construction consists of two systems
the feeder (A) and the loss-in-weight feeder (A) and
the weighed hopper (B) a receptacle (B)

The sequence of the feeding operation:

The Congrav® controls the drive of the The Congrav® controls the drive of the
feeding device and monitors the product feeding device and monitors the product
quantity that has been fed via the quantity that has been fed via the
weighing of the hopper scale. The feeder weighing of the feeder. In this case, the
is only employed for the product supply. hopper only serves as collecting
receptacle.

Feeding of several products:

1 product = 1 feeder 1 product = 1 loss-in-weight feeder

The individual products are fed one after The Congrav® starts the corresponding
the other into the hopper scale. The feeder and monitors the feeding quantity
Congrav® starts the corresponding by weighing of the hopper contents of the
feeder and monitors the feeding quantity loss-in-weight feeder.
by weighing of the hopper scale. A parallel feeding operation of several
A parallel feeding operation of several feeders is possible, as each individual
feeders into one hopper scale is not feeding operation is weighed by the
possible. corresponding loss-in-weight feeder.

2.3.1 The batch modes

The feeding of the product quantity ΔF is called “batch“. The software

LM3 NA offers different batch feeding modes. They are designated as
“batch modes“ and have to be selected on menu page Kxx2 (see chapter
10.4.6, page 66). Please find below a description of the batch feeding
modes, they are the essential part of the software. The modes for loss-in-
weight and gain-in-weight batching are identical, for this reason they are
explained together. With loss-in-weight batching the modes are called
“Cx“, with gain-in-weight batching they are called “Ax“.

2.3.1.1 The mode B1 or A1: Coarse-fine-feeding

With the mode B1 or A1 the setpoint is fed according to the coarse-fine-

principle.
In a first step, called coarse feeding, the systems feeds until it reaches a
defined switch-over point with a high manipulated variable value. Coarse

Brabender Technologie, 2005-06 Page 17 of 112

 Manual Congrav® L/M 3 NA V_._

feeding permits to feed the first part of the quantity to be fed within a time
that is as short as possible.
In a second step, the fine feeding, the remaining difference is fed with a
smaller manipulated variable value. Fine feeding permits to feed the
residual quantity with the utmost accuracy.

The advantages of coarse-fine-feeding:

the principle of functioning is relatively simple

Inconvenients of coarse-fine-feeding:
in case of a setpoint modification it may possibly be required to adjust the
coarse/fine parameters.
the adjustments of the feeding parameters coarse, fine and switch-over
point coarse/fine have to be entered manually, which takes longer.
the adjustments of the feeding parameters coarse, fine and switch-over
point coarse/fine have to be entered manually, which takes longer.

2.3.1.1.1 The sequence of a coarse/fine-feeding operation

Important
The following graph does not take into account the refilling of the
hopper.

Operation

Coarse

Fine

Automatic
derivative action
correction

Tolerance
check

Post-feeding
(fine)

Tolerance
check

Batch end

Start 1 2 3 3

Figure 2-2: The sequence of a coarse/fine-feeding operation

Brabender Technologie, 2005-06 Page 18 of 112

 Manual Congrav® L/M 3 NA V_._

The weighing of the batch starts with a start order to Congrav® L/M3.
After elapse of the coarse delay time (1) for the determination of the
initial weight, coarse feeding will start. During coarse feeding
the digital output “coarse“ will be set and
the manipulated variable will be emitted with the fixed value “coarse
feeding”.

Coarse feeding ends automatically, if the product quantity (setpoint x

coarse/fine switch-over point) has been reached. After elapse of the delay
time switch-over time C/F (2) fine feeding will start. During fine feeding
the digital output “coarse or fine“ will be set and
the manipulated variable will be emitted with the fixed value “fine
feeding”.

Fine feeding stops automatically, if the product quantity that has been fed
out reaches the value (setpoint x derivative action point). The following
batch stabilisation time (3) permits a stabilisation of the feeding system.
After elapse of the batch stabilisation time the automatic check of the
derivative action point will be started. The setting of the derivative action
point is optimised for the next batch feeding by means of the actual
setting and the product quantity that has been fed out. This leads to a
stepwise approximation to the setpoint with each batch feeding cycle.
Under normal conditions approx. 4 batch feeding cycles are required for
the adaptation of the derivative action point.
After the derivative action check, the tolerance check will be started.
Here, the system will check whether the product quantity that has been
fed out lies within the allowed range.

The Congrav L/M3 will:

start post-feeding with the fine feeding value, if not Operator:

enough product has been fed. After the post- Over-

Break-off or
feeding operation the batch stabilisation time runs feeding acceptance?
down and then the tolerance check will be started Setpoint + Feeding tolerance

anew. Figure 2-2 illustrates this case.

stop the batch feeding operation and display the ☺ Setpoint
Batch feeding
will be stopped
end of batch feeding (display, digital output), if the Good

product quantity that has been fed out lies within Setpoint - feeding tolerance

the allowed setpoint range.

discontinue batch feeding with an alarm report if Post-feeding
too much product has been fed (=overfeeding). not enough will be started

Figure 2-3: Batch evaluation

Brabender Technologie, 2005-06 Page 19 of 112

 Manual Congrav® L/M 3 NA V_._

Overfeeding: Here the operator will have to decide how to continue!

If overfeeding is okay for the current operation the operator will

reset the alarm report and start the feeding operation anew.
Feeding will be continued and correctly brought to an end. 1. Alarm reset
2. Start feeding

If overfeeding cannot be accepted for the current operation

the operator will reset the alarm report and discontinue the
current batch feeding with the order batch break-off. The
batch break-off is absolutely necessary. The batch break-off 1. Alarm reset
stops the current batch so that a new start order will start a 2. Batch break-off
new batch.

2.3.1.1.2 List of necessary parameters

Parameter Unit Menu level

Mode B1 or A1: Kxx1
max. batch size kg F600
Setpoint kg F300
Coarse delay s F600
Coarse feeding % Kxx2
Fine feeding % Kxx2
Coarse/fine switch-over % Kxx2
Switch-over time C/F s F600
Feeding tolerance % F600
Derivative action point % Kxx2
Derivative action F600
correction
Batch stabilisation time s F600
Max. feeding time s Kxx2
Refill mode F600
Refill time F600
Weight mode F600
Figure 2-1: List of the parameters that are relevant for B1(A1)-feeding

The input coarse or fine in [%]:

Both parameters define a speed value. The input in [%] refers to the rated
speed of the drive corresponding to a manipulated variable signal of
10VDC.

Brabender Technologie, 2005-06 Page 20 of 112

 Manual Congrav® L/M 3 NA V_._

2.3.1.2 The mode C2 or A2: ART-feeding

With the mode B2 or A2 batch feeding works according to the ART-

principle (Automatic Rate Turndown). The ART-principle optimises the
parameterisation of the feeding parameters as a function of a fixed
feeding time. A batch feeding operation with the ART-principle can be
divided into two phases.
Learning phase
The first batch feeding within an ART-feeding is designated as learning
phase. The first batch of the ART-feeding is characterised by an output
value that equals 0. The elapse of the learning phase is identical to mode
B1(A1). However it differs from B1(A1) insofar as during the coarse phase
there is an automatical calculation of the output. The calculated value
will be memorised and thus the learning phase for the subsequent batch
feedings will be deactivated.

This means also that during the learning phase the preset feeding
time cannot always be respected. This would require the
corresponding parameterisation of coarse/fine feeding during the
Important
learning phase.

ART-feeding
After the learning phase each further batch will be fed out according
to the principle of ART-feeding. The ART-feeding adjusts the feeding
operation by a modification of the manipulated variable as a function
of the feeding time. It is the object of ART-feeding to feed the batch
within the preset feeding time. With each batch feeding the relevant
parameters will be optimised again and thus the curve of the
manipulated variable will be adjusted continuously to the preset
feeding time.
Advantages of the ART-feeding
The respect of a fixed feeding time and thus the integration into a
production process with well defined sequence times and
The automatic adaptation of the parameters in case of a setpoint
modification.
Inconvenients of the ART-feeding:
The parameterisation and the adaptation of ART-feeding take more
time.

Brabender Technologie, 2005-06 Page 21 of 112

 Manual Congrav® L/M 3 NA V_._

2.3.1.2.1 ART-feeding: the sequence of operations

Important
The following chronological representation does not take into
account the refilling of the hopper.

Operation

ART

Automatic
derivative action
correction

Tolerance
check

Post-feeding
(fine)

Tolerance
check

Batch end

Start 1 2

Speed %

1000% Theoretic manipul. var. of the start is replaced

by (max-2%).
Max. -2%

Fine

Figure 2-4: Chronological representation of an ART-feeding with post-feeding

Batch feeding starts with the coarse delay time. During this period the
initial weight for the batch feeding is calculated. After the elapse of the
coarse delay time the feeding operation will start with the start value
coarse feeding or the maximum value. The value coarse feeding is
optimised after each batch feeding as a function of the feeding time. If
the value that has been computed exceeds the maximum value = (speed
max - 2%), after the start of batch feeding the maximum value will only be
emitted until the manipulated variable stays below the maximum value
due to the ramp function.From this point on the manipulated variable will
follow the ramp function (see Figure 2-4)In the course of feeding the
ramp function will reduce the manipulated variable down to the value fine
feedingThe manipulated variable permits to control the product flow of
the feeding device. Thus, feeding approximates the cut-out point (=
setpoint x derivative action point) with a low product flow and a high
measuring accuracy. Feeding will stop on reaching the cut-out pointAfter

Brabender Technologie, 2005-06 Page 22 of 112

 Manual Congrav® L/M 3 NA V_._

elapse of the batch stabilisation time the system will carry out the
automatic check of the derivative action point followed by the tolerance
check.

The Congrav L/M3 will:

Operator:

start post-feeding with the fine feeding value, if not Over-

Break-off or
enough product has been fed. After the post- feeding acceptance?
feeding operation the batch stabilisation time runs Setpoint + Feeding tolerance

down and then the tolerance check will be started

anew. Figure 2-4 illustrates this case. ☺ Setpoint
Batch feeding
will be stopped
stop batch feeding and display the end of batch Good

feeding (display, digital output), if the product Setpoint - feeding tolerance

quantity that has been fed out lies within the

allowed setpoint range. Post-feeding
discontinue batch feeding with an alarm report if not enough will be started

too much product has been fed (=overfeeding).

Figure 2-5: Batch evaluation

Overfeeding: Here the operator will have to decide how to continue!

If overfeeding is okay for the current operation the operator will
reset the alarm report and start the feeding operation anew.
Feeding will be continued and correctly brought to an end. 1. Alarm reset
2. Start feeding

If overfeeding cannot be accepted for the current operation the

operator will reset the alarm report and discontinue the current
batch feeding with the order batch break-off. The batch break-
1. Alarm reset
off is absolutely necessary. The batch break-off stops the current
2. Batch break-off
batch so that a new start order will start a new batch.

2.3.1.2.2 Staying below/exceeding of the defined feeding time

If the ART-feeding stays below the defined feeding time, i.e. has
completed the batch feeding in less time, the ART-feeding will rest until
the feeding time has elapsed and will then terminate the batch feeding.
Exceeding of the defined feeding time will be indicated by the alarm
report “feeding time fault”. In standard this alarm report stops the batch
feeding (=alarm cut-out).
The ART-feeding tries to respect the feeding time by increasing the
manipulated variable of the start.
Should this not be the case, the following alarm report will appear:
Important
Coarse feeding > 1000%.

Brabender Technologie, 2005-06 Page 23 of 112

 Manual Congrav® L/M 3 NA V_._

This alarm report signifies that the defined feeding time is too short for the
feeding device. You can eliminate the fault by
increasing the feeding time or
reducing the setpoint or
changing the feeding system.

2.3.1.2.3 List of necessary parameters

Parameter Unit Menu level

The mode C2 or A2: Kxx2
max. batch size kg F600
Setpoint kg F300
Coarse delay s F600
Coarse feeding % Kxx2
Checking max. output: kg/h Kxx1
Feeding tolerance % F600
Derivative action point % Kxx2
Derivative action F600
correction
Batch stabilisation time s F600
Max. feeding time s Kxx2
Refill mode F600
Refill time F600
Weight mode F600
Setpoint mode F600
Feeding time factor F600
Setpoint factor F600
Table 2-2: List of the parameters that are relevant for B2(A2)-feeding

2.3.2 Important operating states

2.3.2.1 Refilling with loss-in-weight batching

With loss-in-weight batching the time for refilling of the hopper is an

important operating parameter. The refilling can be made
before the start of batch feeding,
after the end of batch feeding or
during batch feeding.
The time for refilling before or after the batch feeding operation is set by
means of the parameter refill time (chapter 0, page 91). Refilling during a
batch feeding operation is designated as partial batch operation, please
see the description in chapter 2.3.2.2.

Brabender Technologie, 2005-06 Page 24 of 112

 Manual Congrav® L/M 3 NA V_._

Refilling permits to fill the hopper until the hopper volume has
reached the defined value filling level max. After the end of refilling
the stabilisation time will run down.

Stabilisation time = WP24 + 4s

This period serves for the stabilisation of the weight value before the
continuation of the batch feeding operation. If the stabilisation time after
refilling is too short, this leads to inaccurate measuring due to the
fluctuating weight values, thus the batch accuracy is reduced
considerably.

2.3.2.2 Refilling during a batch: Partial batch operation

After the start of a batch feeding the software will compute the max.
available product quantity (M =filling level max. - filling level min.) and
compare it to the batch setpoint. If the batch setpoint exceeds the max.
available product quantity the partial batch operation will be activated
automatically.
With partial batch operation the number of partial batches is computed
before the start of batch feeding. The number of partial batches is
calculated as per
batch setpoint
Number partial batches = (round up to the next integer!)
M

Partial batch operation is corresponding to the normal batch operation

with the difference that batch feeding will be stopped upon reaching the
minimum filling level and refilling will start after the batch stabilisation
time. The refilling ends after the maximum filling level has been reached
and after elapse of the stabilisation time the next partial batch or the
feeding operation will start.

With mode B2 (ART-principle) please observe that the input of the

feeding time for the ramp feeding does not include any refill times. The
partial batches as considered as one batch, whereas with the mode
“B2“ (A2) the ramp function starts immediately. The feeding time
monitoring monitors the sum of feeding times of the partial batches Important
without taking into account the refill times and the subsequent
stabilisation times.

Similar to normal batch feeding all feeding parameters for a partial batch
feeding cycle such as derivative action point, coarse/fine switch-over etc.
are referred to the total batch setpoint.

Brabender Technologie, 2005-06 Page 25 of 112

 Manual Congrav® L/M 3 NA V_._

2.3.3 The discharge of a hopper scale

The software supports two different types of discharge:

The manual discharge can be started via the menu page Kxx0 (see
chapter 10.3.4, page 64) or via the digital input DI5, if the automatic
discharge is switched off (AP13=0) and the discharge mode is
switched on (AP10=10).
The automatic discharge is selected by means of the menu point
“discharge auto“ (AP13) and will start after each batch.

After a recipe end there will be no automatic discharge of the hopper

due to the recipe end.

The start of the discharge operation sets the digital output DO3 for the
control of the shut-off device of the hopper. After the end of the discharge
operation the digital output “discharge end“ will be set.

2.3.3.1 Manual discharge

With a manual discharge operation the batch weighing will be carried

through until the end of the batch according to the batch mode that has
been adjusted. Then, a discharge operation or a new batch can be
started. After the start of the manual discharge the “max. discharge time“
(AP07) will run down.
If the hopper weight falls short of the weight value “discharge
tolerance“ before the max. discharge time has run down, the
discharge operation will be stopped. After elapse of a short rest time
the valve will be closed and the time “valve closing time“ (AP06) runs
down. After elapse of this time the permissive discharge tolerance will
be checked.
If the hopper weight falls short of the max. discharge time after elapse
of the max. discharge time, there will be an alarm report “weight >
discharge tolerance“.

The checking of the discharge tolerance is only carried through after a

discharge and the maximum filling level in the hopper of the hopper
scale will not be monitored. The operator has the task to monitor the
hopper filling level or the maximum weight loading and the maximum
hopper volume.

Brabender Technologie, 2005-06 Page 26 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 3

GENERAL NOTES

This chapter lists the specifications for the use of the

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

Brabender Technologie, 2005-06 Page 27 of 112

 Manual Congrav® L/M 3 NA V_._

3 General notes
3.1 Mains supply

On its rear side the Congrav® L/M 3 is equipped with a socket for the
power supply. Mains voltages between 85 VAC and 250 VAC are
allowed. The mains frequency may be between 47 Hz and 63 Hz.
The connection socket is equipped with two time-lag fuses of 2A.

An earthing screw (M5) for the earthing of Congrav® L/M3 is located

below the socket. The earthing screw is connected to ground potential
by means of a suitable lead, e.g. earthing strap 10x1,5mm.

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

3.2 The external 24VDC-supply

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

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

Voltage range 24 VDC +/- 15%, stabilised

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

3.3 Cable types to be employed

Area of use Cable type

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

Brabender Technologie, 2005-06 Page 28 of 112

 Manual Congrav® L/M 3 NA V_._

3.4 Safety notes

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

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

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

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

device.
When working on the plug-in cards the staff has to be sure to prevent
static discharges, as these discharges risk to destroy the plug-in card.
Static discharges may cause the destruction of electronic elements
and thus to a failure of functioning of Congrav® L/M3.
Separate Congrav® L/M3 from the mains by pulling the coupler
plug.
Never insert or draw out the plug-in cards with the voltage being on.
Never use force to insert or draw out the plug-in cards.
The stipulated specifications regarding the slot assignments for the
respective types of card are absolutely binding and must be complied
with to ensure correct operation.
Each Congrav® L/M3 must be equipped with the plug-in card L/M3-
MSIO. Otherwise the Congrav® L/M3 is not ready to function.

3.4.2 Safety instructions for mounting

Never cover or block the venting slots.

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

Brabender Technologie, 2005-06 Page 29 of 112

 Manual Congrav® L/M 3 NA V_._

3.4.3 Safety instructions for cabling

Be sure to provide correct earthing for the Congrav® L/M3. For the
connection to earth please use the earthing screw underneath the
mains connection. The mere earthing via the mains connection is not
sufficient.
Cabling has to comply with the EMC-specifications. This implies a
correct screening of the signal lines.
For the cabling of Congrav® L/M3 the corresponding specifications
concerning the cable type, the allowed cable length etc. have to be
observed.
You have to employ the special I/O-modules. The I/O-modules
permit the cable connection via the terminal strips.

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

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

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

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

3.4.4 Safety instructions for the operation, the manipulation

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

the software and its configuration. Modifications to this configuration
might change the functions of Congrav® L/M3 in a positive or
negative manner. A non-expert parameterisation may lead to severe
failures of the feeding process and may even damage the feeding
system.
Thus, modifications to the operating parameters must only be carried
through by duly qualified operating staff.
The membrane panel of the integrated front keyboard is produced in
polyester and is designed for industrial applications. However, the
user has to handle it with care. Do not employ sharp-edged objects
during the operation.
The LCD panel is produced in plexiglass and must not be scratched
by sharp objects or by dust particles as a result of rubbing, etc.

Brabender Technologie, 2005-06 Page 30 of 112

 Manual Congrav® L/M 3 NA V_._

3.4.5 Specifications based on the software NA

Each DS-controller controls only one loss-in-weight or gain-in-weight

batching operation. Thus, the Congrav® L/M 3 only permits to
control a maximum of 8 weigh-feeders.
Both weighing principles assign different functions to the I/O of the
DS-controller.
The assignment is obligatory due to the slot. I.e. a change of the slot
from -XS4 to -XS5 also changes the functions of the DS-controller,
whereas during a change from -XS4 to -XS6 the function does not
change.
The connection to the peripheral equipment of the weigh-feeders is
made by means of the I/O-modules. Due to the different functions
the connection of the I/O-modules has to be carried out with the
utmost care.

3.5 The software development up to version V1.31

The present manual describes the functions of the software LM3 NA as

per version V1.31. The previous versions include some points that differ
from the version V1.31. The differences for the individual versions are
described in detail by the following versions.

3.5.1 Software version LM3 NA V1.10

The assignment of the weighing principle to the corresponding DS-

controller is made by means of the slot of the DS-controller.

-XS 4,6,8,10 DS-controller with loss-in weight feeders (N-type)

-XS 5,7,9,11 DS-controller with gain-in weight feeders (A-type)

3.5.2 Software version LM3 NA V1.20

Only the N-type can be selected. The parameters of the A-type that
are already available don’t have a function.
DO4 = Tolerance+
DO6 = Reserve

3.5.3 Software version LM3 NA V1.30

The N- or A-type is freely selectable.

Brabender Technologie, 2005-06 Page 31 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 4

HARDWARE DESCRIPTION

This chapter describes the front elements, the front keyboard,

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

The functions and the support of the optional extension cards

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

Brabender Technologie, 2005-06 Page 32 of 112

 Manual Congrav® L/M 3 NA V_._

4 Hardware description
4.1 Congrav L/M3: the types

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

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

4.2 The display and the front keyboard

4.2.1 The integrated front keyboard and its functions

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

3
6

(1) Tricolour status-LEDs for components 1 -8

The LEDs and their status are assigned to the component designated by
the figure above the LED. The LEDs 9 – 16 have no function, as the
software LM3 NA supports a maximum of 8 components.

LEDs normal flashing

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

The software manages the connected weigh-feeders as components.

(2) Function and component keys

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

Brabender Technologie, 2005-06 Page 33 of 112

 Manual Congrav® L/M 3 NA V_._

(3) The cursor-block

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

(4) The numerical keys

The numeric keys are used for numeric inputs. Beside the figures 0 - 9 this
block contains the decimal point and the clear-key (C). An activation of
the clear-key cancels the last figure of the input, as long as the input has
not yet been acknowledged by means of the enter-key. Chapter 4.3
describes the numeric input.

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

Status LED Meaning for the selected components

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

(6) The LCD-display

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

Brabender Technologie, 2005-06 Page 34 of 112

 Manual Congrav® L/M 3 NA V_._

4.2.2 Composition and menu structure of the display

page number page interlocking

The menu pages always consist of a
header, a parameter range and the input F100 V=Aus | ST ST ST ST ST ST ST ST K8

line (last line). The header is always made Startbed. | ST ST ST ST ST ST ST ST K16

up of the first two lines of a menu page. The

header contains: Installation status Feeder status,
Mode display

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

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

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

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

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

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

Representatio Meaning LED

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

Brabender Technologie, 2005-06 Page 35 of 112

 Manual Congrav® L/M 3 NA V_._

4.3 Parameter modifications

4.3.1 The numeric input

According to its designation the numeric

1. Set the cursor to the actual value

input is based on a parameter that is preset K011 B1 B1 B1 B1 B1 B1 B1 I=off

via the numeric keys, for example 100.00.

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

4.3.2 The selection of fixed parameter sets

The second possibility of parameter input, 1. Set the cursor to the actual value + CR

the selection of a defined parameter value,

Mode
indicates a choice of possible inputs for the
parameter selected. The cursor permits to
select the desired parameter value, it is then 2. Set the cursor to the new value

validated by pushing of the CR-key. K011 B1 B1 B1 B1 B1 B1 B1 I=off

|
B2 Batch 2 |

3. CR = validate + return

4.3.3 Parameter modifications are not taken over, if

The new parameter violates the input limitations.

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

The component or not all components have been stopped.

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

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

stopped ≠ started + interlocked!)

Brabender Technologie, 2005-06 Page 36 of 112

 Manual Congrav® L/M 3 NA V_._

The input is not possible because of an interlocking.

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

4.4 Overview of the slots of Congrav® L/M3

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

Slot XS1: (has to be available)

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

Slot XS2:
Reserved for the plug-in card L/M3-CDIO. This optional extension
permits to extend the hardware of Congrav® L/M3 by means of a printer
interface (Centronics) and 6 digital inputs and outputs each.

Slot XS3: (optional extension)

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

and the ControlNet are available.

Slot XS4: (has to be available)

Reserved for the first DS-controller. A DS-controller permits to connect 1

weigh-feeder with loss-in-weight batching (N-type) or gain-in-weight
batching (A-type) to the Congrav® L/M3.

Brabender Technologie, 2005-06 Page 37 of 112

 Manual Congrav® L/M 3 NA V_._

Slot XS5 – XS11: DS-controller

Further DS-controllers
Each further DS-controller permits to connect one 1 more weigh-feeder to
the Congrav® L/M3.

Slot XS5 – XS11: (optional analogue card!)

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

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

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

At present, the software does not yet support the optional analogue
card.

Brabender Technologie, 2005-06 Page 38 of 112

 Manual Congrav® L/M 3 NA V_._

4.4.1 Overview: the possible connections

Supply voltage load cell amplifier

digitales Wägesignal
Motor line

Drehzahlimpulse

integrated in the junction box that is

Analogue
weight signal

mounted to the weigh-feeder

Drive controll

Power supply Speed

depending monitoring BT1094
Digital speed BT1094A
on the type
analogue act. value output 0 - 10VDC

analogue manipu. variable 0 - 10VDC

analogue load cell signal 0 - 10VDC

Setpoint (manipul. output, serial)

analogue leading 0 - 10VDC

Speed signal 0 oder 24VDC

Start speed monitoring
analogue speed 0 - 10VDC

Release (opteration)

serial load cell signal

serial load cell signal

Host computer with Siemens RK512

Modem

Congrav RC3
IO-Modul-Analog-LM3 IO-Modul-DS-LM3 R1
UBE-D/15F

Power supply Power supply Power supply

24 VDC 24 VDC 24 VDC

ProfiBus DP, Printer

ControlNet (Centronic)

Analogue card DS-controller Bus module LM3-CDIO LM3-MSIO

Power
Power supply
source

Figure 4-2: The possible connection of a loss-in-weight feeder

Brabender Technologie, 2005-06 Page 39 of 112

 Manual Congrav® L/M 3 NA V_._

4.5 The basic execution of Congrav® L/M3

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

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

4.5.1 The plug-in card L/M3-MSIO

The L/M3-MSIO
is the Memory-Serial-IO-card of Congrav® L/M3,
-XS1.1
is always plugged into the first slot (XS1) and
is always required for an operation of Congrav® L/M3.
The L/M3-MSIO is equipped with
the program store for the operating software -XS1.2

the systems battery for buffering all SRAM-components

3 RS485/422-interfaces with isolated potential
-XS1.3
The three interfaces are lead out on the rear face of the L/M3-
MSIO as 9-pole DSub-sockets.
-XS1

4.5.1.1 XS1.1: The connection of the host computer

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

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

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

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

4.5.1.2 XS1.3: The connection of a modem

At present, the modem function is not supported.

Brabender Technologie, 2005-06 Page 40 of 112

 Manual Congrav® L/M 3 NA V_._

4.5.2 The DS-controller

The digital/serial controller permits to control either one loss-in-weight or

one gain-in-weight batching operation according to its configuration
(CP01). A DS-controller is only equipped with digital inputs and outputs
and 4 serial RS422-interfaces.

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

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

DS-controller, it can only be provided via an optional analogue card. The
evaluation of the speed monitoring data (BT1094A, etc.) is performed via
digital input 1.
The cabling of the DS-controller is made via the I/O-module-DS-LM3 Rx.

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

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

4.5.2.1 The I/O-module for the DS-controller

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

I/O-module-DS-LM3 Rx (at present x= 1, 2). The connection to the DS-
controller defines the functions of the individual terminals of the I/O-
module based on the configuration of the corresponding component in
the software.

All configuration parameters of the software are affected by this

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

Brabender Technologie, 2005-06 Page 41 of 112

 Manual Congrav® L/M 3 NA V_._

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

Relay output 48VDC/1A 24VDC

Power supply
RB RA TB TA
+ + - -
1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17 18 19

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

K1 K2 K3
IO-Modul-DS-LM3-

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

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

NC NC NC
Relay outputs 250VAC/5A
R1

15VDC
10VDC

GNDP
R2

Figure 4-3: IO-module-DS-LM3 R_

Terminal R1 R2 Power supply

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

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

means of the I/O-module.

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

The following terminal plan designates the functions

for loss-in-weight batching with “N: Function“,
for gain-in-weight batching with “A: Function“.

Brabender Technologie, 2005-06 Page 42 of 112

 Manual Congrav® L/M 3 NA V_._

Terminal strip 1
N: Ready for start
A: Recipe end

Batch-
end Coarse/fine

K4 K5 K6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
RB RA TB TA

Relay Kx
for the internal use drive controller
1A, 48VDC serial

RB RA TB TA

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

power supply
K1 K2 K3

supply
Frequenc converter 24 VDC
B A (RS485) FC-V_ for AC drive
Operation Alarm N: Refill + + - -
A: Discharge
16 17 18 19

Vibration amplitude
controller
3 4 1 2 6 DRS2
(RS422) for the vibration drive
Terminal strip 2

Speed Load cell RS485

monitoring

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

IDL/F- Load cell
N: Refill
Operation Alarm A: Discharge - + Impulse
Load cell RS422 +15V- supply, max. 200mA
Namur sensor IDL/F2-, ED60-Load cell, AED-module
+ Impulse GNDP für 10V- und 15V-supply
Shut-valve DI
K1’ K2’ K3’

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
DA4 24V 24V RB RA TB TA 10V 15V GNDP
GND GND

Relay Kx’ DO Start

motion IO-module-DS-LM3-R2
for the customer use
5A/250VAC monitoring

GND GND RB RA TB TA
DA8 24V 24V 10V 15V GNDP

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

K4’ K5’ K6’ DI

N: Alarm report
A: Feeder 1

Coarse/fine
Batchend
GNDP für 10V- und 15V-supply
N: Ready for start
A: Recipe end +15V-Speisung , max. 200mA
IDL/F2-, ED60-Load cell, AED-modules

+10V- supply, max. 120 mA

IDL/F- Load cell

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

24 VDC
RS422 Belden 9842 300 m Date : 03 - 05 -09

RS485 Belden 9841 300 m by: Schell 0e011545

I/O-module-DS-LM3 R2 for L/M NA

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

Brabender Technologie, 2005-06 Page 43 of 112

 Manual Congrav® L/M 3 NA V_._

4.5.3 The hardware components of the DS-controller

4.5.3.1 The digital inputs and outputs

For each weigh-feeder (N- or A-type) the DS-controller offers

8 digital inputs,
8 digital outputs and
2 serial RS422/485 interfaces (load cell and drive controller)
The I/O-module-DS-LM offers the digital outputs
1-3 and 5-7 via 2 relay outputs each.

DO1: DO2: DO3: DO5: DO6: DO7

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

The two relay outputs have different specified load capabilities. The relay
outputs K1’-K6’ are employed for the on-site treatment and the relay
outputs K1-K6 are employed for the internal cabling, for instance for
enabling the connected drive controller, because of their low loading
capacity.
Chapter 12 describes the functions of the digital inputs/outputs (chapter
12, page 77) and of the serial interfaces (chapter 12.1.3, page 78).

4.5.3.2 The serial interfaces of the DS-controller

The DS-controller is equipped with two RS422/485 for the connection of

a drive controller and the load cell of the weigh-feeder. It is only possible
to connect devices, the interface protocols of which are implemented in
the software. Chapter 12.1.3, page78, describes the devices that are
supported and their configuration.

Brabender Technologie, 2005-06 Page 44 of 112

 Manual Congrav® L/M 3 NA V_._

4.6 The optional extension of Congrav® L/M3

Prerequisites for the use of the optional extensions:

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

4.6.1 The plug-in card CDIO

The option card LM3-CDIO-card (-XS2) expands the hardware of

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

XS2.2: optional digital-I/O

8
-XS2.1
1

9 15

24 VDC DO6
Di 6 DO 5
DI 5 DO 4
DI 4 DO 3
DI 3 DO 2
DI 2 DO 1 -XS2.2
DI 1 24V GND
Screening

Figure 4-5: Pin functions of the digital-I/O of the LM3-CDIO

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

module UBE-D/15F, that is connected by means of an 1:1
connection (pin1 terminal 1, etc.) to XS2.2. Please refer to
chapter 12.1.4, page 81 for the functions of the digital inputs and
outputs.

Brabender Technologie, 2005-06 Page 45 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 5

COMMISSIONING

Brabender Technologie, 2005-06 Page 46 of 112

 Manual Congrav® L/M 3 NA V_._

5 Mounting and commissioning

Mounting of Congrav® L/M3 A

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

Cut-out

Fixing clamps
139,00

Front

Screws for clamps

281,0 Mounting of a clamp

Figure 5-1: Dimensions of panel cut-out and fixing of Congrav® L/M 3A

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

Mounting and dimensions of Congrav® L/M 3B

The Congrav L/M 3B is mounted in

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

no cut-out is required for the Congrav

33,56
29,15

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

cabinet. Due consideration must be
6,29

accorded to the operating conditions,

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

when installing the unit.

Figure 5-2: Mounting dimensions of Congrav® L/M3 B

Brabender Technologie, 2005-06 Page 47 of 112

 Manual Congrav® L/M 3 NA V_._

5.1 Connection plan of a loss-in-weight feeder

Figure 5-3: Example for the connection of a loss-in-weight batching system

Brabender Technologie, 2005-06 Page 48 of 112

 Manual Congrav® L/M 3 NA V_._

5.1.1 Connections of Congrav® L/M3

Figure 5-3 shows an example for the cabling of a loss-in-weight batching

system. The cabling is determined by:
the type of weigh-feeder,
the employed subassemblies,
the hardware configuration of Congrav® L/M 3
and various other points. Further examples for wiring of various standard
subassemblies to the Congrav® L/M3 are shown in a separate appendix.
Please see chapter 12 page 76 for a description of the configuration of
the hardware functions of Congrav® L/M3.

Brabender Technologie, 2005-06 Page 49 of 112

 Manual Congrav® L/M 3 NA V_._

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

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

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

The welcome screen shows the Congrav®- F000

Stopped
|

type and the software version that has been BRABENDER TECHNOLOGIE
recognised. Further tests: Check
Software : LM 3A |
IO address: the available option cards NA V1.31 | o.k.
are displayed according to IO address: 3 3 4
:
|

their order of insertion. :

3 = DS-controller MS-Board: RC Batt. |
CD-Board: 1 |
o.k.

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

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

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

our after sales department.
Attention

Exception: the battery for memory buffering

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

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

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

Brabender Technologie, 2005-06 Page 50 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 6

INSTALLATION CONFIGURATION

This Chapter deals with the menu pages F100 and the
corresponding submenu pages

F100: Installation configuration

F110: Installation modes
F120: Host computer parameterisation (see
chapter12.2)
F130: Text switch
F140: Test of I/O-periphery (see chapter14)

Brabender Technologie, 2005-06 Page 51 of 112

 Manual Congrav® L/M 3 NA V_._

6 F100: Installation configuration

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

6.1 F110: Installation modes

The software distinguishes between two types of modes,

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

This menu point defines the installation mode recipe kg. The individual Recipe kg
components feed independently of each other as a function of the
setpoint. For the totalisation (total setpoint, total actual value, total
throughput) only the preselected components are taken into
consideration. The component setpoints are entered on menu page
F300.

This menu point defines the installation mode recipe %. A group consists Recipe %
of several individual products that are blended in the group according to
fixed proportions. The size of the group is determined by means of the
group setpoint. The setpoints of the individual slave feeders are
determined in relation to a master setpoint in %. Thus, on page F300
you first enter the group setpoint and then the setpoints of the weigh-
feeders in % taking into consideration the setpoint limitation (setpoint <
1,1 ∗ max. batch size of the component).

6.2 Host computer operation

The parameter host computer operation permits to activate the host

computer operation. Please refer to chapter 12.2, page 83 for a
description of the host computer configuration.

6.3 Text switch

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

Brabender Technologie, 2005-06 Page 52 of 112

 Manual Congrav® L/M 3 NA V_._

lb/h: Output, max. output,

lb: Setpoint, actual value, max. batch size, output, weight, auto-
tare
PCF: Bulk density (input range 10 - 250)
cuft: Hopper contents (input range 0.01 - 350)

6.4 Interlocking/stop

off If one weigh-feeder is interlocked, batching remains started.

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

6.5 Date and time

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

Brabender Technologie, 2005-06 Page 53 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 7

PRINTER CONFIGURATION, RESET

OF MEMORY CONTENTS

This Chapter deals with the menu pages F200 and the
corresponding submenu pages

F200: Printer configuration

F210:Reset memory contents

Brabender Technologie, 2005-06 Page 54 of 112

 Manual Congrav® L/M 3 NA V_._

7 F200: Printer configuration, reset of memory contents

7.1 Printer functions

The optional extension card RC4-CDIO permits to connect a printer with

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

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

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

28.05.97 23:45
K 01 Speed minimum

or if the alarm is deleted:

28.05.97 23:46
K 01 Speed minimum reset

The input of the component number 1..08 leads to a printout of Printout of

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

If batch recording has been activated the printer will print a batch Batch record
record with the batch parameters after the termination of the
batch. The batch record indicates the batch parameters date/time,
setpoint, actual value, act. batches, throughput, weight.

Brabender Technologie, 2005-06 Page 55 of 112

 Manual Congrav® L/M 3 NA V_._

7.2 F210: How to clear memory contents

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

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

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

RAM:
Deletes all data in the RAMs of the DS-controllers and loads the booted
data of the master controller.

All data delete:

Deletes all data in all memory chips and replaces them by standard
values.

After execution of the corresponding delete function the report “data

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

Brabender Technologie, 2005-06 Page 56 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 8

SETPOINTS AND SELECTION

Chapter 8 deals with the menu pages F300 and the

corresponding submenu pages

F300: setpoint input, selection

F310: alarm stop

Brabender Technologie, 2005-06 Page 57 of 112

 Manual Congrav® L/M 3 NA V_._

8 F300: Setpoint input and selection

This page permits to enter the setpoints and the selection. For an easy
operation the cursor-keys left and right are active. Depending on the
number of DS-controllers employed, the components are displayed.

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

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

8.1 Installation setpoints

Mode Definition of the setpoint

Recipe kg The total setpoint is calculated from the sum of the
setpoints of all selected components.
Recipe % The group setpoint is entered in kg/h.

8.2 Component setpoints

*only valid for selected

Mode Setpoint in % Setpoint in kg components

Recipe kg - Input without selection:

* max. batch size (CP03)
Recipe % Input SP% ⋅ group _ SP [ kg / h ] instead of
group_SP

The component mode discharge is a special function of the setpoint

input. With this mode the setpoint is defined on menu page Kxx2 with
the parameter “coarse feeding“.

8.3 Selection

The selection of a component has the following effects:

The component selected can be addressed by the keys start, stop and
alarm reset.
The calculation of the total setpoint, total actual value and total
throughput are exclusively carried through under respect of the
components selected.
The option alarm stop (see chapter 8.4) only take into consideration
the selected components.

Brabender Technologie, 2005-06 Page 58 of 112

 Manual Congrav® L/M 3 NA V_._

The mode recipe % only takes into consideration the selected

components.
The selection can only be switched on/off if the feeder is stopped.

8.4 Alarm stop

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

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

Brabender Technologie, 2005-06 Page 59 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 9

THE ACTUAL VALUES OF THE

INSTALLATION

This Chapter deals with the menu pages F400 and the
corresponding submenu pages
F400: The actual values of the installation
F410: The actual values: setpoint, act. value, act-
batches
F420: The actual values: weight, throughput,
speed
F430: Reset of throughputs

Brabender Technologie, 2005-06 Page 60 of 112

 Manual Congrav® L/M 3 NA V_._

9 F400: Actual values of the installation,

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

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

F410 shows a table of the actual values of the feeding operation

Setpoint: Batch quantity to be fed in kg or lb,
Actual value: Actual batch quantity in kg or lb,
Act-batches: Number of batches that have been fed

F420 shows a table of the actual values of the feeding operation

Weight: With a tared weighing system the weight value is
corresponding to the product weight in the hopper of the
feeding device.
Total: The throughput (=total) is the addition of the product
quantity that has been fed out (see chapter 9.1, page
61)
Speed: The speed displays the actual operating range of the
feed drive. With speed monitoring the speed will be
displayed as manipulated variable that has been
emitted.

9.1 F430: Reset throughputs

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

Brabender Technologie, 2005-06 Page 61 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 10

THE COMPONENT OPERATION

Chapter 10 deals with the K-menu pages.

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

Brabender Technologie, 2005-06 Page 62 of 112

 Manual Congrav® L/M 3 NA V_._

10 The component operation

The component pages permit to address all 8 components (weigh-
feeders) individually. The page number Kxxy indicates the
identnumber of the component by means of the figures “xx“ and
the actual menu page means of the figure “y“.
The individual menu pages Kxx0 - Kxx8 show the same structure (K010
== K080, etc.) for all 8 components.

10.1 The header of the component pages

Type of feeder: N = loss-in-weight batching

A: = gain-in-weight batching
Component xx: The component, the parameter values of which are
displayed and that is responded by the operating
functions.
Alarms: Alarm reports of current alarms or missing start
conditions.

10.2 Kxx0: The component control

Menu page K010 – K080 manages all K010 I=off | ST GF GF GF GF GF GF GF

Start cond. | GF GF GF GF GF GF GF GF
operating functions (left column) and
Component operation
displays the actual values (right column) for N-type component 01
the feeding operation.
Start | Setpoint 100.000 kg
This menu page permits to operate each Stop | Actual value 0.000 kg
component individually and independently Alarm reset
Refill
| Control diff.
| Weight
0.000 %
0.000 kg
of the selection. The desired function is | Speed 0.000 %
selected by cursor and validated by the CR- Reset | Throughput
Start tare | Tare
0.000 kg
0.000 kg
key. Recipe cut-out| Set batches 0001
Ba.cut-out| Act- batches 0000

10.3 The operating functions

10.3.1 Start
The component is started, if all necessary start conditions have been
complied with.

10.3.2 Stop
The component is stopped.

Brabender Technologie, 2005-06 Page 63 of 112

 Manual Congrav® L/M 3 NA V_._

10.3.3 Alarm reset

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

10.3.4 Refill
N-type Manual refill can be switched on and off
A-type Manual discharge can be switched on and off

10.3.5 Reset
The throughput of the component is reset to 0.

10.3.6 Start tare

Start of the auto-tare function (please see 0).

10.3.7 The actual value display in the right column

Setpoint: The batch setpoint in kg
Actual value: The batch quantity that has been fed in kg
Difference: Setpoint – actual value in kg
Weight: With a tared weighing system the weight value is
corresponding to the product weight in the hopper.
Speed: The speed displays the actual operating range of the feed
drive. With speed monitoring the speed will be displayed as
manipulated variable that has been emitted.
Throughput: The throughput, the summation of the product quantity that
has been fed (see chapter 9.1, page 61)
Tare: Display of the stored auto-tare value
Set-batches: The batch number to be fed
Act-batches: The batch number that has been fed

10.4 Kxx1 Product parameters

K011 I=off | B1 ST ST ST ST ST ST ST
| ST ST ST ST ST ST ST ST
10.4.1 Auto-tare:
Product parameters
Place the cursor on auto-tare. N-type component 01
Push the Enter-key.
The actual weight value is tared under the Auto-tare
Check max. output
0.000
0.000
kg
kg/h
condition (weight < 5% of the weighing Bulk density 0.500 kg/l
range) (= 0 set). If the actual weight exceeds Reserve
Decade switch 0.000
the maximum auto-tare value, coarse tare Mode GF
(CP06) will first have to be reduced
accordingly.

The input of the auto-tare value

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

Brabender Technologie, 2005-06 Page 64 of 112

 Manual Congrav® L/M 3 NA V_._

10.4.2 Checking max. output

This parameter stores the output that is calculated during the ART-feeding 0–999999 lb/h
(learning phase).
A manual input
= 0, activates the learning phase of ART-feeding
> 0, activates the ART-feeding without learning phase
An input of wrong output values has a bad impact on the feeding
behaviour. Thus you must only enter the output value manually, if the
output value is not known to you. Generally, an automatic checking is
better than a manual input.

10.4.3 Bulk density

The input of the bulk density of the product. A missing bulk density input
(= 0) is displayed as missing start condition bulk density ?.

10.4.4 Coarse maximum

Computation of the starting point of coarse feeding with B2(A2) “Fast

Mode“ (CP35=1).

= 0, switched off
setpo int
> 0, Coarse feeding = × coarse maximum
max .batch size

10.4.5 Decade switch

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

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

An adaptation of the performance range of the DRS2 also changes the

feed rate range of the weigh-feeder.

A modification of the decade switch always requires a check of the

output. With a wrong setting of the output as far as the setting of the
decade switch is concerned might lead to an incorrect functioning of
Attention
downstream processes.

Brabender Technologie, 2005-06 Page 65 of 112

 Manual Congrav® L/M 3 NA V_._

10.4.5.1 The setting of the decade switch

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

the setting of the decade switch via the serial interface 2 = decade 1
(Standard) of the device to the DRS2. Input 1 ... 10 is assigned to : : :
the decade switch setting 0 ... 9 10 = decade 9
Input = 0: In combination with the selection of DRS2 on page
Kxx8 this input has the effect that no decade switch
setting is transmitted via the interface and that the
DRS2 functions with the last setting. This means also
that the hardware setting (DIP-switch) is validated after
a mains reset, because the software does not transmit
any decade switch setting. The hardware setting is not
inquired by the software. Attention

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

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

10.4.6 Mode

B1 Batch1: Mode B1 for loss-in-weight batching

B2 Batch2: Mode B2 for loss-in-weight batching

B3 Batch3: Mode B3 for loss-in-weight batching

A1 Addition1: Mode A1 for gain-in-weight batching
A2 Addition2: Mode A2 for gain-in-weight batching
DI Discharge

With this mode the program uses a constant

manipulated variable. With this mode the setpoint is
defined on menu page Kxx2 with the parameter
“coarse feeding“.
Attention:
The system sets 0% equal to 75%.

The computation of the actual value/throughput

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

The batch modes for loss-in-weight and gain-in-weight batching are

described in chapter 2.3.1, page 17.

Brabender Technologie, 2005-06 Page 66 of 112

 Manual Congrav® L/M 3 NA V_._

10.5 Kxx2 The feeding parameters

Coarse feeding (valid for N- and A-type) [0 – 1000%]

B1 or A1: Defines the manipulated variable for coarse feeding.

B2 or A2: Defines the manipulated variable of the start for ART-
feeding. The parameter is adjusted automatically during
ART-feeding. Parameter values that are higher than the
maximum speed (CP10) are emitted with the max.
permissive speed. This goes for manual inputs and
parameter values that have been computed automatically.
DI Defines the manipulated variable for DI-operation.

Fine feeding (valid for N- and A-type) [0 -100%]

Defines the manipulated variable for fine feeding and post-feeding.

Coarse/fine switch-over (valid for N- and A-type) [0 -100%]

B1 or A1: Defines the time for switch-over from coarse to fine feeding.
The input in percent is a function of the batch setpoint. If
the product quantity that has been fed out reaches the
preset value, coarse feeding will stop and fine feeding will
start automatically after elapse of the switch-over time C/F.
If the input is higher than the derivative action point, the
missing start condition is displayed as derivative action
point?.

Derivative action point (valid for N- and A-type) [0 -100%]

Due to the characteristics of the feeding system or of the product an

accurate feeding to the setpoint is often not possible (e.g. trickling of the
product). The derivative action point has the function to stop the feeding
operation before reaching of the setpoint. The batch feeding stops on
reaching the value (setpoint x derivative action point).
To avoid that the operator has to make a new computation and input of
the derivative action point for each batch feeding operation the
correction of the derivative action point (CP33) checks the necessary
modification of the derivative action point after each batch feeding. With
each batch feeding operation the derivative action point is optimised
until batch feeding lies within the desired setpoint range.
The calibration point AP14 defines the unit of the derivative action point.
You can either select the absolute value in [kg or g] or the percentage
[%] as a function of the batch setpoint.

The following condition always has to be complied with:

Coarse/fine switch-over < derivative action point
Attention

Brabender Technologie, 2005-06 Page 67 of 112

 Manual Congrav® L/M 3 NA V_._

max. feeding time (valid for N- and A-type) [0 -100%]

Defines the maximum permissible feeding time for the batch feeding. The
feeding time is computed as follows:
Feeding time = coarse delay + feeding + batch stabilisation

B1 or A1: Feeding = coarse+ fine feeding + C/F-switch-over

B2 or A2: Feeding = ART-feeding

Brabender Technologie, 2005-06 Page 68 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 11

ALARM REPORTS/START CONDITIONS

This Chapter deals with

The menu page F500 and
The menu page Kxx5.

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

missing start condition.
Thus, the operator is informed about the status of the
individual components in case of a missing start condition of
Congrav® L/M3 (red LEDs light up).
Menu page Kxx5 permits to configure the reaction of the
system to some alarms. The following possibilities are
available: “alarm report with cut-out“ and “alarm report
without cut-out“.

Brabender Technologie, 2005-06 Page 69 of 112

 Manual Congrav® L/M 3 NA V_._

11 F500: Alarm reports and start conditions

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

[A] Load cell? (valid for N- and A-type)

The serial load cell data are missing, because either

the configuration in the I/O-configuration menu is wrong,
the serial connection has been interrupted,
the serial connection is troubled by an external source or
the load cell or the serial interface are damaged.

[A] EE-, MM-error (valid for N- and A-type)

- Please contact the service department of the manufacturer -

[M] Speed min. (valid for N- and A-type)

The minimum speed has been fallen short of, because either
the value determined for minimum speed is too high,
speed-reading of the Congrav® S is damaged,
the setpoint is too small for the dimensioning of the feeder.

[M] Speed min. (valid for N- and A-type)

The maximum speed has been exceeded, because either

the value determined for maximum speed is too small,
the setpoint is too big for the dimensioning of the feeder.

[M] Underload (valid for N-type)

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

[M] Overload (valid for N- and A-type)

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

Brabender Technologie, 2005-06 Page 70 of 112

 Manual Congrav® L/M 3 NA V_._

[M] Refill fault (valid for N-type)

The min. filling level has not been exceeded within the determined refill
time, because
the feeder has not been refilled (failure in the upstream filling device),
the digital output refill of the Congrav® is defective.
[M] Discharge error (valid for A-type)

During the maximum defined discharge time the permissive discharge

tolerance has not been fallen short of, because
the feeder has not been discharged (failure of the shut off/discharge
equipment),
the digital output discharge of the Congrav is defective or
the discharge aid does not work correctly.
[M] Feeding time fault (valid for N- and A-type)

The maximum speed has been exceeded, because either

the feed rate coarse/fine has been set too small,
the rest times (batch stabilisation time, switch-over time C/F, etc.)
have been set too long,
the feeding time has been set too short,
fine feeding has been set too small,
the feeding device cannot feed the product quantity in the time that
has been entered.
[M] Tolerance + (valid for N- and A-type)

The set tolerance has been exceeded, because

the derivative action point has been set incorrectly,
fine feeding is too big and/or too short,
coarse feeding is too big and/or too long,
weight sensing is too delayed (average value too high).
[M] Coarse feeding > 1000%. (valid for N- and A-type)

the automatic adaptation of coarse feeding in mode B2 has exceeded the

max. allowed value, because
the feeding time has been set too small,
the rest times have been set too long,
fine feeding has been set too small,
the setpoint for the actual configuration of the feeding device is too big.
[M] Setpoint error (valid for N- and A-type)

The setpoint input is not validated, because

the setpoint input is equal or superior to the max. permissive setpoint (1,1 x max. batch
size).

Brabender Technologie, 2005-06 Page 71 of 112

 Manual Congrav® L/M 3 NA V_._

11.2 Missing start conditions

With single operation (recipe-kg) the feeding operation can only be

started, if all start conditions of the corresponding component have
been complied with. With group operation (recipe-%) the group
operation can only be started, if the start conditions of the selected
components have been complied with.
Exception: the start condition weight < min. In this case, a start order
Attention
immediately activates refilling. However, you have to make sure that the
weight value in the hopper has to be higher than the underload mark,
otherwise there is an immediate alarm cut-out of the component after
the start.

11.2.1 Missing start conditions

Alarm reports Meaning

Setpoint>max The max. batch size has been reduced or the setpoint has been
raised, so that the setpoint violates the limit value (1.1 * max. batch
size). The start condition disappears after an adaptation of the
setpoint or of the max. batch size.
Setpoint = 0 Enter batch setpoint > 0.
Bulk density Enter bulk density > 0.
Min<underload The filling level limits have to correspond to the following order:
Min > Max Underload < fill. level min < fill. level max < overload
Overload<max
Weight < Min. The product quantity in the hopper is inferior to the minimum filling
(with an N-type) level.
It is possible to start batching with this start condition. However, the
start automatically activates the refilling.
Weight>discharge The product quantity in the hopper is superior to the permissive
(with an A-type) discharge tolerance.
Feeding time? The feeding time and the setpoint do not correspond to one
another. On the basis of the inputs the software will compute a start
value > 1000%.
Derivative action The derivative action point is smaller than the switch-over point C/F.
point?
Weight signal ? The serial load cell is not recognised.

11.2.2 Further reports

Batch end Batch feeding is terminated. The Congrav® L/M3 stops the batch
feeding operation, if the set-batch number has been reached or
starts the next batch feeding operation after elapse of the batch
stabilisation time, if the set-batch number has not been reached.

Brabender Technologie, 2005-06 Page 72 of 112

 Manual Congrav® L/M 3 NA V_._

11.3 Error code for an operation with a serial drive controller

11.3.1 Serial frequency converter FC-V_

Alarm report Error Cause Remedy

FU-Error 11 Short circuit Short circuit on the drive side, e.g. Check whether motor lines
caused by have a short circuit
Damaged motor line Check the motor
Turn-to-turn fault in the motor Substitute the damaged motor
FU-Error 12 Shorts to earth Shorts to earth or line capacity Check whether motor lines
too big (reactive power) have a short to earth
Decrease the line capacity
FU-Error 13 Overload during Run-up time (C012) has been Increase the run-up time
run-up or short- set too short Check the wiring
circuit Damaged motor line Check the dimensioning of the
Turn-to-turn fault in the motor motor
Substitute the damaged motor
FU-Error 14 Overload during Operating time (C013) has Increase the operating time
run-up been set too short
FU-Error 15 Overload Accelerations with overload Check the setting of the device
occur frequently or are too long Check the dimensioning of the
Too high load with constant motor
speed
FU-Error 16 Motor overload Continuous current too high Check the setting of the device
Accelerations with overload Check parameter C120
occur frequently or are too long
FU-Error 22 Overvoltage error Overvoltage of the mains takes Check the mains voltage
longer than 5 seconds Frequency converter has to be
operated with permissible
mains voltage
FU-Error 50 Excess Ambient temperature > 40°C Cool down the device
temperature Incorrect fitting position Provide a better aeration of
dissipator Dissipator extremely dirty the device
Vertical mounting!
Clean the dissipator
FU-Error 76 Error during More than 8 error indications Eliminate the causes for the
automatical error during a period of 10 min. errors that have occurred.
reset
FU-Error 91 External error Signal via the external input Check external encoder
“Trip set“ Substitute the damaged
encoder

11.3.2 Vibration amplitude controller DRS2

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

Brabender Technologie, 2005-06 Page 73 of 112

 Manual Congrav® L/M 3 NA V_._

11.4 Kxx5: The alarm configuration

K011 I=off | B1 ST ST ST ST ST ST ST
| ST ST ST ST ST ST ST ST

Alarm configuration The configuration status of the alarm:

HS-type component 01 Place the cursor to the corresponding line
(e.g. overload) and commute the
S+ Speed minimum cut-out configuration status by means of the CR-key.
S+ Speed maximum cut-out
T+ Tolerance + cut-out
FT Feeding time cut-out
OL Overload report only
UN Underload cut-out
RFRefill/discharge cut-out
AV Anti-vibration cut-out

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

Alarm cut-out (= switch-off)

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

Alarm report (= report only)

In case of an alarm report without alarm cut-out, the feeding operation of
the component and the feeding operations of the other selected
components will not be stopped. The frozen mode display is only
refreshed after the reset of the alarm report. The stop of the feeding
operation cancels the alarm report and resets the digital output alarm
report that has possibly been set. An alarm cut-out is displayed as follows
frozen mode display
dig. output alarm report set.

Brabender Technologie, 2005-06 Page 74 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 12

HARDWARE CONFIGURATION AND

HARDWARE FUNCTIONS

This chapter deals with the following aspects of the hardware

configuration
Assignment of the functions and
Software support

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

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

The configuration of the hardware is provided on several menu

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

Brabender Technologie, 2005-06 Page 75 of 112

 Manual Congrav® L/M 3 NA V_._

12 The hardware configuration

12.1 The configuration of the digital/serial inputs/outputs

Menu page Kxx8 (xx = 01 – 08) permits to K018=off

Stopped
|

configure I/O-configuration
**-type component 01
Dig. input 1 0 3=F 4=S
the digital input 1 of the DS-controller Reserve
the serial interfaces of the DS-controller and Reserve
Load cell type 1 1=IDL 2=AED 3=A
the optional analogue card (at present no LC RS422/485
Drive control
1
1
1=422 2=485
1=FC 2=VC 3=A
support!) St RS422/485 2 1=422 2=485
Analogue control 0 1=0-10V
for the corresponding selected component. Act. value output 0 1=0-20mA 2=4-20mA

12.1.1 The digital I/O of the DS-controller

DI 1 Parameter Kxx8 Input Function (valid for N- and A-type)

Digital input 1 3 Digital speed
4 Speed monitoring

Opposite to the 1st digital input the further digital-I/O of the DS-
controller has a fixed assignment of the functions.

N-type A-type
DI 2 Start Start
DI 3 Stop Stop
DI 4 Alarm reset Alarm reset
DI 5 Refill Discharge (valve open)
DI 6 Batch cut-out Batch cut-out
DI 7 Reserve Batch release
DI 8 Interlocking Interlocking

N-type A-type
DO 1 Operation Operation
DO 2 Alarm Alarm
DO 3 Refilling Discharge (valve open)
DO 4 Sealing flap V1.3 Sealing flap
DO 5 Batch end Batch end
DO 6 Ready for start V1.3 Discharge end
DO 7 Coarse or fine Coarse or fine
DO 8 Alarm report Component 1

With the software version LM3 NA some functions of the digital-I/O for
the N-type have changed. They are marked as follows: “ V1.3“ (Please
observe chapter 3.5!). Attention

Brabender Technologie, 2005-06 Page 76 of 112

 Manual Congrav® L/M 3 NA V_._

12.1.2 Description of the functions: the digital inputs and outputs

The digital inputs always have to be operated with a positive logic. I.e.
the functions are carried out, if a 24VDC-pulse (pulse duration 0.5s – 2s)
lies on the corresponding digital input. The only exception is the function
“interlocking“. This function operates with a permanent signal and with
the logic specified for “interlocking type“ in the calibration parameter
(CP13, chapter 0, page 89).
Digital speed Speed as frequency signal (max. 10kHz). The
frequency reading is configured by means of the
calibration parameter “digital speed“ (CP20).
Speed monitoring No reading (software bridge), the manipulated
variable is displayed as speed.
Start The feeding operation is started under respect of the
start delay time (F310), if the system is not
interlocked or if there are no alarms.
Stop The feeding operation is stopped under respect of
the stop delay time(F310).
Al. reset Reset of alarm reports that are displayed.
Refill The refilling of the weigh-feeder is started.
Discharge The discharge of the weigh-feeder is started.
Batch cut-out The actual batch feeding operation is interrupted
and all actual batch values are reset. A start order
will start a new batch.
Batch release The batching operation is enabled.
Interlocking The feeding operation will not be started as long as
the interlocking input is set.

For the duration of the corresponding function the digital outputs supply a
24VDC-signal.
Operation The feeding operation is started.
Alarm The feeding operation has been stopped due to an
alarm.
Refilling The refilling of the weigh-feeder is started.
Discharge The discharge of the weigh-feeder is started.
Tolerance + The feeding operation has exceeded the permissive
tolerance range.
Batch end Batching is terminated.
Coarse or fine Coarse or fine feeding has started.
Alarm report An alarm report has occurred (no alarm cut-out !).
Sealing flap Control of an optional sealing flap on the feeder.
Ready for start Batching can be started.
Component 1 Control of the 1. component with an A-type
Discharge end The discharge is terminated.

Brabender Technologie, 2005-06 Page 77 of 112

 Manual Congrav® L/M 3 NA V_._

12.1.3 Configuration of the interfaces of the DS-controller

The DS-controller offers two serial RS485 or RS422-interfaces for the

serial connection of a drive controller and a load cell. It only supports
load cells and drive controllers the serial protocols of which are
integrated in Congrav® L/M3.

12.1.3.1 Configuration of the load cell

At present, the following load cells are supported:

IDL/F Digital one-wire load cell. With an EExi-execution the

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

Kxx8: Load cell type:

The indication of the load cell type activates the corresponding load cell
input and weight reading on the Congrav® L/M3.
1: IDL/F-, ED60- or MD-load cell (serial weight signal)
2: AED-module (serial weight signal)
3: At present, the optional analogue card is not supported.
Therefore, this menu point has no function at present.

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

Brabender Technologie, 2005-06 Page 78 of 112

 Manual Congrav® L/M 3 NA V_._

Figure 12-1 shows an overview of the standard weighing systems and the
possible signal forms. At present the serial connection (RS422) is the only
possibility.

Feeders Hopper scale

Weighing syst.

Platform Belt Hybrid Platform Platform Platform Hopper Micro-

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

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

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

BT0296 AED BT1094 BR201 BR200-B BR201 AED

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

mV 0-10VDC RS422 RS422 mV

EX-proof area

DMS IDL/F ED60 ED60(MD) ED60 DMS

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

Ex-proof buffer Ex-proof buffer Ex-proof

KFD2-WAV-Ex1 KFD2-WAV-Ex1
amplifier amplifier buffer ampl.

BT1096R1 BR201 BR201

mit BR200
EX-free area

0-10VDC RS422 RS422 0-10VDC

Figure 12-1: Overview weighing systems and weight signals

Brabender Technologie, 2005-06 Page 79 of 112

 Manual Congrav® L/M 3 NA V_._

12.1.3.2 Configuration of the drive controller

At present, the following drive controllers are supported:

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

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

Kxx8: Drive control

Selection of the drive controller that is connected to the Congrav® L/M3.
The possible inputs are displayed to the right of the input field.
FC: The drive controller FC-V_ permits to drive a threephase
current drive.
VC: The drive controller DRS2 permits to drive a vibrating
conveyor.
A: At present, the optional analogue card is not supported.
Therefore, this menu point has no function at present.
no function

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

12.1.3.3 Definition of the signal range for the analogue inputs and outputs

The definition of the signal range for the analogue inputs and outputs

Kxx8: analogue control

Kxx8: actual value output

At present, the optional analogue card is not supported. Therefore,

these menu points have no function at present.
no function

Brabender Technologie, 2005-06 Page 80 of 112

 Manual Congrav® L/M 3 NA V_._

12.1.4 The digital inputs and outputs of LM3-CDIO

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

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

Digital inputs
DI Function
DI1: Installation interlocking, all weigh-feeders are interlocked
DI2: Collective start, all selected components are started
DI3: Collective stop, all selected components are stopped
DI4: Collective reset, all alarms of the selected components are reset.
DI5: Key switch, the inputs on the menu pages with the option I=on
are interlocked
DI6: Batch cut-out with all selected components

For the duration of the corresponding function the digital outputs supply a
24VDC-signal.

Digital outputs
DO Function
DO1: All selected components have started
DO2: Alarm of one selected component
DO3: Reserve
DO4: Start condition of one selected component is missing
DO5: Reserve
DO6: Reserve

Brabender Technologie, 2005-06 Page 81 of 112

 Manual Congrav® L/M 3 NA V_._

12.1.5 The digital inputs and outputs of the analogue card

This menu page permits the configuration of

the digital inputs and outputs of the optional K017 I=off |
Stopped
analogue card. Digital configuration
**-type component 01
DI Interlocking 00 DO Operation 00
DI Start 00 DO Alarm 00
At present, the optional DI Stop 00 DO Refill 00
analogue card is not supported. DI Al. reset 00 DO Alarm report 00

Therefore, this menu point has DI Refill 00 DO Underload 00

no function DI G-discharge 00 DO Control diff+- 00
no function at present. DI Immediate stop00 DO Reserve 00
DI Reserve 00 DO Overload 00

12.1.6 The analogue inputs and outputs of the analogue card

This menu page permits the configuration of K017 I=off |

Stopped
the analogue inputs and outputs of the Analogue configuration
**-type component 01
optional analogue card.
AI Load cell 00
AI Speed 00
At present, the optional AI Control 00

analogue card is not supported. AO

AO
Manip. var.
Act. value
00
00
Therefore, this menu point has
no function
no function at present.

Brabender Technologie, 2005-06 Page 82 of 112

 Manual Congrav® L/M 3 NA V_._

12.2 Configuration of the host computer operation

12.2.1 The host interface on the MSIO-card

The parameter host computer on menu page F100 permits to select the
menu page F120 for the configuration of the host computer operation. If
it has been configured, you quit the menu page by means of the menu
item return.

The menu points bus address and bus mode configure an optional bus
module, they have no function in the software versions up to V1.20.
no function

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

F121: Brabender PT03

Is not supported at present.

F121: Siemens RK512

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

F120: Baud rate

Adjustment of the transmission speed on the host interface.

Brabender Technologie, 2005-06 Page 83 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 13

THE CALIBRATION PROGRAM

Chapter 13 deals with the menu page F600.

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

Brabender Technologie, 2005-06 Page 84 of 112

 Manual Congrav® L/M 3 NA V_._

13 The calibration program

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

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

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

They are divided into two parameter lists.

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

Brabender Technologie, 2005-06 Page 85 of 112

 Manual Congrav® L/M 3 NA V_._

13.1 The feeder parameters

Feeder parameters Value range Standard Input

01 Feeder type N/A 0-2 0
02 Weighing range 0.1 - 10000 kg 60
03 max. batch output 0.001 - 999999 kg 100
04 Underload 0,001 - 100 % 10
05 Overload 1 - 100 % 90
06 Coarse tare 0 - 100 % 0
07 Average values 2 - 32 8
08 Throughput divisor 0.001 - 1000 kg 1
09 Speed minimum 0 - 100 % 2
10 Speed maximum 0.1 - 100 % 99
11 Control difference 0.1 - 100 % 1
12 Alarm cut-out time 1 - 600 s 60
13 Type of interlocking 0-3 0
14 Indication of actual value 1 - 20 s 2
15 Lever factor 0.1 - 10000 1
16 Hopper volume 1 - 100000 l 200
17 Filling level minimum 1 - 100 % 30
18 Filling level maximum 1 - 100 % 60
19 Window/K1/Filter 1 - 10 6
20 Digital speed 0 – 12 kHz 0
21 Maximal refill time 1 - 600 s 60
22 Refill time 0-2 0
23 Stabilisation time 1 - 60 s 15
24 AV-cut-out time 1 - 600 s 60
25 Anti-vibration 0–5
26 Actual value adaptation 0–5 3
27 Weight mode 0-1 0
28 Refill mode 0–1 0
29 Setpoint mode 0–1 0
30 Batch stabilisation time 0 – 600 s
31 Coarse delay 0 – 100 s
32 Switch-over time coarse/fine 0 – 600 s
33 Derivative action correction 0–1 0
34 Switch-over kg/% 0–1 0
35 Fast mode 0–1 0
36 Tolerance mode 0–1 0
37 Feeding tolerance+ 0 – 100 %
38 Feeding tolerance- 0 – 100 %
39 Setpoint factor 0–2 1
40 Feeding time factor 0–1 0.3

Brabender Technologie, 2005-06 Page 86 of 112

 Manual Congrav® L/M 3 NA V_._

13.2 Explanation of the functions of the feeder parameters

13.2.1 CP01 – Feeder type N- and A-type

Number of feeder types (N-, A-type or blocked)
= 0 the feeder is blocked and is not taken into consideration
= 1 the feeder is an N-type (loss-in-weight batching)
= 2 the feeder is an A-type (gain-in-weight batching)

13.2.2 CP02 – Weighing range N- and A-type

The actual weighing range of the weigh-feeder in kg.
The actual weighing range of the weigh-feeder must never be exceeded,
as the load cell risks to be damaged despite the mechanical protections.
The damaged load cell must not be treated as equivalent to a load cell
that is out of function, because it also means a modification of the load Attention
cell characteristics (linearity). This would lead to an inaccurate feeding.
The so-called usable weighing range serves for the processing by the
software.

Definition: the usable weighing range

(act. weighing range x lever factor) - tare ⇔ (CP02 x CP15) - CP06
but if
(hopper contents x bulk density) < (CP02 x CP15)
the usable weighing range is computed as follows:
(hopper contents x bulk density) ⇔ CP16 x bulk density

13.2.3 CP03 - max. batch output N- and A-type

The batch setpoint is limited to < 1.1 x max. batch size.

13.2.4 CP04 – Underload N- and A-type

The input in % is a function of the usable weighing range and defines
the minimum hopper contents.

13.2.5 CP05 - Overload N- and A-type

The input in % is a function of the usable weighing range and defines
the maximum hopper contents.

Brabender Technologie, 2005-06 Page 87 of 112

 Manual Congrav® L/M 3 NA V_._

13.2.6 CP06 – Coarse tare N- and A-type

The input in % is a function of the actual weighing range (CP02). The
tared weight value is subtracted during the computation of the weight.
The parameter has the function to reduce mechanical preloads so far that
an auto-tare operation can be carried out. For this purpose, coarse tare
is determined in such a way that with an empty weigh-feeder a positive
weight value < 5%* weighing range can be displayed after the input of
the coarse tare value.

13.2.7 CP07 - Average values N- and A-type

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

13.2.8 CP08 - Throughput divisor N- and A-type

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

13.2.9 CP09 - Speed minimum N- and A-type

The input in % determines the minimum speed (see 0).

13.2.10 CP10 – Speed maximum N- and A-type

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

Brabender Technologie, 2005-06 Page 88 of 112

 Manual Congrav® L/M 3 NA V_._

13.2.11 CP11 – Control difference N-type

The input in % is a function of the setpoint and defines the allowed max.
control difference. This difference is only computed and monitored in the
component mode "B3 batch". If the calculated control difference exceeds
the max. permitted control difference this will be displayed in the mode
display by "D+" or "D-" and the alarm cut-out delay time (CP12) expires.

13.2.12 CP12 - Alarm cut-out time N-type

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

13.2.13 CP13 - Type of interlocking N- and A-type

Determination of the logic of the digital input “interlocking“ (DI8) and
the digital output “alarm“ (DO2).
0: Interlocking = 24V Alarm output = 24V
1: Interlocking = 0V Alarm output = 24V
2: Interlocking = 24V Alarm output = 0V
3: Interlocking = 0V Alarm output = 0V

13.2.14 CP14 - Indication of actual value N- and A-type

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

13.2.15 CP15 – Lever factor N- and A-type

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

13.2.16 CP16 - Hopper contents N- and A-type

The total hopper volume of the hopper scale or the weigh-feeder.

13.2.17 CP17 - Filling level minimum N-type

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

Brabender Technologie, 2005-06 Page 89 of 112

 Manual Congrav® L/M 3 NA V_._

13.2.18 CP18 – Filling level maximum

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

13.2.19 CP19 - Window/K1/Filter IDL/F, AED N- and A-type

Filter for the IDL/F load cell: 1 = weak .... 9 = strong
The filter setting 6 should be sufficient for most of the applications. As a
general rule, a strong filter setting leads to high interference immunity but
also a high inertia of the signal. Attention
Filter for the AED-module: 1 = weak .... 8 = strong

13.2.20 CP20 – Digital speed N- and A-type

This parameter permits to configure the speed monitoring. Three different
types can be selected.

13.2.20.1 Standard motion monitoring

Input <= 50Hz

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

13.2.20.2 Motion monitoring for the FlexWallplus-feeder

50Hz < input <= 500Hz

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

13.2.20.3 Digital speed reading

Input > 500Hz

Input of the number of pulses with nominal speed (=100%). The alarm
report “speed min.“ will be displayed, if

Brabender Technologie, 2005-06 Page 90 of 112

 Manual Congrav® L/M 3 NA V_._

the number of pulses read falls short of the limit value speed min. for 6s
the pulses read fall short of the dynamic limit value. The dynamic limit
value is a function of the value that has been entered in CP20. The
dynamic limit value is calculated from the integer divisor input/200.
The measuring interval for the dynamic limit value is 500ms. There
will be an alarm cut-out after 5s.

13.2.20.4 Recommended inputs

Standard : 0.010 kHz

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

13.2.21 CP21 - Maximum refill time N-type

Refilling is finished off on reaching filling level max or at latest after
elapse of the maximum refill time. The alarm report (with/without cut-out)
will be activated, if the refilling has not exceeded the filling level filling
level min.

13.2.22 CP22 – Refill time N-type

Defines the time for refilling before or after a batching operation.
= 0 before the start of batch feeding,
= 1 after the start of batch feeding
= 2 without refilling. The batch will be fed until reaching the limit
value “underload“. Then there will be an alarm report or an
alarm cut-out depending on the alarm configuration.

13.2.23 CP23 - Stabilisation time N-type

After the refill period the material stabilisation time starts. After elapse of
the material stabilisation time follows the switch over to the selected
component mode. The feeding time is computed as follows:
Input + 4s

13.2.24 CP24 - AV-cut-out time N-type

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

Brabender Technologie, 2005-06 Page 91 of 112

 Manual Congrav® L/M 3 NA V_._

13.2.25 CP25 – Anti-vibration N-type

The parameter anti-vibration permits to protect the gravimetric feeding
(B3) against external vibrations. The protection against vibrations is
adjusted to the feeding environment, so that it presents a sufficient
protection against external vibrations, however, it must not impede the
feeding operation. If the vibration protection is activated during the
gravimetric feeding operation, feeding will be continued in the volumetric
mode for the duration of the trouble. The constant manipulated variable
for this volumetric feeding operation is computed from the average of the
last 64 manipulated variable values.

13.2.26 CP26 – Actual value adaptation N-type

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

13.2.27 CP27 – Weight mode N- and A-type

The weight monitoring for the switch-over point or the cut-out point
coarse/fine or (setpoint x derivative action point) takes into account
= 0 The unaveraged weight value
= 1 The averaged weight value

13.2.28 CP28 – Refill mode N-type

=0 Refilling operates with the unaveraged weight value
=1 Refilling operates with the averaged weight value

13.2.29 CP29 – Setpoint mode N-type

=0 No setpoint modification during batch feeding
=1 Setpoint modification during batch feeding

13.2.30 CP30 – Batch stabilisation time N- and A-type

The batch stabilisation time permits a safe measuring of the weight
values. High values increase the complete feeding time, whereas too
small values have a negative impact on the feeding accuracy. Set the
batch stabilisation time as long as required and as short as possible.

Brabender Technologie, 2005-06 Page 92 of 112

 Manual Congrav® L/M 3 NA V_._

13.2.31 CP31 – Coarse delay N- and A-type

The coarse delay time runs down after each start of a batch. During this
rest time the system will find the start values for batching.

13.2.32 CP32 - Switch-over time coarse/fine N- and A-type

The rest time during switch-over from coarse feeding to fine feeding. The
rest time permits smooth and trouble-free switch-over of the drive.

13.2.33 CP33 – Derivative action correction N- and A-type

=0 switched off
=1 switched on
The batch feeding stops on reaching the value (setpoint x derivative
action point). The derivative action correction adjusts the derivative action
point automatically to the batch setpoint. After a batch feeding operation
the derivative action check verifies whether the batches have reached the
setpoint range. Should this not be the case, the derivative action
correction will compute the modification of the derivative action point
and memorise it for the next batch. The derivative correction takes app. 4
batch feeding cycles with an unchanged batch setpoint until batch
feeding is within the desired setpoint range.

13.2.34 CP34 – Switch-over kg / % N-type

=0 Input of the filling level parameters (underload etc.) in kg
=1 Input of the filling level parameters in % as a function of CP02

13.2.35 CP35 – Fast mode N- and A-type

= 0 Standard ramp function
= 1 The ramp does not function with time optimisation, it terminates
the batch after it has been fed.

13.2.36 COP36 – Tolerance mode N-type

=0 The tolerance input is a function of the weighing range
=1 The tolerance input is a function of the setpoint

Brabender Technologie, 2005-06 Page 93 of 112

 Manual Congrav® L/M 3 NA V_._

13.2.37 CP37 – Feeding tolerance+ N- and A-type

The feeding tolerance+ defines the “okay“-range for overfeeding as a
function of the tolerance mode (CP36).

13.2.38 CP38 – Feeding tolerance- N- and A-type

The feeding tolerance- defines the “okay“-range for underfeeding as a
function of the tolerance mode (CP36).

13.2.39 CP39 – Setpoint factor N- and A-type

The setpoint factor is an adaptation factor for this new computation in case of a setpoint
modification with mode B2 or A2.
If the setpoint is raised, coarse feeding is calculated as follows:

setpo int_ new

Coarse feeding = coarse feeding × × setpo int factor
setpo int_ old

If the setpoint is decreased, coarse feeding is calculated as follows:

setpo int_ new

Coarse feeding = coarse feeding ×
setpo int_ old × setpo int factor

Standard setpoint factor = 1

13.2.40 CP40 – Feeding time factor N- and A-type

The feeding time factor permits to evaluate the new computation of the
manipulated variable of the start with mode B2 or A2. An input = 0.5
signifies that the difference between the old and the new manipulated
variable of the start is only taken into account up to 50% for a new
computation of the manipulated variable of the start.
=0 deactivates the new computation of the manipulated variable of
the start;
<1 attenuates the influence of the new computation;
=1 does not influence the new computation.
Standard feeding time factor = 0,3

Brabender Technologie, 2005-06 Page 94 of 112

 Manual Congrav® L/M 3 NA V_._

13.3 Additional parameters

Feeder parameters Value range Standard Input

01 P-portion
02 I-portion
03 D-portion
04 Reserve
05 Recipe stabilisation
time
06 Valve closing time
07 Max. discharge time
08 Discharge tolerance
09 Time discharge aid
10 Discharge mode
11 Batch mode
12 Recipe enable
13 Discharge auto 0–1 0
14 Derivation mode 0–1 0
15 Reserve
16 Reserve
17 Reserve
18 Reserve
19 Drive control 2 min. 0 – 100 % 0
20 Drive control 2 max. 0 – 100 % 0

13.3.1 AP01 - 03 PID-controller N-type

These parameters permit to adjust the PID-controller for gravimetric
feeding with B3 mode.

13.3.2 AP05 – Recipe stabilisation time A-type

With an automatic batch repetition (set-batches > 1) the recipe
stabilisation time runs down after the end of batch feeding and before the
start of the new batch feeding operation. The recipe stabilisation time
permits a stabilisation of the system for the weight sensing of the new
batch feeding sequence. The recipe stabilisation time has to be set as
long as required and as short as possible.

13.3.3 AP06 - Valve closing time A-type

In standard, the shut-off device that is mounted to the outlet of the
hopper scale is controlled by the Congrav® via the digital output
“discharge“. The parameter determines the delay time that runs down
after the reset of the digital output “discharge“. The time has to be

Brabender Technologie, 2005-06 Page 95 of 112

 Manual Congrav® L/M 3 NA V_._

adjusted in such a manner that it has no negative impact on the weight

measuring and that the outlet of the hopper scale is closed before the
start of a new batch feeding sequence.

13.3.4 AP07 – Max. discharge time A-type

Defines the max. discharge time for the discharge operation.

13.3.5 AP08 – Discharge tolerance A-type

Determines the max. permissive residual quantity that is allowed to
remain in the hopper scale after the discharge. The input in % is a
function of the actual weighing range (CP02).

13.3.6 AP09 – Time discharge aid A-type

The duration for an external mechanical discharge aid mounted to the
hopper scale. The discharge aid has the function to support the
discharge of the hopper scale. The execution of the discharge aid is a
function of the requirements. The discharge aid is controlled by the At present:
Congrav® via the digital output 23 discharge aid contact. The time that without function!
has been entered determines the period during which the discharge aid
contact is set.

13.3.7 AP10 – Discharge mode A-type

=0 With an input = 0 the discharge functions without any change.
>1 Configuration of the discharge for the operation of a MicroBatch-
Feeder. The input determines the duration between the setting of
the digital output valve open and the start of the reading of the At present:
digital input discharge. without function!
With the use of a Microbatch-Feeder, the bowl of which permits a 360°
rotation, the rotation is controlled via the digital output “valve open“. The
digital output remains set until the digital input “discharge“ receives a
pulse signal of the sensor on the bowl.
In order to avoid functional failures during reading, a delay between the
activation and the start of reading is required.
In standard, the discharge mode = 2s is set.

Brabender Technologie, 2005-06 Page 96 of 112

 Manual Congrav® L/M 3 NA V_._

13.3.8 AP11 – Batch mode A-type

=0 Recipe release is related to the recipe feeding.
=1 Recipe release is related to each batch feeding sequence. I.e.
each batch is only started after the setting of the recipe release.
After the start of the recipe the Congrav® will activate the digital At present:
output “recipe release is expected“ and will only start the batch without function!
sequence if the digital input “recipe release“ is set. After the end
of the batch the digital output “recipe release is expected“ will be
set and the systems waits until the recipe is released.
And so on until the recipe is terminated.

13.3.9 AP12 – Recipe release A-type

=0 The batch is started with the start order.
=1 The batch feeding operation will only be started after the batch
release.

13.3.10 AP13 – Discharge auto N- and A-type

=0 The discharge will be started manually.
=1 The discharge will be started automatically after each batch. (see
chapter 2.3.3, page 26)

13.3.11 AP14 – Derivation mode N- and A-type

=0 The input of the derivative action point in [%]
=1 The input of the derivative action point in [kg or g]

13.3.12 AP19 - Drive control 2 min. N-type

In a feeding system a second serial drive controller can be employed (e.g.
for a separate paddle or agitator drive). The second drive controller
receives a setpoint signal that is proportional to the first drive controller.
The linear curve of the setpoint signal is determined by the two points
drive control 2 min and drive control 2 max. Drive control 2 min is
assigned to a 0%-signal of the 1st drive controller.

13.3.13 AP20 - Drive control 2 max. N-type

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

Brabender Technologie, 2005-06 Page 97 of 112

 Manual Congrav® L/M 3 NA V_._

13.3.14 Notes on AP19 and AP20

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

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

Brabender Technologie, 2005-06 Page 98 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 14

HARDWARE TEST FUNCTIONS

Brabender Technologie, 2005-06 Page 99 of 112

 Manual Congrav® L/M 3 NA V_._

14 Hardware test functions

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

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

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

LM3-CDIO.
Test off
Test: Dig.in. : 0 0 0 0 0 0 0 0 0 0 0 0
Dig.out. : 0 0 0 0 0 0 0 0 0 0 0 0 0
Test printer interface
Switches on/off the test functions. System check Rx Tx Rx Tx

Dig.in.
Displays the status of the digital inputs (1 = activated, 0 = not activated)

Dig.out.
Display of the status of the digital outputs.
With Test=on the digital outputs (1 - 12) can be set or reset. For this, the
cursor has to be set to the corresponding position and the status can be
changed by pushing the CR-key (0=not set, 1=set).
Point 13 permits to set all digital outputs at the same time.

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

Test printer interface:

Output of the string: “Brabender Technologie“

Brabender Technologie, 2005-06 Page 100 of 112

 Manual Congrav® L/M 3 NA V_._

14.2 Kxx3: Status display of I/O-periphery

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

01 Analogue inputs Display = 0 - 100%

Analogue input 1: analogue load cell signal 0 - 10VDC (=100%)
Analogue input 2: analogue speed signal 0 - 10VDC (=100%) without function!

02 Analogue outputs Display = 0 - 100%

Analogue output 1: anal. manip. varia. signal 0 – 20mA (=100%)
Analogue output 2: analogue act. value signal 0 – 20mA (=100%) without function!

03 Digital inputs Display = 0 or 1

The display of the digital inputs shows the software adjustments, the
functions are listed according to their order. 0 means that the
corresponding digital input with the function belonging to is not set, 1
means that it is set. The order is as follows:
DI 1 DI 2 DI 3 DI 4 DI 5 DI 6 DI 7 DI 8

04 Digital outputs Display = 0 or 1

The display of the digital outputs shows the software adjustments, the
functions are listed according to their order. 0 means that the
corresponding digital output with the function belonging to is not set, 1
means that it is set. The order is as follows:
DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8

05 Load cell Display = ppm

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

06 Freq. converter Display= xxx%

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

07 Filter limits Display= xxx%

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

08 Coriolis drive Display= xxxkHz xxx%

At present: without function!

Brabender Technologie, 2005-06 Page 101 of 112

 Manual Congrav® L/M 3 NA V_._

14.3 Kxx4: Test functions and simulation

14.3.1 The simulation mode

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

The simulation permits feeding operation without a feeding system being

connected. The simulation computes a weight value and reads in the
manipulated variable as speed. For this reason a connected feeding
system must not be operated in simulation mode. The weight functions
(refilling, filling levels, etc.) as well as the speed monitoring refer to the
simulated input values.

Commissioning of the simulation:

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

14.3.2 Testing of the inputs/outputs (component)

Kxx4: Test:
Switching on/off test functions.

Kxx4: Ana. output At present: without function!

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

Kxx4: Dig. output

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

Brabender Technologie, 2005-06 Page 102 of 112

 Manual Congrav® L/M 3 NA V_._

CHAPTER 15

GLOSSARY

Brabender Technologie, 2005-06 Page 103 of 112

 Manual Congrav® L/M 3 NA V_._

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

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

Operating unit:
The ISC-component ISC-CM does not offer any possibility for the
parameterisation or the control. A central operating unit is employed for
this purpose, it is connected to the ISC-field bus and permits to address
each ISC-CM with its identnumber. Congrav® L/M3 is employed as
standard operating unit.

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

Digital inputs/outputs (24VDC)

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

Brabender Technologie, 2005-06 Page 104 of 112

 Manual Congrav® L/M 3 NA V_._

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

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

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

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

Feed rate curve

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

Weigh-feeder:
General designation of a feeding system in ISC-design. Please observe
that the software in the ISC-CM is a function of the type of weigh-feeder.

ED60
Digital two-wire load cell with integrated filter technology. The connection
to the Congrav® is provided via the corresponding processor module.

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

Frequency converter

Brabender Technologie, 2005-06 Page 105 of 112

 Manual Congrav® L/M 3 NA V_._

Drive controller for threephase current drives. The frequency converter

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

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

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

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

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

IDL/F:
Digital one-wire load cell with integrated filter technology. The
connection to the Congrav® is provided via the corresponding processor
module.

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

ISC-drive controller:

Brabender Technologie, 2005-06 Page 106 of 112

 Manual Congrav® L/M 3 NA V_._

The weigh-feeder is equipped with a drive for the feeding device.

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

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

ISC- VC:
Drive controller for a vibrating conveyor.

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

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

Software:
The software determines the functions of the individual hardware
components and of the complete ISC-system. The software is employed in
the ISC-CM-units and in the operating unit Congrav® L/M3. A
compatible software for the ISC-CM and the Congrav® L/M3 is required
for a correct operation of the ISC-system.

Manipulated variable:
Control signal from the ISC-CM for the drive controller ISC-FC or ISC-
VC. The manipulated variable sets the speed or the vibration amplitude of
the drive motor to the drive controller. A serial interface or an analogue
output (only possible with ISC-CM-A) permit to transmit the manipulated
variable.

Transport catches:
Transport catches permit to lock in position the mobile part of a weighing
system to a fixed point. They protect the load cell during transports and

Brabender Technologie, 2005-06 Page 107 of 112

 Manual Congrav® L/M 3 NA V_._

maintenance or conversion work against an overloading of the load cell.

Especially, they protect the load cell against rotational or torsional forces.

Overload protection screw:

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

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

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

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

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

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

Brabender Technologie, 2005-06 Page 108 of 112

 Manual Congrav® L/M 3 NA V_._

APPENDIX

Brabender Technologie, 2005-06 Page 109 of 112

 Manual Congrav® L/M 3 NA V_._

16 Appendix
16.1 Technical data

Voltage range 85 - 250 VAC Congrav L/M3

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

Logic positive Digital inputs

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

Output type Transistor Digital outputs

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

Input voltage 24 VDC Frequency input

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

Input voltage 0 - 10VDC Analogue inputs

Resolution 14 Bit Analogue card
Input resistance ~20MΩ
Number 4 at present not supported

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

Resolution 12 Bit Analogue card
max. burden 500 Ω
Number 4 at present not supported

Brabender Technologie, 2005-06 Page 110 of 112

 Manual Congrav® L/M 3 NA V_._

Internal cycle time 100ms Software

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

16.2 Electromagnetic compatibility

Radio interference Conforms to EN 50081-1

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

16.3 Spare parts list

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

Brabender Technologie, 2005-06 Page 111 of 112

 Manual Congrav® L/M 3 NA V_._

16.4 List of the possible mode displays

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

Mode Meaning
CF Coarse feeding
FF Fine feeding
RF Refilling
MS Stabilisation time
BS Batch stabilisation time
DI Discharge
CE Batch end
TC Tolerance check
B1(A1) The selected batch mode
B2(A2)
B3
DI Discharge

Mode Meaning
AV Anti-vibration protection of the feeder has been activated.
S-, S+ Minimum or maximum speed has been fallen short of or
exceeded.
UN, Hopper contents inferior to filling level limit value underload or
OV superior to filling level limit value overload.
FT Feeding time error
T+ Tolerance error, weight > tolerance+
WS The serial load cell signal cannot be received.
ST A start condition is not fulfilled and the feeding operation
cannot be started. Exception: “Weight < Min”.

Brabender Technologie, 2005-06 Page 112 of 112