OPERATING INSTRUCTIONS Digi-Drive Controller for DC Motors
REM
Alarm
%A % CAL rpm
S P
DISP DI SPLA LAY
LOCAL
REMOTE
HI
LO
RUN
STOP
Digi Di gi Dr Driv ive e
Read this manual prior to operating or servicing the equipment. This manual contains all safety labels and warnings.
0890019601-EN Rev. 1.0.1
Service
If you need assistance, please call your local service center or: K-TRON (Switzerland)
Tel. 0041 (0) 62 / 885 71 71
Lenzhardweg 43/45
Fax 0041 (0) 62 / 885 71 80
CH-5702 Niederlenz K-TRON (U.S.)
Tel. 001 (0) 856 / 589 90 83
Rt 55 and Rt 553
Fax 001 (0) 856 / 589 56 64
Pitman, NJ 08071 Web:
http://www.ktron.com
Before you c all... all...
Do you have alarm displays? Can you eliminate their causes?
Have you modified part of the system, product or operating mode?
Have you tried to eliminate the fault in accordance with the operating instructions?
Note down the 6 digit project or job number. This can be found at the machine or in the project manual.
- Example: 400545 Using the manual:
This arrow identifies an individual action.
1. Numbers Numbers identify identify a sequenc sequence e of actions actions which which have to to be executed executed step-by-step.
This symbol identifies a general safety note
Reference to another manual. Important information. This symbol indicates that tools are required for the following task. Specifies where information or a situation must be checked.
Docu-No.: 0890019601-EN Date: 2009/May/26 Original: 0890019601-EN
K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part of operating personnel. Further, reference is made to the purchase order, acceptance or other document that contains the express K-Tron disclaimer of warranties for a statement of the provisions limiting or disclaiming certain warranties with respect to the Company's equipment. equipment. Except as otherwise expressly provided provided by K-Tron in any such document, K-TRON MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NOR ANY OTHER WARRANTY, EXPRESS OR IMPLIED, WITH RESPECT TO THE EQUIPMENT.” If an error or ommission is found, please contact:
[email protected].
Inhaltsverzeichnis 1
Safety Safety notes ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ....5 .5
1.1 1.1.1 1.1.2 1.1.3 1.1.4
Safety Safety symbols symbols definitions definitions ........ ............ ........ ........ ........ ........ ......... ......... ........ ........ ........5 ....5 Electrical Electrical Hazard Icon ........ ............. ......... ........ ......... ......... ........ ......... ......... ........ ........ ........6 ....6 Ground Icon ........................ ..................................... .......................... .......................... ....................6 .......6 No Hands Icon ........................ ..................................... .......................... .......................... ................6 ...6 Power Icon ........................ .................................... ......................... .......................... .......................6 ..........6
1.2
Respon Responsib sibili ilitie ties s of the owner owner ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....7 ..7
1.3
Proper use ......... ............. ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... .....7 .7
1.4
Organi Organizat zation ional al measur measures es ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....7 ..7
1.5
Safety-con Safety-consciou scious s work ........ ............. ......... ........ ........ ........ ......... ......... ........ ........ ........ ........8 ....8
1.6
Safety Safety devices devices ......... ............. ........ ........ ........ ......... ......... ........ ........ ......... ......... ........ ........ ........ ........8 ....8
1.7
High Voltage Voltage ........ ............ ........ ......... ......... ........ ......... ......... ........ ........ ........ ........ ........ ........ ........ ........9 ....9
1.8
Additional Additional equipment equipment ........ ............ ........ ........ ........ ........ ........ ........ ......... ......... ........ ........ ........9 ....9
1.9
Custom Customer er servic service e and repair repairs s ...... ......... ...... ...... ..... ..... ...... ...... ..... ..... ...... ...... ...... ......9 ...9
1.10
Shut-down Shut-down procedure procedure .......... .............. ........ ........ ........ ........ ........ ......... ......... ........ ........ .........9 .....9
2
Featu Features, res, Assembly, Assembly, Function Function .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ...1 .10 0
2.1 Features Features ........ ............ ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ........10 ...10 2.1.1 Operating Operating mode ......... .............. ......... ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ......10 ..10 2.2 Assembly Assembly Digi-Drive Digi-Drive ........ ............ ........ ........ ........ ........ ........ ........ ......... ......... ........ ........ .......11 ...11 2.2.1 Operating part ......................... ...................................... .......................... ........................ ..............11 ...11 2.3
Intern Internal al compo componen nents ts of the DigiDigi-Dri Drive ve ....... .......... ...... ...... ...... ...... ...... ...... ....13 .13
2.4
Method Method of operat operation ion of the Digi-D Digi-Driv rive e ...... ......... ...... ...... ..... ..... ...... ...... ......1 ...13 3
3
Technical Technical Data Data .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ...14 .14
3.1
Genera Generall Techni Technical cal data ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ......1 ...14 4
3.2 3.2.1 3.2.2 3.2.3
Cable length ........ ............ ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......15 ..15 Power supply supply 230 VAC ........ ............ ........ ........ ........ ........ ........ ......... ......... ........ ........ ......15 ..15 Power supply supply 115 VAC ........ ............ ........ ........ ........ ........ ........ ......... ......... ........ ........ ......15 ..15 Speed feedback feedback ........ ............ ........ ........ ........ ........ ........ ......... ......... ........ ........ ........ ......... .........16 ....16
3.3 Techni Technical cal data data of optio option n board board ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....16 .16 3.3.1 Cable connections connections ........ ............. ......... ........ ........ ......... ......... ........ ........ ........ ......... ......... ........17 ....17 4
Installation ...... ......... ...... ..... ..... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....18 ..18
4.1 Unpack Unpacking ing and assemb assembly ly ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ......1 ...18 8 4.1.1 Mounting Mounting onto the K2M feeder feeder ........ ............ ........ ........ ......... ......... ........ ........ .......19 ...19 4.1.2 Assembly Assembly in control control cabinet cabinet ........ ............ ........ ........ ......... ......... ........ ......... ......... ......20 ..20 4.2
Connec Connectin ting g the Digi-Dri Digi-Drive ve ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....21 ..21
5
Operation ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ......2 ...23 3
5.1 The level levels s of the Digi-D Digi-Driv rive e ...... ......... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....23 .23 5.1.1 Operating mode ........................... ....................................... ......................... .......................23 ..........23
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 3
5.1.2 Programmin Programming g mode ......... ............. ......... ......... ........ ........ ......... .......... ......... ........ ........ ........24 ....24 5.2
Quick Quick start ........ ............ ........ ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ...... 25
5.3 5.3.1 5.3.2 5.3.3
Progra Programmi mming ng and calib calibrat ration ion ....... .......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 26 Introducti Introduction on to programming: programming: ........ ............ ........ ........ ......... ......... ........ ........ .........26 .....26 Programmin Programming g variables variables ......... .............. ......... ........ ........ ........ ......... ......... ........ ........ ........27 ....27 Calibratio Calibration n of the Digi-Drive Digi-Drive ........ ............ ......... ......... ........ ........ ........ ......... ......... ...... .. 34
5.4 5.4 5.4.1 5.4.2 5.4.3 5.4.4
Adju Adjust stme ment nt of the the set setpo poin intt val value ue on the the option board .......................... ....................................... .......................... ........................ ................ ..... 35 Set reference voltage ............ ................. ......... ........ ........ ........ ......... ......... ........ ........ ........ ....35 35 Setpoint Setpoint value value for voltage voltage ......... ............. ........ ........ ......... ......... ........ ........ ........ .........35 .....35 Setpoint Setpoint value for current ........... ............... ........ ........ ........ ......... ......... ........ ........ ........36 ....36 Setpoint Setpoint value value for frequency frequency ........ ............. ......... ........ ......... ......... ........ ........ ........ ...... 37
6
What What to do when.. when...? .? .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....38 ..38
6.1 Genera Generall infor informat mation ion on fault fault detect detection ion ...... ......... ...... ..... ..... ...... ...... ...... ..... .. 38 6.1.1 Measuring Measuring motor current ............. ................. ........ ........ ........ ......... ......... ........ ........ ....... ... 38 6.1.2 Measure Measure and and set speed frequency frequency signal signal ......... ............. ......... ......... ...... 38
Page 4
6.2
Troublesho Troubleshooting oting ........ ............. ......... ........ ........ ........ ......... ......... ........ ........ ......... .......... ......... ...... 39
6.3
Alarm Alarm messag messages es ...... ......... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 40
7
Maintena Maintenance nce .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....42 ..42
7.1
Cleaning Cleaning ......... ............. ........ ......... ......... ........ ......... ......... ........ ......... ......... ........ ........ ......... ......... ........ ...... 42
7.2
Preven Preventiv tive e mainten maintenanc ance e work ...... ......... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ......42 ...42
8
Appendix .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 43
8.1
Connection diagrams ......................... ...................................... ......................... ................ .... 43
Docu-No.: 0890019601-EN Rev. 1.0.1
Safety notes Safety symbols definitions
1
1 1.1
Safety notes
Installation, commissioning and programming of the specified equipment should only be undertaken by qualified personnel.
1.1
VORSICHT
Safety sy mb ol s d efi nit io ns
The safety alert symbol is used to alert to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in property damage.
CAUTION with safety alert indicates a potentially hazardous situation which, if not avoided, could lead to light bodily injuries.
WARNING indicates a potentially hazardous situation which, if not avoided, could lead to heavy bodily injury or to death.
DANGER indicates a extremely hazardous situation which, if not avoided, could lead to heavy bodily injury or to death.
Important information to explosion protection.
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 5
1 1.1
Safety notes Safety symbols definitions
1.1.1
El ec tr ic al Hazar d Ic on
This sign indicates an electrical hazard. It is located on covers and doors. Only qualified personnel are allowed to remove these covers or open the doors. 1.1.2
Ground Icon
This sign indicates that a ground/PE connection is required.
1.1.3
No Hands Icon
Do not place hands or other body parts into moving parts or machine.
1.1.4
Power Icon
Power off and disconnect air supply before working on the equipment.
Page 6
Docu-No.: 0890019601-EN Rev. 1.0.1
Safety notes Responsibilities of the owner
1.2
Res po ns ib il it ies o f t he o wn er
Ensure that only qualified and trained personnel work with the equipment.
Establish personnel maintenance.
Ensure that the personnel has read and understood the operating instructions to all installation components, particularly this chapter "Safety notes".
Strictly follow the operation and maintenance instructions.
The plant owner must replace immediately damaged or missing components.
The plant owner is responsible for compliance with legally prescribed accident prevention and safety regulations.
1.3
responsibilities
for
operation
and
Proper use
Only operate the equipment in accordance with the specified technical data. Any modifications and changes on safety devices are prohibited Do not use the equipment in a manner not intended by the manufacturer.
1.4
Docu-No.: 0890019601-EN Rev. 1.0.1
1 1.2
Or gan izat io nal m eas ur es
Always keep the operating instructions near the equipment, within easy reach. Ensure that they are always complete and legible.
Observe the safety notes for the connected equipment.
In addition to the operating instructions, always comply with generally prescribed safety regulations governing accident prevention and environmental safety.
Page 7
1 1.5
Safety notes Safety-conscious work
1.5
Safety-conscious w ork
Read the operating instructions, in particular these safety notes, and follow these instructions.
Ensure that only authorized personnel enter the working and danger area of the equipment.
Any changes (including changes in the operational behavior) which affect safety must be immediately reported to the responsible member of the staff.
Always keep safety in mind while working.
Before working on the equipment always switch the equipment off at the main power switch.
1.6
Safety devices
Operating the equipment without safety devices:
– is dangerous for the health and life of the operator or third persons – can damage the equipment or other material Never alter the mechanical safety devices or the electrical control system for the safety devices. Increased risk of accident.
Page 8
Only operate the equipment if all safety devices are installed and fully functional.
Check that all safety devices operate properly every day.
Never open or remove covers or hoods while the equipment is in operation.
Never operate the equipment when the housing is open.
Do not modify the electrical safety devices, for example fuses. Increased risk of accident.
Only use the specified fuse types when replacing fuses.
Replace damaged cable joints and connections immediately.
Docu-No.: 0890019601-EN Rev. 1.0.1
Safety notes High Voltage
1.7
1 1.7
High Voltage
Only qualified electricians may work on the electrical equipment of the Digi-Drive.
Switch of the power, wait 3 minutes before opening the Digi-Drive before:
– disassembly, maintenance and repair work. High voltage occurs at the motor connections.
After switching off the main power supply there are still some internal electrical components of the motor drive carrying high voltage which discharges slowly. Protect electrical parts against humidity.
1.8
Modifications to the equipment are prohibited.
The operator is responsible for complying with all safety regulations related to operation with any additional equipment, e.g. refilling units.
1.9
Cu st om er ser vi ce an d r epai rs
Have repairs to the feeder carried out by - by the responsible K-Tron customer service (customer service address is found on the inside cover) – or – - by specialized personnel trained by K-Tron. Only use original K-Tron parts.
1.10
Docu-No.: 0890019601-EN Rev. 1.0.1
Additional equipment
Shut-down procedure
The operator is responsible for the proper removal and disposal of the equipment from service.
Page 9
2 2.1
Features, Assembly, Function Features
2
Features, Assembly, Function
2.1
Features
The Digi-Drive is a DC motor controller. The setpoint input can be made using: • Keyboard of the device • Analogue input • Frequency input 2.1.1
Oper at in g m od e
The following operating modes are available with the Digi-Drive: Local mode
The input of the speed setpoint value, hereafter called setpoint value, is made on the keyboard of the Digi-Drive. The input and display of the setpoint value can optionally be made in • rpm • % of maximum speed • a user-defined unit of measurement (kg/h, g/min, lb/h, etc.) External-direct mode
The input of the setpoint value takes place as a frequency or analogue signal. The display of the setpoint value can optionally be made in • rpm • % of maximum speed • a user-defined unit of measurement (kg/h, g/min, lb/h, etc.) In this setting, it is not possible to change the setpoint value of the Digi-Drive using the keyboard. External-ratio mode
The setpoint is transferred to the frequency or analogue input of the Digi-Drive as a ratio to a master setpoint value signal or to process variable. The desired percentage ratio is input on the keyboard with a value range from 0.0 to 100 %. In the operating configurations • External-direct mode • External-ratio mode see Technical data capter 3.
Page 10
Docu-No.: 0890019601-EN Rev. 1.0.1
Features, Assembly, Function Assembly Digi-Drive
2.2
2 2.2
Assembly Digi-Drive
The housing of the Digi-Drive contains the operating part (display and keyboard), controller and power part. 2.2.1
Oper at in g part
LEDs on the keys
Fig. 2.1
LOCAL
HI
REMOTE
LO
LOCAL:
Setpoint value input on the Digi-Drive
REMOTE:
External setpoint value input using external controller
HI:
Speed stage high active (only with double-reduction K2M feeder)
LO:
Speed stage low active (with single and double-reduction K2M feeder)
RUN:
Motor in operation
RUN
LEDs on the keys
Display
The messages which appear on the display have the following meanings: REM:
External direct mode or external ratio mode Setpoint value input on external controller.
Al arm
flashes or lights up when faults occur (see capter 6).
REM
Alarm
%A/W:
Percentage of the present motor power measured via current intensity or Watt (see P23).
%
Percentage display of the actual or setpoint value.
CAL:
Display of the actual or setpoint value in a user-defined unit.
rpm:
Display of the actual or setpoint value in rpm.
SP:
Display of the setpoint value;
%A
S P
% CAL rpm
additional setpoint value input possible in "local mode". P0 - P24
Docu-No.: 0890019601-EN Rev. 1.0.1
Programming level and displayed programming variables.
Page 11
2 2.2
Features, Assembly, Function Assembly Digi-Drive
Changing the DIS PLAY
• Values of the process DISPLAY
or • Programming variables (P0 - P24).
LOCAL
HI
REMOTE
LO
RUN
STOP
Fig. 2.2 Keys on the Digi-Drive
• Raising the setpoint value. • In programming mode: numerical input of programming variables.
• Reducing the setpoint value. • In programming mode: numerical input of programming variables.
Held down at the same time as “high“ or „deep“ rapid increase or decrease of setpoint value. Pressing „DISPLAY“ key: display of the programmed value of a programming variable.
Start the motor. Key green: Motor in operation. RUN
Stop the motor. STOP
Shift key for the input of the setpoint value on the LOCAL
• Digi-Drive (LOCAL) or
REMOTE
• external controller (REMOTE).
At ten ti on : Using the following key for HI/LO switching with a single reduction gear can damage the gearbox. Therefore set the program variable P3 to 2. Check the screw rotation after this programming. HI
Shift key for the speed stage for double-reduction feeders.
LO
Page 12
Docu-No.: 0890019601-EN Rev. 1.0.1
Features, Assembly, Function Internal components of the Digi-Drive
2.3
2 2.3
Internal components of the Digi-Drive
Warning! High voltage! Danger! During operation and immediately after shut-down, the capacitors and, therefore, the conducting parts of the Digi-Drive are under high voltage:
Disconnect the Digi-Drive from the power supply.
Switch of the power, wait 3 minutes before opening the Digi-Drive.
Open the Digi-Drive only: • For install cables. • For maintenance and repair work. • If the internal programming switch is to be operated. 1. Cable terminal block TB2 2. Cable terminal block TB 1 Supply and Motor
1
3
2
3. Option board 4. Jumper 5. Potentiometer 6. Internal programming switch 1 1
T
B
4
0
2
7. Terminal block X 1 8. Power part
T
B
1
9
9. Fuses (mounted on the rear)
8 1
5
8
Fig. 2.3
2.4
7
6
Internal components of the Digi-Drive
Method of operation of the Digi-Drive
The setpoint value of the feeder is input in a user-defined unit of measurement on the keyboard of the Digi-Drive or via an external controller. During operation, the feed motor speed is recorded by a speed pickup and transmitted to the Digi-Drive. The Digi-Drive compares the setpoint and actual values, and controls the speed of the feed motor accordingly.
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 13
3 3.1
Technical Data General Technical data
3
Technical Data
3.1
Gen er al Tec hn ic al d ata
Manufacturer
K-Tron (Schweiz) AG
Name
Digi-Drive
Control precision
±1 rpm over 5 S at 70 - 2000 rpm ±5 rpm over 5 S at > 70 rpm
Housing
NEMA 4/IP65
Front panel
Enclosed diaphragm with arched keys on the keyboard
Display
4digit LED-display, 0.56“ high
Operating temperature range
4 - 50°C (40 - 122°F)
Al arm s
Motor overload, flow interruption
Power supp ly
115 VAC ± 10%, 50/60 Hz or 230 VAC -10% /+ 15%, 50/60 Hz selectable 3000 VA bei 230 V AC
Max. power inpu t
1500 VA bei 115 V AC 400/800W
Max. power output
800/1600W Efficiency
85 - 95%
Inputs
Frequency input (external setpoint)
V
5 VDC square-wave voltage
5
ratio of capacity level 1:1 adjustable from 20 Hz to 25 kHZ
0
∆t1
∆t2
t
Speed pick-up: 5 VDC square-wave voltage from 0 Hz to 7.2 kHZ
∆t1 = ∆t2
Outputs
Page 14
250 VAC, 5 A or 28 VDC, 5 A
Docu-No.: 0890019601-EN Rev. 1.0.1
Technical Data Cable length
Al arm rel ay
3 3.2
• Relay de-energized ∅ = contacts 1 and 2 closed, contacts 1 and 3 open • Relay energized ∅ = contacts 1 and 2 open, contacts 1 and 3 closed. • Contacts 4 and 5 open: Motor is not enabled
Enabling signal
• Contact 4 and 5 closed: Motor is enabled 160 Vp, square-wave PWM
Motor output
0.... 99.6 % at 115VAC (120 V DC) 322 Vp, Square-wave PWM 0...99.6 % at 230 VAC (240 VDC) Fuses
10 A 1/4“ X 1-1/4“
Recommended prefuse
16 A
3.2
Cable length
3.2.1
Po wer su pp ly 230 VA C
Motor
U Anker
I Anker
Cablelength 1.5mm“
Cablelength 2.5mm2
Lenze 55W
180V
0.46A
300m
300m
Lenze 70W
180V
0.7A
300m
300m
Bison 95/98W
180-200V
0.6A/0.75A
300m
300m
Lenze 250W
180V
1.7A
300m
300m
Saramel 370W
180V
2.6A
257m
300m
Stephan 370W
180V
2.4A
278m
300m
Baldor 450W
200V
2.5A
267m
300m
ABB 780W
180V
4.1a
162m
272m
Baldor 1000W
200V
5.6A
118m
198m
Baldor 2000/1600W
200V
11.5A/9.2A
56/71m
95/120m
3.2.2
Po wer su pp ly 115 VA C
Motor
U Anker
I Anker
Cable length 1.5mm“
Cable length 2.5mm2
Lenze 70W
90V
1.25A
264m
300m
Lenze 250W
100V
3.5A
93m
156m
Stephan 370W
90V
4.9A
65m
111m
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 15
3 3.3
Technical Data Technical data of option board
Motor
U Anker
I Anker
Cable length 1.5mm“
Cable length 2.5mm2
Baldor 450W
100V
5.4A
59m
100m
Grossenbacher 700W
90V
9.5A
33m
56m
3.2.3
Speed f eed bac k
Pick-Up/ Encoder
Type
Cables length without Line-Driver
Cables length with Line-Driver
Jaquet
FTG 1088.01Ex
30m
300m
W+S (Lenze-Motor 55W)
HGI 490 063600
30m
300m
HP (Bison-Motor 95/98W)
HDES 5600 C06
30m
300m
* The Line driver is located in the terminal box on the feeder. * The Line driver convert asymmetric signals in symmetric signals.
3.3
An alo g i np ut
Tec hn ic al d ata o f o pt io n bo ar d
0 - 10 VDC 4-20 mA selectable by jumper
Bit-inputs
Start/Stop* (logic „zero“ = start and setpoint must be > 1% ).
* Raising/falling edge triggered inputs.
Alarm shut-down (logic „zero“ = Stop)
Pull down to Com. Proc. for falling edge
Local/Remote* (only active if P4 is 7/8) Hi/Lo-Switch* (logic „zero“ = see P3) Max. voltage 12 VDC
Bit-outputs
Alarm (logic „zero“ = Alarm)
(open collector)
Feeder runs (logic „zero“ = running) Hi/Lo-Switch (logic „zero“ = Hi) Max. voltage 24 VDC Imax. 100 mA Min. voltage 1.6 VDC for logic high RL at12 VDC = 150 ohms RL at 24 VDC = 300 ohms
Frequency in put
Page 16
0 - 20 kHZ, 5 V
Docu-No.: 0890019601-EN Rev. 1.0.1
Technical Data Technical data of option board
3.3.1
3 3.3
Cab le c on nec ti on s
Terminal block TB1
1 = earth
5 = rotor + (A)
2 = AC to L (L1)* see chapter 4.2
6 = rotor - (B)
3 = AC to N (L2)*
7 = Motor field+ (J)
4 = earth
8 = Motor field - (K)
* Attention Voltage! - see capter 4.2 - Voltage selection Terminal block TB2
1 = Alarm relay ground
6 = setpoint value input (freq.)
2 = Alarm ralay (N/closed)
7 = setpoint value ground
3 = Alarm ralay (N/Open)
8 = 5 VDC
4 = enabling input
9 = speed signal
5 = enabling ground
10 = speed pick-up ground
Terminal block X1
1 = 4 - 20 mA+
11 = not used
2 = 4 - 20 mA-
12 = ground
3 = 0 - 10 V+
13 = not used
4 = 0 - 10 V-
14 = start/stop (edge triggered input)
5 = 0 - 20 kHz, 5 V
15 = alarm shut-down
6 = ground
16 = Hi/Lo-Toggle (edge triggered input)
7 = 10 VDC reference voltage potentiometer 17 = Local/Remote (edge triggered input) 8 = feeder runs (open collector)
18 = ground
9 = alarm (open collector)
19 = +5 VDC
10 = Hi/Lo-Anzeige (open collector
20 = +5 VDC
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 17
4 4.1
Installation Unpacking and assembly
4
Installation
Ensure that the Digi-Drive is connected and put into operation only ba authorized personnel.
The Digi Drive includes not a disconnecting switch. Ensure that you include this disconnecting or an emergency shut-down switch according the EU machine guide line.
Am bi ent co nd it io ns
Only use explosion-proof feeders in hazardous areas.
Only install the feeder in an environment conforming to the technical data (see Section 3) and the safety notes (see Section 1).
The Digi-Drive can be mounted: • directly to a volumetric feeder or • inside a control cabinet.
4.1
VORSICHT
Un pack in g an d as sem bl y
In order to avoid damage, unpack the Digi-Drive carefully.
1. Remove the feeder carefully from the packaging. 2. Check whether the supplied goods are complete and check them for transport damage. 3. Report any damage immediately to K-Tron.
Page 18
Docu-No.: 0890019601-EN Rev. 1.0.1
Installation Unpacking and assembly
4.1.1
1
4 4.1
Mounting onto the K2M feeder
2
3 4
1. Mount the Digi-Drive onto the fixing support (2) using the fastening screws (3). 2. Mount the fixing support (2) onto the feeder with the two anchor bolts (1). 3. Fix the fixing support (2) with setting screw (4).
Fig. 4.1
Mounting K2M
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 19
4 4.1
Installation Unpacking and assembly
4.1.2
A ss em bl y i n c on tr ol cab in et
Note: Observe the fitted dimensions during assembly. 122 mm
R
) a x M ( m m 3
200 mm 295 mm
Fig. 4.2
Fig. 4.3
Digi-Drive 400/800W
Digi-Drive 800/1600W
Procedure for Digi-Drive 400/800 W
1
1. Slide the Digi-Drive (1) from the front into the recess.Tighten the screws (2) for the front panel.
2
2. Slide the electrical duct rails (3) into the groove of the Digi-Drive housing from the rear.
3
Fig. 4.4
Page 20
In the control cabinet
Docu-No.: 0890019601-EN Rev. 1.0.1
Installation Connecting the Digi-Drive
4.2
4 4.2
Co nn ec ti ng t he Di gi -Dr iv e
Improper connection of the feeder can cause danger to life through electric shock.
The feeder may only be connected by qua lified electricians.
Observe the local regulations.
1. Connect the feeder in accordance with the electrical wiring diagram. 2. Ground the feeder carefully. Connect the ground connection to a low-impedance equipotential bonding (≤ 0.1 Ω), see the grounding information on the feeder.
Provide a lockable main switch to disconnect the main power supply from the feeder.
Carefully follow all wiring and shielding procedures as indicated on the provided wiring diagrams and operating instructions of the controls.
It is necessary to make the following connections: Before connection check the setting for the power supply on the power board. 115 VAC
T1
230 VAC
• Connection for the motor drive and the speed pick-up between the Digi-Drive and the feeder. • If necessary, input/output connections for the alarm relay, for the enabling signal and/or for the input of the setpoint value via the external controller.
Fig. 4.5
Voltage selector
Power supply. Attention: Check if the power board is auto selectable (relays instead of jumper/switch, Fig. 4.5) or plugable/switchable.
Cables are not included in the items supplied. Please refer to the table below and on chapter 3.2 for the recommended cable sizes and maximum lengths. Cables for feeder motor and pick-up must be shielded.
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 21
4 4.2
Installation Connecting the Digi-Drive
Function
DIN cable size
Power supply
according to regulation applicable in your country max. 2.5mm2
Feeder motor max. 2.5 mm2 (shielded) cable length see table 3.2 input/output
0.5 mm2, max. 30m (shielded)
Speed pick-up 0.5mm2, max. 150m shielded, cable length see table 3.2.
TB1
1. Open the front panel (2). Loosen the Phillips screws, but do not remove them.
TB2
4
2. Remove the cable to the display (1). 3. Remove the assembly screws on the power part (4) and pull the power part (3) out of the housing.
3
4. Connect the Digi-Drive according to the connecting diagram. 2 1 Fig. 4.6
Components
Pull the cables in through the bottom of the Digi-Drive. 1. Input/output alarm relays, enabling (M20 / PG11, 7-12mm). 2. Bit-Input (M20 / PG11, 9-12mm). 3. Analog input of external controller (M20 / PG 11/7, 5-7mm). 4. Feeder motor (M20 / PG 13.5/9, 7-10mm). 1
2
3
5. Power supply (M20 / PG 13.5/9, 7-10mm).
4
5
6
6. Speed pick-up (M20 / PG 11/9, 7-10mm).
Fig. 4.7 Assignment of holes to cables
2
Cable length from the cable grip (1) until the relevant terminal block (2) is 23 cm. Kabellänge: 23 cm
Fig. 4.8
Page 22
1
Cable length
Docu-No.: 0890019601-EN Rev. 1.0.1
Operation The levels of the Digi-Drive
5
5 5.1
Operation
When entering the setpoint using an external analogue controller or frequency controller or an external potentiometer, adjust the DigiDrive before operation (see capter 5.4).
5.1
Th e l ev el s o f t he Di gi -Dr iv e
Work is done on two levels in the Digi-Drive. At the operation level, the process characteristic values for monitoring the system are shown by pressing the
DISPLAY
key:
• actual value in rpm or a user-defined unit • setpoint value in rpm or user-defined unit • actual value in % of maximum speed • current motor power in % or Watt The programming level is used to configure the Digi-Drive. A programming number P0 to P24 is assigned to each control characteristic value. 5.1.1
Oper at in g m ode
Ac tu al v alu e di sp lay : REM
Alarm
%A % CAL rpm
S P
REM
Alarm
%A % CAL rpm
S P
REM S P
Alarm
%A % CAL rpm
Docu-No.: 0890019601-EN Rev. 1.0.1
rpm
% display
user-defined unit
Page 23
5 5.1
Operation The levels of the Digi-Drive
Setpoi nt value display Local REM
rpm
REM
%
user-defined unit
S P
REM
Fig. 5.1
REM
Alarm
Fig. 5.2
%A
S P
S P
%A
Alarm
Alarm
REM % CAL rpm
S P
% CAL rpm
S P
% CAL rpm
S P
%A
REM
%A
REM
Alarm
Alarm
Alarm
external-ratio
%A
REM % CAL rpm
S P
% CAL rpm
S P
% CAL rpm
S P
%A
%A % CAL rpm
REM
%A
Alarm
Alarm
%A % CAL rpm
REM
Alarm
%A % CAL rpm
Matrix of setpoint value displays
Example: external direct mode, setpoint value display in %.
% CAL rpm
S P
Alarm
external-direct
Example of setpoint value display
5.1.2
Pr og ram min g m od e
The change from operating mode to programming mode takes place by REM
Alarm
%A % CAL rpm
S P
REM S P
Fig. 5.3
Alarm
%A % CAL rpm
pressing
DISPLAY
and the
.keys at the same time.
After approx. 2 sec., the programed value of the previously displayed programming variables is displayed.
Programming mode
Access to programming mode can be restored with the internal programming switch. This internal programming switch is located on the rear of the swivel front cover .
Page 24
Docu-No.: 0890019601-EN Rev. 1.0.1
Operation Quick start
5.2
5 5.2
Quick start
The Digi-Drive is factory set to standard values. For this reason, the Digi-Drive is ready for operation after assembly and connection. If you wish to change the standard values, please refer to the sections "Programming and Calibration". You can start the Digi-Drive as follows after entering a setpoint value in local mode.
REM S P
Alarm
Press the
Change the setpoint value for the required speed with
DISPLAY
key, until the following display appears:
%A % CAL rpm
key ant the
or
.key.
Start feeding with the
key. RUN
Fig. 5.4
Setpoint value display in local mode
K2 M feeder with du al-reduction gear
The standard setting is "low speed". Press "Stop" to check and select "high speed". Restart feeding. The screw must turn noticeably faster with the same setpoint value. If this is not the case, change over motor cables 5 and 6 on the terminal block TB1. Warning! High voltage! Danger! During operation and immediately after shut-down, the capacitors and, therefore, the conducting parts of the Digi-Drive are under high voltage. For this reason, to change the wiring, before opening:
Disconnect the Digi-Drive from the power supply. After switch of the power, wait 3 minutes before working on the Digi-Drive.
Feeder with s ingl e-reduct ion gear
Docu-No.: 0890019601-EN Rev. 1.0.1
Using the following key for HI/LO switching with a single reduction gear can damage the gearbox. Therefore set the program variable P3 to 2. Check the screw rotation after this programming! If rotation is wrong change motor cable 5 and 6 at screw terminal TB1.
Page 25
5 5.3
Operation Programming and calibration
5.3
Pr og ram mi ng an d c al ib rat io n
5.3.1
In tr od uc ti on to pr og ram mi ng :
The change from operation mode to programming mode takes place by REM
Alarm
%A
pressing the
% CAL rpm
S P
DISPLAY
and the
. at the same time.
Pressing the keys at the same time until the display changes to the first programming variable 'P0'. REM
Alarm
Fig. 5.5
After approx. 2 sec., the display automatically changes to the programmed value.
%A % CAL rpm
S P
Programming mode
Press the
DISPLAY
key to show further program variables until the re-
quired variable is shown. 'P0' reappears after 'P24'. Enter the numerical value for the selected variable:
Press
or
key and hold it down until the required value
is shown. Repeated pressing and holding down the key
accelerates
the scrolling of the data display.
Select the next programming variable, press the
DISPLAY
key once
again.
To exit programming mode, press the
key. STOP
The changed values are stored as soon as you press the
key STOP
and "SAVE" is displayed.
REM
Alarm
% CAL rpm
S P
Fig. 5.6
Page 26
%A
Save display
Docu-No.: 0890019601-EN Rev. 1.0.1
Operation Programming and calibration
5.3.2
5 5.3
Pr og ram mi ng v ar iab les
The standard settings are marked with an asterisk "*" in the following section. Programming of standard values: During power on the Digi-Drives press the
Parameter
P0
DISPLAY
and
key.
Description
Maximum motor speed. Standard value: 2000 rpm (use the value shown on the motor nameplate (max. 2270 rpm)).
P1/P2
Alarm limit value in the case of interruptions of the feeding product flow resulting from lack of product or building of bridges in the product. Entering the limit value: • P1 for low speed gear and feeding with just a single gear speed. • P2 for high speed. Input 0: Function off: If the value falls below the value entered, the alarm display flashes. Determine the start value for the limit values as follows:
Program all programming variables and specify setpoint value for later operation.
Press the
Let the feeder run without product and note the percentage of the nominal current.
Fill the feeder with product, allow it to run and note the percentage of the nominal current.
Enter the mean value of the two values obtained according to the gear speed in P1 or P2.
DISPLAY
key until "%A" or Watt is shown.
Optimize the two values in continued feeding operation.
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 27
5 5.3
Operation Programming and calibration
Parameter
P3
Description
Input of „low speed“ and „high speed“.
Input
Function
0
Digi-Drive sets the standard value to "low speed" when switched on. The operator can change this setting by pressing the "HI/LO" key on the keyboard.
1
Digi-Drive sets the standard value to "high speed". The operator can change this setting by pressing the "HI/LO" key on the keyboard.
*2
Start-up and operation only with "low speed". The key "HI/LO" is deactivated (for single-reduction gear).
3
Start-up and operation only with "high speed". The key "HI/LO" is deactivated.
Parameter
P4
Description
Input • of the control mode (origin of the setpoint value). • of the possibility for changing the control mode on the keyboard. P4 is not shown, if P18 is programmed to 1.
Input
Control mode
Function
0
Permanent „Local“
The setpoint value input is made on the keyboard. The control mode cannot be changed using the "LOCAL/REMOTE" key.
1
Permanent “External direct“
The setpoint value input is made on the external controller. The control mode cannot be changed using the "LOCAL/REMOTE" key.
2
Permanent “External ratio“
The setpoint value input is made on the external controller in ratio mode. The control mode cannot be changed using the "LOCAL/REMOTE" key.
*3
Start with „Local“
Shifting between "local mode" and "external direct mode" with the key "LOCAL/REMOTE" is possible.
4
Start with „External direct“
Shifting between "external direct mode and "local mode" with the key "LOCAL/REMOTE" is possible.
5
Start with „Local“
Shifting between "local mode" and "external ratio" with the key "LOCAL/REMOTE" is possible.
Page 28
Docu-No.: 0890019601-EN Rev. 1.0.1
Operation Programming and calibration
Input
6 7 8
5 5.3
Control mode
Function
Start with „External-ratio“
Shifting between "local ratio" and "local ratio" with the key "LOCAL/REMOTE" is possible.
Local or external-direct
Keypad LOKAL/REMOTE disabled. Bit input Local/Remote enabled.
Local or external-ratio
Keypad LOKAL/REMOTE disabled. Bit input Local/Remote enabled.
Parameter
P5
Description
Input of the span factor for "external direct mode" or "external ratio mode". The span factor determines the factor required for the scaling of the input frequency to 2 kHz at 2000 rpm. Span factor = 2000 rpm / input frequency (Hz) Example: Input frequency: 10 kHZ / Calculated span factor: (2000/10000)x100 = 20
Parameter
P7
Description
Specifying the type of setpoint value input.
Input
Function
0
Input and display of the setpoint value as speed of the motor in rpm.
1
Input and display of the setpoint value as percentage of the maximum motor speed (see P0).
2
Input and display of the setpoint value in a user-defined unit, e.g. lb/h, g/min, etc. (see section "calibration").
Parameter
P8
Parameter
P9
Description
For the new Digi-Drive Sw 4.7 and U3.0 and later not used and displayed. Description
Input of calibration factor. The calibration factor is used to calculate the feeding capacity in a previously defined unit, e.g. kg/h (see section "calibration").
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 29
5 5.3
Operation Programming and calibration
Parameter
P10
Description
Access to programming mode.
Input
Function
*0
Programming on keyboard possible.
1
Programming on keyboard not possible.
Access to programming mode can be restored with the internal programming switch. This internal programming switch is located on the rear of the swivel front cover .
Parameter
Description
P11/12
Input of the maximum admissible nominal current intensity of the motor. When the value input is exceeded, the alarm display on the display of the Digi-Drive lights up. At the same time, the alarm is transmitted to the alarm relay. Nominal current intensity, see motor nameplate. Standard value: 2.5 Values which exceed the programmed value at P13 are not accepted. Input of maximum current intensity • P11 for gear speed ("low") and feeder with just one gear speed, • P12 for gear speed ("high").
Page 30
Docu-No.: 0890019601-EN Rev. 1.0.1
Operation Programming and calibration
Parameter
P13
Description
Specifying the power supply unit
Input
Function
*6
Digi-Drive with 6-amp power supply (standard value)
12
Digi-Drive with 12-amp power supply unit.
Parameter
P14
5 5.3
Description
Suppression of start enabling. Specify start enabling via terminals 4 and 5 or suppressed.
Input
Function
*0
Start enable via terminals suppressed.
1
External start enable via terminals is necessary.
Parameter
P15 Input
Function
*0
Alarm
1
Motor runs
Parameter
P16
Parameter
P17
Description
Function of the relay.
Description
Display of software-version.
Description
Programming the option board.
Input
Function
*0
option board not installed.
1
option board 9191-60241 installed.
2
option board 9191-60237 installed.
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 31
5 5.3
Operation Programming and calibration
Parameter
P18
Description
This programming variable is used to set the programming variable P4 for gravimetric operation to "external direct".
To activate the following function, turning off and on again the main power. Input
*0
Function
Volumetric operation. If programming is done from 1 to 0, the programming vari able P4 must be set to the new value.
1
Sets the programming variable P4 to 2 (Start with "external ratio"). P4 is no longer displayed in programming level (gravimetric operation).
2
Sets the programming variable P4 to 0 (Start with "fixed local"). P4 is no longer displayed in programming level (manual control maintenance).
3
Sets the programming variable P4 to 4 (Start with "external direct"). P4 is no longer displayed in programming level (gravimetric operation).
Parameter
P19
Parameter
P20
Description
Selecting of the motor ramp rate in seconds. How many seconds to reach the setpoint. Range from1-5 Sec.
Description
Input of the selected power supply from the Digi-Drive.
This variable is not used to select the incoming power supply.
Input
Function
*230
Current limit calculated for 230 VAC
115
Current limit calculated for 115 VAC
Page 32
Docu-No.: 0890019601-EN Rev. 1.0.1
Operation Programming and calibration
Parameter
P21
5 5.3
Description
Input of the used speed pick-up type.
Input
Function
60
Set the right divider for the rpm display.
90 100 *120
Parameter
P22
Description
Input corresponds to a number of speed offset in % of the entered max. Input and display of the setpoint as %-portion of the maximum number of speed of the motor (see P0). Range from 0 - 100 %
Parameter
P23 Input
Function
*0
Display in Watt.
1
Display in % A.
Parameter
P24 Input
Function
*0
All alarms active.
1
Alarm A disabled.
Docu-No.: 0890019601-EN Rev. 1.0.1
Description
Power current display (Power or- Watt display).
Description
Switching on-off Alarm A (see capter 6.2).
Page 33
5 5.3
Operation Programming and calibration
5.3.3
Calibration of the Digi-Drive
Introduction The feeding capacity can be displayed in a certain unit, e.g. kg/h on the Digi-Drive. To do this, the feeding capacity must determined at a certain speed in order to be able to calculate the calibration factor .
Step
Function
1
Change to programming mode and program the programming variable P4 to "0" (local controller) and P7 to "0" (setpoint value in rpm). Exit programming mode with the "Stop" key (see Programming 5.3).
2
Select required speed with the "High/Low" key.
3
Enter setpoint value 1000 rpm.
4
Start feeder. If the feed flow is constant, fill a collecting hopper three times for a period of 1 minute in each case.
5
Weigh the samples and calculate the average feed rate in kg/h. Calculate the calibration factor for the programming variable P9 using the average capacity on the basis of the following formula:
( Average ) [kg/h] ( c al ⋅ factor ) P9 = --------------------------------------------------------------------( Setpointvalue ) [ rp m ]
6 E.g.
15 [kg/h] 0, 015 = --------------------------------1000[ rpm ] 7
Enter the multiplied value P9 (e.g. 0,015).
8
Return to programming variable P7 and change the entry to "2" (Cal). The Digi-Drive is now calibrated. If necessary, change the control mode of programming variable P4 to "External".
9
Press the "STOP" key to exit the programming mode. The "CAL"-symbol now appears on the screen. Note: The setpoint value 1000 U/min should now have changed to 15 CAL = 15 kg/h at 1000 rpm.
Page 34
Docu-No.: 0890019601-EN Rev. 1.0.1
Operation Adjustment of the setpoint value on the option board
5.4
5 5.4
Adjustment of the setpoint value on the option board
The following section applies to the setpoint value input via an external analogue controller or frequency controller or an external potentiometer. Before operation of the Digi-Drive, adjust the setpoint value on the option board with the external controller. 5.4.1
Set ref er en ce v ol tag e
Inputting the setpoint value via an external potentiometer: Set the reference voltage on Digi-Drive before adjustment. • Connect the digital multimeter to terminal block X1, terminals 6 and 7. • Set reference voltage U PT1 on potentiometer 10 V ±0.1 V. Setting JU 1, 5, 4 Pos. VDD
Fig. 5.7
Setting JU
5.4.2
Set po in t v al ue f or vo lt ag e
The voltage range for the setpoint value is 0 - 10 V. Requirements: Digi-Drive
• Input device for setpoint value is connected according to Fig. 5.8 or Fig. 5.9; • on the option board: Jumper 1 and 2 are in position 1..2 U; • setting of the motor speed (programming variable P0): 2000 rpm.
Option board 3
4
Analog controller
Set programming variable P4 to 1 or 2. Then show setpoint value on Digi-Drive.
Specify 10 V (100 %setpoint value) on terminals 3 and 4.
Set setpoint value display using potentiometer S PT3 to
– 2000 rpm (external direct) or – 100 % (external ratio) Specify 0.1 V (1 % setpoint value) on terminal 3 and 4.
Fig. 5.8 Analog controller
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 35
5 5.4
Operation Adjustment of the setpoint value on the option board
Digi-Drive
Option board 3
Fig. 5.9
4
6
7
Set setpoint value display with potentiometer 0 PT2 to: – 20 rpm (external-direct) or – 1 % (external-ratio) Repeat setting until no imprecision can be found.
Potentiometer
5.4.3
Set po in t val ue f or c ur ren t
The current range for the setpoint value is: 4 - 20 mA. Requirements: Input device for the setpoint value is connected to terminals 1 and 2; on the option board: Jumper 1 to pos. 2..3 I, Jumper 2 to pos. 1..2; Setting the motor speed (programming variable P0): 2000 rpm.
Set programming variable P4 to 1 or 2. Then show setpoint value on the Digi-Drive.
Specify 20 mA (100 % setpoint value) on terminals 1 and 2.
Set setpoint value display with potentiometer S PT3 to:
Page 36
– 2000 rpm (external-direct) or – 100 % (external-ratio). Specify 4,16 mA (1% setpoint value) on terminals 1 and 2. Set setpoint value display with potentiometer O PT2 to: – 20 rpm (external-direct) or – % (external-ratio) Repeat setting until no imprecision can be found.
Docu-No.: 0890019601-EN Rev. 1.0.1
Operation Adjustment of the setpoint value on the option board
5.4.4
5 5.4
Set po in t val ue fo r fr eq uen cy
Requirement: Jumper 2 pos. 2..3. Jumper 2 bridges the U/f-converter, thus Jumper 1 no longer has any function. Specification of frequency max. 20 kHZ on terminal 5. Calculation of span factor for programming variable P5 see programming 5.3.2.
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 37
6 6.1
What to do when...? General information on fault detection
6
What to do when...?
6.1
General information on fault detection
Immediately after shut-down, the capacitors and, therefore, the conducting parts of the Digi-Drive are under high voltage
Disconnect the Digi-Drive from the power supply.
6.1.1
Meas ur in g m ot or c ur ren t
The motor current can be read off the screen of the Digi-Drive. Connect an external current measuring device only to the DC current input of the Digi-Drive, as the control of the motor takes place via pulse width modulation and the current to the motor cannot be measured using conventional instruments. 6.1.2
Measure and set speed frequency signal
(only for Jaquet-speed Pick-up).
V 5
The speed signal is a square -wave signal from 0 to 7,2 kHz/5 VDC. The Signal can be measured at the following locations: • On the feeder: Connect frequency counter between 1 (5 VDC) and 2 (signal). • On the Digi-Drive: Connect frequency counter between TB2-8 (5 VDC) and TB2-9 (signal). Note The ratio of capacity level of the speed signal is influenced by the distance of the Hall effect pick-up (1) to the field spider (2). A ratio of capacity level worse than 1 : 2 can lead to failure of the controller .
1
•Pick Up according to Fig. 6.1. and check ratio of capacity level. Note Pick-up is located in the feeder beside the drive shaft of the motor . 2
Fig. 6.1
Page 38
For all opto speed pick-up's no adjustments necessary.
Setting the pick-up
Docu-No.: 0890019601-EN Rev. 1.0.1
What to do when...? Troubleshooting
6.2
6 6.2
Troubleshooting
Before you reset one of the programming variables, check whether or not the previously selected setting was deliberately selected. To set the programming to default values, press programming switch on the display board during power on. Error
Cause
Elimination
No setpoint value input possible on keyboard.
• Programming variable P4 is set to „external-direct“ or „external-ratio“.
Chance programming variable P4.
No shift of value range (HI/LO) possible on keyboard.
• Programming variable P3 is set t to 2 or 3.
Check programming variable P3 and set 0 or 1.
No shift from LOCAL/ REMOTE possible on keyboard.
• Programming variable P4 is set to 0, 1 or 2.
Check programming variable P3 and set to 3, 4, 5 or 6.
No access to programming mode possible.
• Access to programming mode is blocked by programming variable P1.
Open front panel and press the key on the rear of the keyboard.Check setting in programming variable P10.
The setpoint value of an external controller is not accepted.
• Input frequency or analogue value do not correspond to the requirements in the technical data 3.
Check input frequency or analogue value with specifications in chapter "technical data 3".
• Programming variable P4 wrongly set.
Check programming variable P4 (display: SP %).
• Programming variable P5 is set to 0.
Ensure that the value for programming variable P5 is not zero (0).
Digi-Drive will not start or switches itself off.
• No setpoint value below 10 rpm specified.
Specify setpoint value.
Digi-Drive does not start or switches itself off, and the RUN LED flashes.
• No enabling signal present for the motor.
If no external enabling is installed: check the functioning of the jumper between terminals 4 and 5 on TB2.
If external enabling is installed: test enabling signal. Position the jumper between terminals 4 and 5 on terminal block TB2 and press the "RUN" key. If the motor then runs, there is a defect in the cable and the connections for the enabling signal.
Docu-No.: 0890019601-EN Rev. 1.0.1
Page 39
6 6.3
What to do when...? Alarm messages
6.3 Error code-number and meaning
ERR 1 Digi-Drive is not receiving any speed pulses from the speed pick-up and the measuring current from the motor is to high.
Alarm messages
Possible cause
Elimination
Press the „RUN“ key and check whether the motor turns:
• Speed pick-up has failed.
• If the motor turns, check the speed pick-up and replace if necessary.
• Motor is blocked or sits tight.
If the motor does not turn, check whether the feeder screw is blocked and eliminate the blockage. If the feeder screw is not blocked, have the motor or Digi-Drive checked by K-TRON customer services and repaired.
Compare the max. nominal current intensity of the motor (nameplate) with the programming variables P11/P12. Adjust the entries.
Check the quality of the feeding material and check whether the feeding material can be metered using the feeder.
Have the Motor checked by K-TRON customer services.
• No material in feed hopper.
Fill up with feeding material.
• Feeding material has formed bridges inside the feed hopper.
Eliminate bridges.
• The value set for programming variables P1/P2 are wrong.
Correct values in the programming variables P1/P2.
ERR 4 Speed picked up is higher than the one programmed.
• Power supply part or control part of the Digi-Drive is defective.
Have the Digi-Drive replaced by K-TRON customer services.
ERR 5 Digi-Drive is measuring the current from the motor, but no speed impulses
• No speed impulse present at the screw-on terminals of the Digi-Drive.
Check the speed pulse at the screw-on terminals of the DigiDrive and restore the connection.
Have the Digi-Drive replaced by K-TRON customer services.
• Motor has failed (brush or rotor failure).
ERR 2 Alarm display lights up, motor overloaded but is receiving pick-up pulses.
• Programming variables P11/P12 wrongly programmed.
• Motor is overloaded by feeding material.
• Motor is defective. ERR 3 Alarm display flashes, motor load too low.
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• Digi-Drive defective.
Docu-No.: 0890019601-EN Rev. 1.0.1
What to do when...? Alarm messages
Error code-number and meaning
ERR 6 No measurement of • motor current
6 6.3
Possible cause
Elimination
• Defective wiring on motor.
Check and correct motor wiring.
Have the Digi-Drive replaced by K-TRON customer services.
• speed impulse • Motor defective. ERR 7 Eeprom error
• Defective on the display board (data cannot be stored).
Replace display board.
ERR 8 Requested torque is higher than the digiDrive can deliver.
• Too high motor load at low speed.
Check feeder.
ERR 9 Measured AC Voltage outside of allowed range.
• Problem with power supply.
Use line filter. Change power supply.
• Defective power board.
Change power board.
ERR A Speed ≠ Setpoint
• Pick-up wrong adjusted.
Readjust pick-up.
• Disturbances on the speed signal line.
Shield cables.
Docu-No.: 0890019601-EN Rev. 1.0.1
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7 7.1
Maintenance Cleaning
7
Maintenance
7.1
Cleaning
If there is any external soiling of the housing of the Digi-Drive, wipe down using a damp cloth and normal industrial cleaners.
Do not use corrosive cleaning agents.
7.2
Pr ev en ti ve m ai nt en an ce w or k
During operation and immediately after shut-down, the capacitors and, therefore, the conducting parts of the Digi-Drive are under high voltage. For this reason, before opening the Digi-Drive: • Disconnect the Digi-Drive from the power supply. Carry out the following preventive maintenance work after every 10,000 hours of operation: • Check for wear and tear and rust on the screwed connections of the AC connection and on the motor drive. • Check the strength of all connections. • Check the condition of the fuses. • Check the operating readiness of all external safety switches or interlocks. Change fuses after every 25,000 hours of operation, even if they are not burn-out.
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Docu-No.: 0890019601-EN Rev. 1.0.1
Appendix Connection diagrams
Docu-No.: 0890019601-EN Rev. 1.0.1
8
Appendix
8.1
Connection diagrams
8 8.1
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8 8.1
Appendix Connection diagrams
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Docu-No.: 0890019601-EN Rev. 1.0.1
Appendix Connection diagrams
Docu-No.: 0890019601-EN Rev. 1.0.1
8 8.1
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8 8.1
Appendix Connection diagrams
Page 46
Docu-No.: 0890019601-EN Rev. 1.0.1
Appendix Connection diagrams
Docu-No.: 0890019601-EN Rev. 1.0.1
8 8.1
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