LM2 (HGC Software)

Program version: HG V2.6/2.
7
for the continuous operation of:
- Loss-in-weight feeders (H-types)
- Weigh-belt feeders (G-types)
- Feeding pumps
Brabender Technologie KG
Kulturstrasse 55 - 73
Service: D-47055 Duisburg
(: 0203/9984-139 P.O.Box 350138

D-47032 Duisburg
FAX: 0203/9984-166
(: 0203/9984-0
Web: http://www.brabender-technologie.com
Date: 97-08-12 FAX: 0203/9984-155
E-mail: email@brabender-technologie.com
Revision: 2.3
© BRABENDER Technologie, 1996 Copyright as per DIN 34 31123103.doc
Table of contents
1 Introduction 4
2 Switching on the supply voltage: system check 5
3 The manipulation 6
3.1 The front keyboard 6
3.2 The digital inputs 7
3.3 The host computer interface 7
3.4 Functions of the integrated LEDs of Congrav LM 2 7
4 General structure of the pages 8
4.1 The status line 8
4.1.1 The mode displays 8
4.2 The parameter inputs 9
4.3 Page overview 10
5 Menu page F100: Installation parameters 11
5.1 Text switch 11
5.2 Mode (of the installation) 11
5.3 Analogue control 12
5.4 Host computer operation 12
5.5 Total output 12
5.6 Date and time 12
6 Menu page F150: Recipe administration 13
7 Menu page F200: Printer parameterization 14
7.1 Total throughput divisor 14
7.2 Menu page F210: Reset memory 15
7.2.1 Reset RAM 15
7.2.2 Reset EEProm 1 15
7.2.3 Reset EEProm 2 15
8 Menu pages F300, F301: Setpoints and selection 16
8.1 The setpoints 16
8.1.1 The installation setpoint 16
8.1.2 The component setpoints 16
8.1.3 Setpoint ramp, setpoint threshold (menu page F150) 16
8.2 The selection 17
9 Menu pages F310,F311: Alarm stop, delay times 17
9.1 The delay times 17
9.2 Alarm stop 17
10 Menu pages F400 - F420: Total survey page 18
10.1 Menu page F430: Reset all totals 18
11 Menu page F500: Alarm reports 19
12 Menu page F600: Calibration program 20
12.1 Explanation of the functions of the feeders parameters 22
13 Manipulation of the components 30
13.1 The component page Kx00 30
13.2 The component page Kx10 31
13.3 Component page Kx20: Control parameters 34
©Brabender Technologie, April 1999 Operating Instructions LM HG V2.6/2.7 Page 2/39

Table of contents
13.4Component page Kx50: Alarm configuration 35

14 Test functions of Congrav LM2 36
14.1 Menu page F140: Test of I/O-periphery 36
14.2 Component page Kx30: The I/O-status of the component 36
14.3 Component page Kx40: Test of the I/O-periphery of the component 36
Appendix A: Commissioning of a DDW 37

Appendix B: Commissioning of a DBW 38
Appendix C: Functions of the I/O of Congrav LM2 39

Chapter 1
1 Introduction
The Congrav LM2 is a microcomputer for the control and evaluation of continu-
ous feeding processes. As a function of its execution it is capable to monitor si-
multaneously the feeding operation of a maximum of 16 weigh-feeders, loss-in-
weight feeders (DDW, H-type) or weigh-belt feeders (DBW, G-type). We distin-
guish the following 3 types of Congrav LM 2:
Congrav L/M-2A opposite to the other two Congrav L/M-types it is equipped

with a front plate with a foil-covered keyboard and a liquid
crystal display. This Congrav permits to control a maximum
of 8 weigh-feeders (=components). As an option it is possible
to retrofit actual value outputs for the components. Alterna-
tive manipulation possibilities are obtained by connecting a
remote group controller PT-02 and/or a process terminal
PT-03. Moreover it is possible to connect a host computer to
Congrav L/M-2A. If the Congrav is connected to a process
terminal PT-03 the host computer connection will be done on
PT-03. The Congrav L/M-2A is equipped with a Centronics-
interface, so that the connection of a printer for alarm re-
cording etc... is possible.
Congrav L/M-2B has no front manipulation unit of its own and no Centronics-
interface. Manipulation is only possible via a remote group
controller PT-02 and/or a process terminal PT-03. Option:
the connection of a printer to the process terminal PT-03.
Congrav L/M-2B as well can control a maximum of 8 com-
ponents if the actual value outputs are optionally retrofitted.
Furthermore, it is possible to connect a host computer to
Congrav L/M-2B. If it is already connected to a process ter-
minal PT-03, the host computer is connected to PT-03.
Congrav L/M-2C has the same features as Congrav L/M-2B. The difference
between both Congravs is that the Congrav LM-2C is dimen-
sioned for a maximum of 16 components, it is not possible to
retrofit actual value outputs, moreover it is not possible to
connect the Congrav L/M-2C to the remote group controller
PT-02.
Host computer connection is only possible via PT-03.
In order to ensure an optimum feeding operation the Congrav LM 2 has to be

adapted to the feeding conditions. This adaptation is realised via the software of
the Congrav LM 2. In our works we will provide a first adaptation of the soft-
ware parameters to the weigh-feeder. Moreover, during commissioning a fine
adjustment will be carried through, during this operation the parameters are de-
termined under consideration of the process ambience.
Any modification of the values determined can alter the operating

! conditions essentially and therefore should be made by skilled person-
nel only!
©Brabender Technologie KG, April 1999 Operating Instructions LM HG V2.6/2.7 Page 4/39
Chapter 2
2 Switching on the supply voltage: system check
Before switching on the supply voltage it is im-
portant that you check the mechanical modules F000
of the connected feeders as per the mechanical BRABENDER TECHNOLOGIE KG DUISBURG
documentation and the electrical connections as Check
Software : L/M2A |
per the enclosed wiring diagrams.
HG V2.70 | o.k.
After switching on of the mains there is an inter- IO address: 1 1 | o.k.
nal check of the system. After app. 2 sec. the MC-Board : MC Batt. | o.k.
following welcome screen will be displayed:
Software:
Displays the type of Congrav and the software version. If the Congrav emits an
alarm report, it has to be checked whether the LM2 is equipped with a uniform
software version. For this purpose you have to pull out the mains plug and then
take out the insert cards of Congrav LM2 one after the other. On the insert cards
of the Congrav all Eproms (white stickers) have to be equipped with the same
software version, in this case: HG V2.70. Continuation of the operation is only
possible if the error has been cleared.
I/O addresses:
Shows the number of I/O controllers recognised by the Congrav. In case of an
alarm report during the check, the bus address of this I/O controller has to be
checked. Continuation of the operation is only possible if the error has been
cleared.
Please refer to the Technical Manual for a description of the addresses

! of the I/O-controller, they must only be addressed by accordingly
trained operating staff.
Example:
11 Congrav LM2 is equipped with two standard I/O-controllers.
41 Congrav LM2 is equipped with two standard I/O-controllers, the
first controller is additionally equipped with the optional actual
value card.
MC-Board:
MC MC displays that the Congrav has recognised a memory card. All
operating parameters will be memorised on the Memory Card by the
Congrav LM2.
Batt Batt. displays that both, the battery of the memory card and the
system battery of Congrav LM are allright.
With the alarm reports „Memory-Card?“ and „MC-Batt empty“ the

operation can be continued, however, the corresponding memory
function is not available.

Chapter 3
3 The manipulation
There are several possibilities to command the Congrav LM2:
3.1 The front keyboard

The integrated front keyboard permits to do all manipulations necessary for the
command and parameterisation of Congrav LM2A directly on site. Optionally, it
is possible to connect a remote front keyboard, the so-called PT02, as this Con-
grav does not have an integrated front keyboard.
Cursor keys
The keys of Congrav LM2 can be di-
vided into 4 main groups: TECHNOLOGIE KG DUISBURG
R
Congrav L/M
7 8 9 Numerical keys
• The function keys
4 5 6
call up the menu pages necessary 1 2 3
for the manipulation. 0 C
• The cursor keys F1 F2 F3 F4 F5 F6 ? HC CR

Operating keys
select the parameters to be changed K1 K2 K3 K4 K5 K6 K7 K8 I 0
or the function to be carried
through.
Function keys
• The numerical keys

are used for the numerical inputs. You start a numerical input by setting the
cursor on the corresponding parameter and enter the first figure, thus the in-
put zone in the lower left corner of the display will be opened. The C-key is
used to erase the figures put in by a numerical input. The input is validated by
means of the CR-key (enter-key) and the new parameter value will be memo-
rised if it is corresponding to the specified conditions.
• The operating keys
Key Function
?
calls up the help menu. The individual menu pages can be called up by
using the scroll-keys.
HC
prints out the menu page selected on a connected printer which is ready
for operation. (Hard copy not possible with type B)
CR
this key (Enter) permits to complete inputs or to select operating pa-
rameters directly.
this key (START) permits to start all components selected on menu page
I F300. If all selected components are started, the LED will light up
green.
0
this key (STOP) permits to stop all components selected on menu page
F300.
this key (RESET) permits to acknowledge faults of all components pre-
selected on menu page F300, so that the installation can be started anew.

Chapter 3
3.2 The digital inputs
For the manipulation of Congrav LM 2 elementary control functions such as
START, STOP, INTERLOCKING or ALARM RESET can be activated by
setting the corresponding digital input. The Congrav LM 2 has 4 digital inputs
for each component, as well as 6 digital inputs for the manipulation of the in-
stallation (e.g. COMMON START, COMMON STOP etc.). The required wir-
ing of the digital inputs and their specifications are to be found in the Technical
Manual.
3.3 The host computer interface

As an alternative, the entire manipulation of the Congrav LM 2 can be done via
the serial host computer interface.
The availability of manipulation possibilities is a function of the selected inter-
face procedure. Please see the corresponding operating instructions of the in-
terface for a detailed description of the function and the structure of the host
computer interface.
It has to be observed that the host computer interface of Congrav LM 2 is not
available if a PT03 as overriding manipulation unit is connected. In this case, the
host computer will be connected to PT03.
3.4 Functions of the integrated LEDs of Congrav LM 2

The LEDs integrated in the start-key and in the K-keys display to the operator
the actual operating status of the installation and of each component, they are
very important for the correct manipulation.
Lightning Function of the LED in the start-key

off at least one or all of the selected components have not started..
green all selected components have started.
flashing red at least one or all of the selected components have a fault.
Lightning Function of the LED in the K-keys

off the component is stopped.
constantly the component is started.
green
flashing green the component is started and the start delay time runs down.
flashing red the component has an fault. The type of the fault can be seen on
page F500 by pushing the F5 key.
constantly red at least one start condition of the component is not fulfilled. The
type of the start condition can be seen on page F500 by pushing the
F5
key
flashing or- the component is started and interlocked via the digital input
ange "interlocking".

Chapter 4
4 General structure of the pages
Due to the high number of parameters and the possible functions there are a lot
of operating menus that are all identified by a page number. The page number
helps the operator to see which menu page has been called up (see chapter 4.3).
4.1 The status line

F100 GF GF GF GF GF GF GF GF PLC I=on
The first line of each menu page is the so called Congrav L/M HG V2.60 27.07.97 23:10
status line. This line displays the page number, Mode: Single
8 mode displays for the components 1- 8, an in- Analogue control: off AI: 0
formation field for the display of a host com- Host comp oper.: Siemens (3964R)
puter operation (PLC), an active simulation Text switch: English
(Sim) or an active test function (TST) and last Total output: 1000.00 kg/h
but not least the status field for the screen page
interlocking. The status I=on means that this Input zone Alarm report
menu page can be interlocked against any input
by setting the digital input key switch. In this case, the alarm report no inputs
possible will be displayed if the operator should try to make an input.
4.1.1 The mode displays

The mode displays for the components 1 -8 Representation Meaning
(from left to right ) signalise to the operator in normal component stopped
an unambiguous manner the operating status of inverse component started
the corresponding component. This is realised by flashing component has a fault
means of the representation and the mode text. empty component interlocked
The type of representation displays the operating status of the component, the
mode text delivers the corresponding description. Example: a flashing D+ in the
3rd mode display means that the 3rd component was cut out due to „control dif-
ference pos.“ to continue the operation it is necessary to reset the alarm and then
to start the component anew.
Mode Signification
GF, VF, The selected component mode is displayed. With modes GF, VR and GD the
VS, VR, indications GF, VR or GD this mode display means that the control differ-
DI, GD ence lies within the allowed control tolerance.
CM The mode check max. output is selected (normal), started (inverse) or has
been finished off by an alarm (flashing).
D+, D- The control difference = setpoint - actual value exceeds (D-) or falls short of
(D+) the allowed tolerance. Alarm cut-out (flashing) after run-off of the de-
termined alarm cut-out delay time.
S+, S- The read in speed value has exceeded or fallen short of the maximum or
minimum limit value.
OL This indicates that the overload mark defined is exceeded by the actual hop-
per weight. With the standard software there will be an alarm cut-out after
6s.
AV The upper or lower filter limit has been violated and the AV cut-out time
starts.
RF Filling of the hopper is displayed herewith (H-type). A refill fault (flashing)
occurs if the filling level min. has been fallen short of after the max. refill
time.

Chapter 4
Mode Meaning
UN The underload mark defined has been fallen short of by the actual hopper
weight. In standard execution there is an alarm cut-out after 6s.
MS The material stabilisation period runs down after refilling.
AT With a G-type feeder the auto-tare mode has been selected (normal),
started (inverse) or has been finished off by an alarm (flashing).
DT The start- or stop delay time runs down.
Start delay The representation in the mode display is normal and
the LED in the component key flashes green.
Stop delay The representation of the mode display is inverted and
the LED in the component key lights up green.
== The component is started and interlocked. This mode display is accompa-
nied by a flashing LED in the component key (orange).
-- The component is stopped and interlocked.
ST One start condition has not been met. At the same time the LED in the
component key lights up red.
WS The serial load cell signals are missing. There is an immediate cut-out.
MM Access to memory module could not be effected correctly.
Please contact the Brabender service department.
4.2 The parameter inputs

Except for some exceptions (setpoints, controller), parameter modifications are
only possible if the component or installation is stopped. The software of Con-
grav LM2 assists the following input possibilities:
the numerical input: for numerical parameter values
You select the parameter value by means of the cur-
sor and make the input with the numerical keys. The
inputs are displayed in the lower left corner of the in-
put zone. To validate the input you push the CR-key,
it will thus be checked whether the specific input
limitations of the parameter have been respected. If
an input limitation has been violated, the input will be
refused by the message input error.
Switch function: Parameters that can only be switched on or off. The
parameter is selected by means of the cursor, the CR-
key permits to change the setting.
Predefined inputs: These parameters only have predefined inputs possi-
bilities that the operator can see from a sub-menu.
The corresponding sub-menu will be called up after
having been selected by means of the cursor and
pushing the CR-key. In the sub-menu you select the
desired setting with the cursor and deactivate it with
the CR-key. After pushing of the CR-key, the soft-
ware will jump automatically back to the main menu
and the new parameter value will be memorised.

Chapter 4
4.3 Page overview
The illustration below shows an overview of the menu page structure. The first Designation of the page no
page with different blocks is called up by pushing the indicated F-key or K-key.
The scroll (up/down) keys permit to call up a menu page from a block. The
F1 00
menu pages hatched in grey are sub-menus with predefined parameter settings
and can only be selected via the corresponding parameter.
Level
Function pages Key
F 150 Memory card and setpoint parameters
F 140 Test of I/O-periphery
F 130 Text switch
F120 Host computer parameters F210 Reset RAM and EEprom
F110 Installation modes F200 Printer parameters
F100 Installation parameters
direct selection by:

direct selection by:
F2
F1
F430 Reset throughputs

F421 Overview weight/diff.%/speed 5-8
F311 Start-/stop-delay times comp.5-8 F420 Overview weight/diff.%/speed 1-4
F310 Start-/stop-delay times comp.1-4 F411 Overview setp.-/actual-/total val. comp. 5-8
F301 Setpoint page component 5-8 F410 Overview setp.-/actual-/total val. comp. 1-4
F300 Setpoint page component 1-4 F400 Overview total setpoints/actual values
direct selection by: direct selection by:

F3 F4
F500 Alarm reports F600 Calibration data of components

F5 F6 and K...
Component pages
K150 Alarm configuration component 1 K250 Alarm configuration component 2
K140 Test program component 1 K240 Test program component 2
K130 Control page for I/O component 1 K230 Control page for I/O component 2
K120 PID-control parameters component 1 K220 PID-control parameters component 2
K111 Modes component 1 K211 Modes component 2
K110 Feeding parameters component 1 K210 Feeding parameters component 2
K100 Individual control of component 1 K200 Individual control of component 2

K1 K2
etc... up to component 8
Manipulation functions in the calibration program F600:

- the cursor-keys select the desired feeder parameter
- the scroll-keys indicate the feeder parameters in blocks of 5
- the K-keys permit to select the desired component

Chapter 5
5 Menu page F100: Installation parameters
5.1 Text switch
For the display texts you can switch between the Congrav L/M HG V2.60 27.07.97 23:10
following languages: German, English, French, Mode: Single
English lb, Italian and Danish. If the language Analogue control: off AI: 0
English lb has been selected, the units will Host comp oper.: Siemens (3964R)
change at the same time from lb/h (pounds per Text switch: English
Total output: 1000.00 kg/h
hour) to lbs (pounds). The following parameters
are concerned:
lb/h: Setpoint, actual value, sampling, output, max. output, total output
lb: Throughput, weight, auto-tare
PCF: Bulk density (input range: 10 - 250)
cuft: Hopper contents (input range: 0.01 - 350)
5.2 Mode (of the installation)

Single The individual components feed independently of each other
relative to the setpoint. A linkage of the individual compo-
nents is only provided by the selection for the calculation of
the total values (total setpoint, total actual value, total
throughput) and for the alarm stop-function.
Group A group consists of several components which are activated
by the selection. The group size is determined by the group
setpoint. The setpoints of the individual selected components
are entered in percent of the total setpoint of the group.
100%-group This mode is corresponding to group operation. In addition to
the latter it is monitored that the sum of the individual se-
lected component setpoints must be 100%. If this is not the
case the alarm report "group setpoint. <> 100%", appears
on the display and group operation cannot be started.
Master/Slave With master/slave operation a basic product can be mixed
with several other products (e.g. additives). The setpoints of
the individual slave feeders are determined in relation to a
master setpoint in %. The master feeder is characterised by a
setpoint input of 100%. In case of no master feeder or several
master feeders there is an alarm report.
M/S-actual value This point is corresponding to the master/slave operation. With the master feeder the
However, the setpoints of the individual slave feeders are de- function "alarm stop" has to be
termined in relation to a master setpoint in %. As there is no selected, furthermore it has to
actual value for the master during the start period, the system be in GF mode. The slave
will first take the setpoint of the master component. After 15s feeders have to be in modes
the system will automatically switch over to the actual value GF, VR, VS, GD or VF.
of the master.

Chapter 5
5.3 Analogue control
With the modes group, 100%-group and master/slave it is possible to control the
group or master setpoint by means of an external 0-10 VDC signal. For this, a
10 VDC-signal will be assigned to the group or master setpoint that has been
entered on menu page F300. The component setpoints entered in % are a function
of the actual group or master setpoint. With the analogue control the following
points have to be observed:
1. An analogue control of the components (single mode) is not possible.

2. Due to the control of the group or master setpoint the analogue control is
only available for selected components.
3. The analogue input for the analogue control signal can be determined by
means of menu point AI by inputting the component number 1-8. The in-
put determines the component, the 1st analogue input of which is to be
used as control input. With standard software the 1st analogue input serves
for the connection of an analogue load cell. For this reason you have to
select a component that is not equipped with an analogue load cell.
4. The analogue control can be switched on and off via the digital input
analogue control, this is not a function of the setting of the menu point
analogue control. This is also possible if the feeding operation has started.
The configuration of the control input is to be done according to point (3).
5.4 Host computer operation

The host computer operation has to be activated in the sub-menu by means of the
menu point selection.
Different procedures are available for the host computer operation. For a detailed
description of the individual procedures please refer to the corresponding inter-
face descriptions. Example: the procedure PT03, that has to be selected for an
operation L/M 2 - PT03. If this procedure is activated the Congrav will cut out
the feeding operation due to the alarm CO-error, if the communication was
faulty for at least 5s. With Congrav LM2B,C this procedure will be selected
automatically, as soon as a PT03 has been connected to the interface.
5.5 Total output

Calibrates the total actual value output, by assignment of an output signal of
20mA to the total output that has been entered. A total actual value output is
only available in combination with the optional actual value card, and only if one
actual value output of a component is not used. The configuration and the selec-
tion of the total actual value output is carried through by means of the calibra-
tion program point 20.
5.6 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). The date/time-function is
only assisted by an LM 2A.

Chapter 6
6 Menu page F150: Recipe administration
In its standard execution the Congrav LM2 is
equipped with a SRAM memory card for the F150 GF GF GF GF GF GF GF GF PLC I=on
memorisation of the actual parameters Recipe number : 01
(installation backup). The installation backup is Load recipe from Memorycard
administrated as recipe 0 and automatically up- Store recipe on Memorycard
dated with each parameter modification. Moreo- Setpoint ramp : 000 s
ver, with a combination of LM2A or LM2B and Setpoint threshold: 010 %
a PT02 it is possible to memorise 14 recipes. Memorycard status : MC not included
These recipes contain all parameters that are
valid for the time of the memorisation. Setpoint ramp, setpoint threshold see chapter l
Available recipe functions: storing and loading of a recipe. First you select the
recipe by the input of the recipe number. After that you select either the function
store or load by means of the cursor and activate it by means of the enter-key di-
rectly without further warning.
Load recipe: All memorised data of the selected recipe (recipe number)
will be loaded from the Memory-Card into Congrav LM2.
This is displayed by the message load recipe. During this
procedure it is not possible to manipulate the Congrav via the
keyboard. This loading procedure will not be carried through,
if the alarm message recipe faulty appears on the screen. In
this case the selected recipe does not exist, as nothing had
been stored for this recipe number.
Store recipe: All actual parameters (except for the throughputs) are stored
under the recipe number that has been entered. During the
procedure the message store recipe will be displayed and it is
not possible to manipulate the Congrav via the keyboard.
Change recipe: First the recipe has to be loaded from the Memory Card.
Thus, all actual data will be written over and get lost. Carry
through the required modification (e.g. setpoint modification)
and memorise the recipe once again.
Each recipe contains all calibration data. If you make a change for one
! calibration point, e.g. for the calibration point lever this change will have
to be made for all recipes.
If the Memory Card is not included this will be displayed by the alarm report
memory card missing and the memory card status MC not included. Further-
more the internal battery of the Memory Card is continuously monitored. If the
battery voltage falls under a minimum value, the message battery empty will be
displayed. Both alarm reports block the recipe functions and have to be cleared
first. For a detailed description of the handling of the Memory Card and espe-
cially the battery change please see the Technical Manual of Congrav LM2.
With a newly inserted Memory Card (e.g. after a battery change) the first thing
to do is to store the actual configuration. For this purpose you enter the recipe
number 00 and activate the storage-function. After that the actual configuration
can be stored once again with another recipe number.

Kapitel 7
7 Menu page F200: Printer parameterization
With Congrav LM2A it is possible to connect a

printer, this menu page permits to configure the F200 GF GF GF GF GF GF GF GF PLC I=on
following printer functions.
Print time 000 Min
1. Interval print Screen page F 000
With an interval print the menu page selected Alarm printout off
will be printed according to the interval Print CP-data 1-8 0
(print time) defined. Throughput divisor inst. 1.000 kg
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 screen 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.
2. Alarm recording
The function alarm printout activates an alarm recording for 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
3. Printout of calibration data

The input of the component number 1..8 leads to a printout of the actual cali-
bration parameters of the corresponding component. After the printout the
component number that has been entered will be automatically reset to 0.
7.1 Total throughput divisor

According to the input the digital output "total pulse" will give a pulse corre-
sponding to the value. Input in kg. The input "0" switches off the function so that
no pulse will be emitted. With input 10 a pulse is always sent if the total
throughput has increased by 10 kg (and so on). This is also valid for unit lbs. For
every throughput divisor input it has to be observed that the Congrav LM2 can
emit a maximum of 3600 pulses/h. I.e. with a total setpoint of 3600 kg/h, as an
example, the smallest divisor input is 1 kg. Smaller divisor values cannot be read
in by the digital output „total pulse“. If the maximum value has been reached,
the throughput counter will be refreshed.

Chapter 7
7.2 Menu page F210: Reset memory
Congrav LM2 stores the feeding parameters on

two memory levels. Accumulator-buffered RAM Reset RAM and EEProm
components are employed as working memory.
Moreover, all feeding parameters are automati- Reset RAM
cally memorised on the Memory-Card (S-RAM, Reset EEProm 1
battery-buffered) with recipe 0. Reset EEProm 2
The menu points of this menu page permit the
concerted reset of the corresponding memory
elements.
It has to be absolutely observed that the resetting of a selected memory element

cannot be undone. The data are definitively lost and overwritten by new data. For
this reason the reset functions are locked by a code - this is independent of the
key switch - and they will have to be released by entering the code „0884“ before
selection of the reset function. Input of the code is only possible directly after
call-up of the page, i.e. before any cursor function. During RAM or EEprom re-
set the message "reset RAM" or "reset EEprom" is displayed. After the reset, the
welcome screen is displayed.
7.2.1 Reset RAM

All data in all available RAM components will be reset and replaced by the data
of recipe 0.
All throughput values get irrevocably lost, as the throughputs are not stored
! with recipe 0.
7.2.2 Reset EEProm 1

All installation parameters and all component parameters of the 1st I/O-
controller (components 1 - 4) in recipe 0 on the Memory-Card will be reset and
replaced by standard values.
7.2.3 Reset EEProm 2

All component parameters of the 2nd I/O-controller (components 5 - 8) in recipe
0 on the Memory-Card will be reset and replaced by standard values.
As per software version HG V2.0 and higher no EEProms will be em-

! ployed for the data storage in the I/O-controllers of Congrav LM2. The
EEProms will be replaced by the recipe 0 of the Memory-Card.

Chapter 8
8 Menu pages F300, F301: Setpoints and selection
This page permits to enter the setpoints and the F300 GF GF GF DI PLC I=on
selection, for an easy manipulation the cursor Total setpoint 100.000 kg/h
keys left and right are active. The menu page No | Setpoint% | Setpoint kg/h |Select
F300 displays the components 1-4 and the menu 01 | 20.000 | 20.000 | on
02 | 80.000 | 80.000 | on
page F301 displays the components 5-8. If the 03 | 100.000 | 100.000 | off
Congrav LM2 is only equipped with one I/O- 04 | 75.000 | 10.000 | on
controller (max. 4 components) there is no menu
page F301.
8.1 The setpoints

With the setpoints displayed, we have to distinguish between two types: namely
the calculated 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 feeder has started. However, the setpoint
modification will only be taken over, if the setpoint limitation has not been vio-
lated by an input or by a following calculation.
Setpoint < 1.1 * max. output
8.1.1 The installation setpoint

Single The total setpoint is calculated from the sum of the setpoints of all
selected components.
Group The group setpoint is entered in kg/h.
Master/Slave The master setpoint is entered in kg/h.
8.1.2 The component setpoints

Mode Setpoint in % Setpoint in kg/h
*
SP[kg / h]
Single 100%⋅ Input
Total SP
*
Group Input SP [%] ⋅ group SP [ kg / h]
* * only valid for selected com-

Master/Slave Input SP [%] ⋅ master SP [ kg / h] ponents
The input refers to 10V DC and no selection:
determines the constant ma- The kg/h-setpoint will not be cal- max. output (CP03)
Discharge nipulated variable. The setpoint culated. instead of totalSP
groupSP
entered will not be taken into masterSP
consideration by a 100%-
monitoring.
8.1.3 Setpoint ramp, setpoint threshold (menu page F150)

Only setpoint modifications < setpoint threshold will be controlled by the system.
Ramp = 0
With setpoint modifications > setpoint threshold there will be a jump of the ma-
0s
setpoint p=1
Ram
nipulated variable of ( 75% ⋅ )in order to assist the control procedure.
output 0 10
The setpoint ramp determines the steepness of the change of the manipulated
variable.

Chapter 8/9
8.2 The selection
The selection of a component has the following effects:
1. The selected component can be addressed by the keys start, stop and alarm
reset.
2. The calculation of the total setpoint, total actual value and total throughput
are exclusively carried through under respect of the selected components.
3. The option alarm stop (see chapter 9.2) only takes into consideration the se-
lected components.
4. The modes group and master/slave only take into consideration the selected
components.
5. The 100%-monitoring for the mode 100% group only take into consideration
the selected components.
9 Menu pages F310,F311: Alarm stop, delay times

The menu page F310 displays the components F310 GF GF GF DI PLC I=on
1-4 and the menu page F311 displays the com- |Delay times / s|
ponents 5-8. If the Congrav LM is only No | Start | Stop |Alarm stop
01 | 000 | 000 | on
equipped with one I/O-controller (max. 4 com-
02 | 000 | 000 | off
ponents) the menu page F311 is not available. 03 | 000 | 000 | off
For an easy manipulation the cursor keys left 04 | 000 | 000 | off
and right are active on these menu pages.
9.1 The delay times

Between the activation and the carrying-out of the start or stop order of a com-
ponent you can fix a delay time (in seconds).
Start delay: After the start order of the component the run-off of the start
delay time will be indicated by a green and flashing LED in
the corresponding K-key and a "DT"-mode display in the
status line. Parameter modifications during the start delay are
refused, exception: setpoints and controller parameters.
Stop delay: After the stop order of the component the run-off of the start
delay time will be indicated by a green and flashing LED in
the corresponding K-key and an inverse "DT"-mode display
in the status line. During the stop delay time the actual feed-
ing operation will be continued according to the parameteri-
sation and parameter modifications will be refused, excep-
tion: setpoints and controller parameters.
9.2 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 selected com-
ponents.

Chapter 10
10 Menu pages F400 - F420: Total survey page
The menu pages F400, F410 and F420 (with 8 components also the menu pages
F411 and F421) the actual values of the feeding operation are displayed. With
these pages it is not possible to enter parameters.
F400: Displays the actual values of the installation total actual value and total
throughput. These values are calculated from the sum of the component
values of the selected components.
F410: The setpoint, the actual value and the throughput (= total) for the com-
ponents 1 - 4 are listed in columns. With an 8-component-execution re-
newed activation of the scroll key permits to call up the menu page F411
for the components 5 - 8.
F420: The weight, the control difference and the speed (= total) for the com-
ponents 1 - 4 are listed in columns. With an 8-component-execution re-
newed activation of the scroll key permits to call up the menu page F421
for the components 5 - 8.
10.1 Menu page F430: Reset all totals

F430 GF GF GF DI PLC I=off
Reset all totals
Sel. 0.000 t L Total 0.000 t L
01 0.000 kg L 05 0.000 kg L
02 0.000 kg L 06 0.000 kg L
03 0.000 kg L 07 0.000 kg L
04 0.000 kg L 08 0.000 kg L
To erase the throughputs place the cursor on the respective "L"-field and push
the enter-key.
Select: The throughputs of all selected components are reset.

Total: The total throughput, the sum of the single throughputs of the selected
components, will be reset. All cleared total throughputs are added as
reset offset and then memorised. With the new calculation of the total
throughput the reset offset will be subtracted from the sum of the single
throughputs of the selected components.
Single: The throughput of the corresponding component will be reset. The total
throughput will be reduced by the single throughput that has been
cleared, however, it cannot adopt a negative value. If a single through-
put is reset that is higher than the total throughput, the total throughput
will be reset to zero. For resetting the throughputs it is thus not re-
quired to keep a special order (first the single throughputs, then the to-
tal throughput).

Chapter 11
11 Menu page F500: Alarm reports
Menu page F500 displays the alarms or the missing start conditions of the mode
display in plain text.
Alarm report Meaning and causes
Speed min. the minimum speed has been fallen short of, because either
- the value determined for minimum speed is to high,
- the speed reading-in of the Congrav is defective,
- the setpoint is to small for the dimensioning of the feeder or
- the PID-controllers have been adjusted incorrectly.
Speed max. the maximum speed has been exceeded, because either
- the value determined for maximum speed is to small,
- the setpoint is to big for the dimensioning of the feeder or
- the PID-controllers have been adjusted incorrectly.
Underload the hopper filling level has fallen short of the min. quantity, because
DDW - the hopper has not been refilled,
- the limit values underload and filling level min are to close to one another,
- the overload protections have been adjusted incorrectly or
- the mode gravimetric discharge has been selected.
- the minimum belt load has been fallen short of, because
DBW - no product or to little product on the belt
Overload the hopper filling level has exceeded the max. quantity, because
DDW - the limit values overload and filling level max are to close to one another for the
refill operation or
- the DDW has been overloaded by an external charge.
DBW The product layer on the belt is heavier than the max. belt load.
Refill fault the min. filling level has not been exceeding within the determined refill time, be-
DDW cause
- the feeder has not been refilled (failure in the upstream filling device),
- the digital output refill of the Congrav is defective or
- the refill quantity is to small compared to the setpoint.
Control differ- the control difference took longer than the alarm cut-out time, because either
ence pos. / neg. - the PID controllers have been adjusted incorrectly,
- the PID controllers build up due to external perturbations,
- the filter limits are constantly violated and thus the control is to much attenu-
ated,
- the screw is not filled with product (e.g. bridging) or
- product pours out of the upstream filling station
AV-fault the violation of the filter limits took longer than the AV-cut-out time, because ei-
DDW ther
- the filter limits that have been input are to small,
- due to external perturbations the filter limits have been continuously violated or
- the PID controllers have been adjusted incorrectly.
Load cell? the serial load cell data are missing, because either
DDW - 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
AT-fault the AT-operation of the weigh-belt feeder was troubled, because
DBW - the belt load violates the allowed auto-tare range or
- the belt load is ≤ 0 and cannot be tared.
MM- fault Memory module fault, to find the cause for these faults it is required to contact the
EE- fault BRABENDER service department.
• the causes listed before do not claim for completeness, they are only meant to help the operator with trouble
shooting.

Chapter 12
Start Meaning and causes
conditions x = 1...8
Bulk density ? Missing input of bulk density on page Kx10.

Output =0 Missing input of output value on page Kx10 or the mode checking
of max, output still has to be carried out.
Min<Underload The filling level limits have to correspond to the following order:
Min > Max Underload < fill. level min < fill. level max < overload
Max>Overload
Weight < Min. The product quantity in the hopper is inferior to the minimum fill-
ing level.
It is possible to start the feeder with this start condition. The start
automatically activates the refilling.
Tare weight=0 With a weigh-belt feeder you have to enter an auto-tare value on
page Kx10 or you have to carry out auto-tare.
Feeder locked The input for feeder type is 0. For the Congrav this component does
not exist.
SP > max. out- The setpoint violates the setpoint limitation. This start condition
put will only be displayed with group or master/slave operation, if a
component has been selected by the input of the master or group
setpoint.
12 Menu page F600: 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:
1. 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 de-
vice is released.
2. 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 reasons the changes must only be do-
ne by authorized and specially trained operating staff. The changes have to
be noted in the corresponding lists, so that they are available in case of a pos-
sible service support by telephone.

Calibration list
H+G-parameters for loss-in-weight feeders (DDW) and weigh-belt feeders (DBW)

Feeder parameters Value range Standard Input
01 Feeder type HS/HA/HD/G/HM 0-5 0
02 Weighing range 0.1 - 10000 kg 60
03 Maximum output 0.01 - 999999 kg/h 100
04 Underload 1 - 100 % 10
05 Overload 1 - 100 % 90
06 Coarse tare 0 - 100 % 0
07 Average weight acq. 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 deviation 0.1 - 100 % 1
12 Alarm cut-out time 1 - 600 s 60
13 Type of interlocking 0-3 0
14 Indic. of actual value 1 - 20 s 2
H-parameters only for loss-in-weight feeders (DDW)

15 Lever factor 0.1 - 10000 1
16 Hopper volume 1 - 100000 l 200
17 Fill. level minimum 1 - 100 % 20
18 Fill. level maximum 1 - 100 % 70
19 Window/K1/Filter 0.1 - 255 7
20 Actual value output 0-4 0
21 Maximal refill time 1 - 600 s 60
22 Refill optimise 0-2 0
23 Stabilisation time 1 - 60 s 5
24 Sampling time 1 - 600 s 60
25 AV cut-out delay time 1 - 600 s 15
26 Contr. 2 access time 0.5 - 3600 s 10
27 Control automatic 0 - 15 3
28 Filter limits 1 - 5000 % 50
29 Actual value adaptation 0-5 3
30 Adapt. of manip. variable 0 - 100 % 0
31 Adapt. actual value VR 0.1 - 10 1
32 Alarm delay time for VR 0 - 600 s 20
G-parameters only for weigh-belt feeders (DBW)

33 Length weighing bridge 0.1 - 10 m 0.412
34 Weight test value 0.1 - 10 1
35 Adaptation 0.1 - 10 1
36 Auto-tare range 1 - 50 % 10
37 No load time auto-tare 0 - 600 s 60
38 Rated belt speed 0.01 - 1000 m/min 20
39 Belt length 0.01 - 1000 m 2.390
40 Dead-time way 0.01 - 10 m 0.8

Chapter 12
12.1 Explanation of the functions of the feeders parameters
01 Feeder type HS/HA/HD/G/HM
Input of the feeder type of the connected weigh feeder.
0= no feeder connected, feeder is locked
1= DDW with a serial IDL(-F) load cell
2= DDW with an analogue strain gauge load cell (SGL)
3= - not assisted by Congrav LM2 -
4= DBW with an analogue strain gauge load cell
5= DDW with an analogue strain gauge load cell and a serial AED inter-
face for data transfer
02 Weighing range
Input of the actual weighing range of the weigh feeder, it results from mul-
tiplication of the weighing range value of the load cell with the mechanical
lever of the loss-in-weight feeder (DDW).
In case of a weigh-belt feeder (DBW) the input equals the weighing range of
the load cell.
The actual weighing range of the weigh feeder must never be ex-
ceeded, 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 modifica-
tion of the load cell characteristics (linearity). This would lead to an
inaccurate feeding.
Definition: the usable weighing range

The usable weighing range that is available for the feeding operation is cal-
culated from the following feeder parameters:
1. (act. weighing range x lever factor) - tare ⇔ (CP02 x CP15) - CP06
2. (Hopper contents x bulk density) ⇔ CP16 x bulk density
if
(Hopper contents x bulk density) < (act. weighing range x lever factor)
Special function with the mode volumetric regulation (DDW):
Input of maximum throughput [l/min]
03 Maximum output
The input of the maximum output in kg/h or lb/h is required for the follow-
ing functions:
1. Input limitation for the setpoints
2. Assignment of 20mA to the optional actual value outputs
04 Underload
The input in % is a function of the usable weighing range and defines the
minimum hopper contents (DDW) or the minimum belt load (DBW).
05 Overload
The input in % is a function of the usable weighing range and defines the
maximum hopper contents (DDW) or the maximum belt load (DBW).

Chapter 12
06 Coarse tare
The input in % is a function of the actual weighing range (CP02). The tared
weight value is subtracted when calculating the weight. The parameter has
the function the reduce mechanical preloads so far that an auto-tare opera-
tion can be carried out.
07 Average values
The input defines the number of measuring values for the calculation of the
average values.
08 Throughput divisor
The input in kg or lb determines the value for the throughput counter
(totalizer) of the component. The input should be selected in such a way that
the internal counter has at least 0.1% of the rated output. A value between
1g (= 0.001) and 1t (= 1000) can be defined for the throughput divisor.
However, for the definition it has to be taken into consideration that the
Congrav LM2 can emit a maximum of 3600 pulses/h.
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 = 999999kg
Divisor = 10kg: max. value = 999990kg
Divisor = 1000kg: max. value = 999000kg etc.
If the max. value has been reached, the throughput counter will be refreshed.
The addition of the divisor values also takes into consideration the carry.
For a measured value of 1001g, 1kg (divisor = 1kg) will be displayed and
1g taken into consideration for the next calculation.
09 Speed minimum
The input in % is referred to 10 VDC and defines the minimum speed.
10 Speed maximum
The input in % is referred to 10 VDC and defines the maximum speed.
11 Control deviation
The input in % is referred to the setpoint and defines the allowed max. con-
trol deviation. This deviation is only calculated and monitored in the compo-
nent modes "gravimetric feeding" (GF), "gravimetric discharge" (GD) and
"volumetric regulation" (VR). If the calculated control deviation exceeds
the max. permitted control deviation this will be displayed in the mode dis-
play by "D+" or "D-" and the alarm cut-out delay time (CP12) expires.
12 Alarm cut-out delay time
The alarm cut-out delay time entered determines the maximum time in
which a violation of the permitted control deviation is allowed. If the viola-
tion of the permitted control deviation 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 delay time is reset if the violation of the permitted control deviation
is no longer on.

Chapter 12
13 Type of interlocking
This calibration point determines the logic of the
digital input "interlocking", the digital input "stop" Interlocking Alarm
and the digital output "alarm". The following table 0 24 V normal
lists the possible inputs. The logic "inverted" means 1 0V normal
that the alarm output is set if no disturbance is pres- 2 24 V inverse
3 0V inverse
ent and is not set if a disturbance is present. This in-
put has no influence on the digital input
installation interlocking of the master controllers, that is generally set to
(24V = interlocked).
14 Indication of actual value

Determination and updating time for actual value and time base for short-
term actual value.
15 Lever factor
Adaptation factor for the static weight adjustment of the loss-in-weight
feeder.
16 Hopper contents
The value input in litres contains the screw trough and the hopper.
17 Filling level minimum
The input in % is referred to the usable weighing range and defines the fill-
ing level value at which automatic switch over from feeding operation to re-
fill mode occurs.
18 Filling level maximum

The input in % is referred to the usable weighing range and defines the fill-
ing level value at which automatic switch over from refill mode to stabilisa-
tion time (= end of refilling) occurs.
19 Window/K1/Filter only for the feeder types HS and HM

Generally, the value that has been entered will only be sent to the corre-
sponding load cell by means of the stop function. The definition of the load
cell filtering has an influence on the inertia of the signal and thus on the
control of the feeding operation.
HS-type (= IDL(-F) load cell types)
Window Filter function with an IDL-F
0, 1 no or slight filtering (=standard setting in the cell)
2, 3, 4, 5, average filter setting with increasing filter effect
7 strong filter setting with increasing filter effect
6, 8, 9 only interpreted as input for the window value (IDL), i.e.
>9 refresh time of the load cell = input x 20ms
The filter setting 6 should be sufficient for most of the applications.
HM-type (strain gauge load cell with AED-module):

1= no filtering ............................ 8= very strong filtering

Chapter 12
20 Actual value output
Selection and configuration of the optional actual value card of Congrav
LM2. The inputs 1,2 permit to configure the corresponding actual value
output as actual value output of the component. The inputs 3,4 permit to
configure the corresponding output as total actual value output.
Input Function
0 Output is deactivated
1 0 - 20mA, 20mA = max. output (CP02)
2 4 - 20mA, 20mA = max. output (CP02)
3 0 - 20mA, 20mA = total max output (F100)
4 4 - 20mA, 20mA = total max output (F100)
21 Maximum refill time

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.
22 Refill optimise
Inputs > 0 activate the refill optimisation, that serves for an adaptation of Example:
the constant speed during refilling by means of the course of the speed after Input = 0.9
refilling.
After each refilling and after each start without memorised speed, the aver- average speed = 30%
age speed of the feeding operation will be measured for 20s and then memo- RF_speed = 27%
rised. Setpoint modifications after the calculation will be calculated linearly. after PS = 30%
Setpoint modifications that cause the feeder to be stopped or interlocked
during the measuring time, will reset the measuring time. The constant speed
of the next refilling is calculated from the adjusted factor multiplied by the
memorised speed. The speed that has been calculated for the refilling will be
adopted if the feeder refills and the Congrav recognises an increase in
weight.
The factor will be reset after elapse of the stabilisation period, so that the
feeding starts with the memorised speed. The memorised average speed is
reset by a modification of the parameters bulk density, output, fill. level
min., overload and switching off the refill optimise (=0 set).
23 Stabilisation time
After the refill period the material stabilisation time starts. After elapse of
the material stabilisation time follows the switch over to the selected com-
ponent mode.
24 Sampling time
With this calibration point the time for sampling and the component mode
"checking max. output" (CM) is defined.
25 AV-cut-out time
If a filter limit value is violated during the component mode "gravimetric
feeding" the AV cut-out time starts. If the filter limit violation still exists
after elapse of the AV cut-out time there is an alarm cut-out or an alarm re-
port. The AV cut-out time is reset if the violation of the filter limit value is
no longer on.
26 Controller 2 access time

Chapter 12
The access time for the 2. controller may be changed; the access time of
controller 1 cannot be changed. Access time of the second controller can
only be a multiple of the computer cycle time of 0.5 sec.
27 Controller automatic
Input Function
0 no function
1 controller automatic selected
2 filter automatic selected
3 controller and filter automatic selected
4 non-repetitive start automatic selected
5 non-repetitive start and controller automatic selected
6 non-repetitive start and filter automatic selected
7 non-repetitive start, controller and filter automatic selected
8 general start automatic selected
9 general start and controller automatic selected
10 general start and filter automatic selected
11-15 general start, controller and filter automatic selected
a) Controller automatic
The adjusting factor for the adjusting controller is set to 0.8. Inputs on
the component pages Kx20 have no function.
b) Filter automatic
To protect the installation from disturbances from outside, e.g. vibra-
tions, the control sequence is limited by means of a band filter. Structure
and operation of this band filter are described by the function of calibra-
tion point CP28. The filter automatic functions with a 20s-cycle and
adapts the entered filter limits (CP28) in a dynamic manner to the feed-
ing process. The filter automatic functions within a range of [10% -
CP28]. During the feeding operation, an activated filter automatic will
start a short AV mode in constant intervals. An AV alarm report
(with/without alarm cut-out) is only displayed, if the maximum value
(CP28) has been violated for the duration as per CP25.
c) Start automatic
If on commissioning the component mode "checking max. output (CM)"
cannot be carried out, the output always must be entered. A wrong out-
put generally has a negative impact on the complete control behaviour of
the feeding, in the worst case, this might lead to an alarm cut-out.
With the start automatic it is possible to determine the output after the
start of component mode gravimetric feeding during a volumetric start
period and to memorise this value subsequently.
ci) Non-repetitive start automatic
The non-repetitive start automatic is selected by means of the respective
input of an output value and activated by means of an output change.
The non-repetitive start automatic is only used after the first start of the
installation and after activation of this function. All subsequent changes
of the manipulated variable due to a setpoint change or a new start of the
installation will be made with the calculated output.

Chapter 12
This results in the following sequence for the non-repetitive start auto-
matic:
1. Input 4 ... 7 for CP27
2. Change the output (Kx10).
The chronological order of this process must always be observed because
an activation of the non-repetitive start automatic is not possible without
activation. The activation is maintained even after the non-repetitive start
automatic has been carried through, so that each change in the max. out-
put reactivates the non-repetitive start automatic again. The non-
repetitive start automatic is put out by changing the input in CP27 ac-
cordingly (0 - 3 or 8 -15).
cii) General start automatic
The general start automatic is made with each new start of the installa-
tion. Selection and activation of the general start automatic is made by
means of the respective input (8 - 15).
ciii) Sequence of the start automatic (non-repetitive/general)
1. Input of all feeder-specific data and selection of the non-repetitive
start automatic or activation of the general start automatic.
2. Input of an output value and fulfilment of the other start conditions.
3. After the input of a setpoint the installation can be started. The start
of the installation begins with a manipulated variable which is calcu-
lated from the following equation:
y: manip.variable Outp: output
y = DI_SP x (7,5V x w/Outp) w: setpoint DI_SP = discharge setpoint in %
In order to avoid overfeeding the manipulated variable of the start

will be reduced by the discharge setpoint (≤ 100%). Thus the security
factor of the start automatic can be adjusted manually. If the dis-
charge setpoint is set to 0%, the manipulated variable of the start will
be reduced by 40%. The more exactly the output is known, the
smaller the reduction may be.
Manipulated variables of the start < 10 % have to be avoided.
After the start there will be a period of volumetric feeding that will be
followed by a so called check phase. During this check phase the loss in Product reduction
product will be checked. If no loss in product can be observed, the check IDL, AED 50 ppm
phase will automatically be extended by 1 s each. If the max. time of the SGL 4 digits
check phase has been exceeded (CP12), there will be an alarm report D+
with/without cut-out. The measuring phase starts after the check phase.
During this measuring phase (total duration 20 s) 6 samples that take 15
s each, are measured. The samples are started with a delay of 1 s with
respect to the others. The minimum and the maximum value out of these
six values are not taken into consideration, and the average value will be
calculated from the remaining 4 sample values and memorised. This
method of calculation permits to achieve a higher precision and a better
resistance against failures. But despite the enhanced calculation method
it is important to avoid external disturbances.
Directly after the start automatic the gravimetric feeding will start with a
manipulated variable for the start that is a function of the calculated out-
put.

Chapter 12
28 Filter limits
The control process is encompassed by a band filter during the gravimetric
feeding period. Thus, the influence of disturbances from outside will be re-
duced. The input in % is related to the setpoint and leads to the so-called ab-
solute filter limit values, they are employed to determine the maximum
feeding range of an undisturbed control. If this range is violated , e.g. by ex-
ternal pulse spikes, the controller parameter will be damped and the weight
value will be evaluated with a filter function. I.e., the influence of the exter-
nal pulse spikes is reduced so that after the fading of the disturbance and
control will soon return to its former sequence. When defining the filter lim-
its you should proceed according to the principle not higher than necessary.
If the filter limits have been selected to low, they will deteriorate an undis-
turbed control process, if they have been selected to high, disturbances from
outside will be lead into the control circuit without having been filtered.
29 Actual value adaptation

Adjustment of the actual value filtering for the actual value calculation:
0 = old act. val. calculation 1 = weak filtering 5 = strong filtering
volumetric regulation: Actual value calculated from the average value read
Number = 2 input
in. Input determines the number of average values.
30 Adaptation of manipulated variable
Compensation of the non-linear characteristic line of the RMS1- power unit.
The parameter must only be employed with a RMS1- power unit.
31 Adapt. actual value VR
In the component mode volumetric regulation the flow quantity or the
throughput of the product is determined by means of suitable measuring
methods. If there are measuring instruments which are not suitable for cali- I Con
APnew = ⋅ APold
bration, i.e. these instruments cannot provide a standard signal, this calibra- I act
tion point can be used for an adaptation between the actual value displayed
on the Congrav LM2 (ICon) and the real actual value (Iact).
32 Alarm delay time for VR
After the start of the mode volumetric regulation, all possible disturbances,
like speed min. etc., are not taken into consideration so that there will be no setpoint
ycon = 100% ×
display nor a cut-out caused by this disturbance. First, the system will be output
started with the constant manipulated variable ycon and after elapse of half of
the alarm delay time the control will start.
33 Length of weighing bridge (LWB)
Correction factor for small differences between the setpoint of the DBW and setpoint ⋅ LWB
LWBact =
the actual value of sampling. actual value
34 Weight test value (WTV)
Factor for the static weight adjustment of the strain gauge load cell of a weight value
WTVact = ⋅ WTV
DBW. weight display

Chapter 12
35 Adaptation (AP)
Adaptation factor for the weight value and the weight display of a DBW. weight value
APTat = ⋅ AP
weight display
36 Auto-tare range
The input in % is related to the weighing range, it determines the allowed
maximum auto-tare range of a DBW.
0 < tare value < tare range
If the mode auto-tare calculates a belt load that exceeds this range or this is
inferior or equal to zero, the alarm message auto-tare error will be dis-
played.
37 No load time auto-tare

Duration of the run-up phase during auto-tare.
38 Rated belt speed

The speed of the belt in m/min at nominal speed.
vn = nominal belt speed in m/min
nM = outgoing speed of motor gear in tpm
Z1
Vn=nM⋅ dm⋅ π⋅
Z2 dm = drive roller diameter dA + belt thickness (dA = 0,12m)
π = 3,14159
Z1 = no. of teeth motor side Z2 = o. of teeth drive roller side
39 Belt length
Total length of the belt of the weigh belt feeder.
40 Dead-time way
If after the weigh-belt feeder has been started there are less than 50 g of
product on the belt, the belt will run for this distance without regulating and
without giving alarms. (Distance between inlet and centre of weighing
bridge.)
Gravimetric feeding will be activated automatically after elapse of the dead-
time way or with a belt load > 50g.

Chapter 13
13 Manipulation of the components
The K-keys permit to call up the manipulation level of the corresponding compo-
nent (K1 = component 01). After call-up with the K-key the further menu pages
can be called up with the scroll keys.
13.1 The component page Kx00

The first menu page administrates all manipulation functions (left column) and
displays the actual values (right column) for the feeding operation. This menu
page permits to control each component individually, independent of the selec-
tion. The desired function is selected with the aid of the cursor and activated by
pressing the Enter-key.
K100 GF GF GF DI PLC I=on

HS-Type Feeder 01
Start | Setpoint 0.000 kg/h
Stop | Actual value 0.000 kg/h
Alarm reset | Speed 0.000 %
Refill | Weight 0.000 kg
Start sample| Sample 0.000 kg/h
01 Start
The component is started under consideration of the determined start delay
time if all required start conditions have been fulfilled.
02 Stop
The component is stopped under consideration of the fixed stop delay time.
03 Alarm reset
The present alarm is reset so that operation of the component is again possi-
ble.
04 Refill DBW: no function

Manual refill can be switched on and off.
05 Start sample DBW: no function

The function "sampling" is started. The right column adds up the product
quantity in kg(lb) that has been fed during the sampling time. After elapse of
the sampling time the sample quantity in kg/h (lb/h) calculated from the fed
product quantity is displayed. The sample quantity is a measure for the
feeding accuracy, if the weighing system has been calibrated correctly.
Sampling will be stopped, if
- an alarm occurs during sampling
- the component is stopped or interlocked
- manual refill or automatic refill is activated

Chapter 13
13.2 The component page Kx10
01 Auto-tare: 2 functions!
1. With a loss-in-weight feeder the actual K110 GF GF GF DI PLC I=on
HS-type Feeder 01
weight value will be tared automatically
Auto-tare 0.000 kg
under the condition (weight < 5% of Check. max. output 0.000 kg/h
weighing range), if the cursor is set on the Bulk density 0.000 kg/l
menu point and the enter-key is activated. Mode GF
If the actual weight exceeds the maximum I/O-configuration I: 0 O: 0
auto-tare value, coarse tare (CP06) will
first have to be adjusted accordingly.
With a weigh-belt feeder, in this case the auto-tare operation will be se-
lected and with a following start order it can be started with a constant
manipulated variable of 50%. The AT-procedure ends automatically after
elapse of the no-load time and one further revolution of the belt. The AT-
procedure ends with an alarm report, if the tare value ≤ 0 or if it is bigger
than the AT-range.
2. Manual input of the auto-tare value in kg(lb), if the cursor is placed on the
value (1 x cursor to the right).
02 Checking max. output DBW: no function

The output is required for the start and for the jump of the manipulated vari-
able in case of a setpoint modification. This jump of the manipulated variable
leads to a rough setting of the setpoint, so that the control needs a shorter
transient phase. A wrong output value extends the transient phase and may
lead to an alarm cut-out in extreme cases due to a control violation that is
much to high or due to a filter violation. The output value displayed is as-
signed to a speed of 75%.
1. During the mode "checking max. output (CM)" the product quantity that
has been fed is added in kg for the speed ranges (15%, 45%, 75%). If the
operating mode "CM" has come to an end, the calculated output will be
displayed in kg/h.
2. After a soft start the calculated output will be displayed.
3. If the mode "CM" cannot be carried out, the output value must be entered
manually.
4. In case of a change of the feeder type (CP01) the CM-value will be auto-
matically reset and has to be entered/calculated anew.
03 Bulk density DBW: no function

The bulk density of the product is required for the calculation of the filling
level. The input of the filling level is limited to the range 0.01-10 kg/l (0.01-
200 PCF). A modification of the bulk density has no influence on the ma-
nipulated variable of the start (bulk density_old is not taken into considera-
tion).

Chapter 13
05 I/O-configuration
Configuration of the 4th digital output DO4 as well as the 1st digital input DI1
of a component.
Input DO4 DI1

0 Control deviation +/- Interlocking
1 Throughput pulse Refill DDW
Auto-tare DBW
2 Overload Gravimetric discharge (GD)
3 Underload
4 Alarm report
04 Mode DBW: only GF, DI, MA

The range for gravimetric operation is located between filling level min. gravimetric feeding GF
(CP17) and overload (CP05). In this range the actual value is generated from
the weight decrease per time unit. The actual value is used for the calculation
of the control difference (setpoint - actual value) for the PID-control algo-
rithm. On reaching of filling level min., refill (RF) is initiated. The control is
deactivated with the start of refilling and during the complete refill phase the
average of the manipulated variable is put out constantly. During this feeding
phase a setpoint modification is processed proportionally. After elapse of the
stabilisation period (ST) the refill phase will be finished and the gravimetric
feeding (GF) is again active.
During the gravimetric feeding phase (D+), (D-) or (AV) are possible mode
displays. (D+), (D-) indicate a positive or negative control difference which is
bigger than the maximum permitted control difference (CP11). (AV) signalises
a filter violation (CP28).
Volumetric regulation functions according to the principle of the throughput volumetric regulation VR
control. The actual value matches the flow rate of the product and is meas-
ured by means of suitable acquisition methods (micro motion or impact
plates) and processed for the PID-control. The 0-10VDC signal of the meas-
uring instrument is read in via the analogue load cell input of the Congrav.
The transport device (e.g. pump) is controlled via the manipulated variable
output of the Congrav. A parameterisation takes into account the following
parameters:
1. weighing range (CP02) = maximum flow rate in [l/min]
2. weight display = actual flow rate in [l/min]
3. output (Kx10) = maximum output in [l/h]
4. act. value adaptation (CP29) = average value for calculation of act. value
5. lever factor (CP15) =1
With measuring instruments that cannot be calibrated and do not provide a
standard signal, the adaptation between setpoint and actual value has to be
carried out by means of the parameter adaptation of actual value VR (CP31)
(does not replace (CP29)).
setpoint
The mode VR starts with the manipulated variable ycon. As long as the alarm y con = 100% ×
delay time runs down all disturbances are suppressed to stabilise the feeding output
operation. The control starts after half of the alarm delay time.

Chapter 13
With this mode the speed of the feeding device is used as actual value. The volumetric setting VS
speed is measured by means of appropriate methods and is then made avail-
able to the Congrav LM2. The feed rate of the feeding device and the flow setpoint
rate have to be adjusted to each other so that the setpoint in kg/h and the ac- y con = 75% ×
output
tual feeding capacity are matching. The product flow will not be measured.
With this mode the program uses a constant manipulated variable of + 7,5 V discharge DI
which is issued automatically together with the start. It is possible to change
the manipulated variable by entering a desired setpoint in %. The calculation DI-SP = 0% ≡ 75%
of the actual value/throughput functions according to the selected weigh
feeder and all weight related limit values are out of function. Alarm monitor-
ing only functions for the speed monitoring.
With this mode it is possible to determine the max. output of the loss-in- Checking max. output CM
weight feeder as a function of the product. Checking the max. output is auto-
matically carried out in three speed ranges (15 %, 45 % and 75 %), according
to the listed order. For each speed range a CM-value is memorised, this re-
sults in a characteristic that is a function of the product. The total time for
checking the max. output can be defined by the sampling time (CP24) (one
third for each speed range). Before the start of checking the max. output the
discharge device has to be filled with product (e.g. in a short-term DI-
operation). The allowed filling level range for checking the max. output is the
range between overload and underload. In these two ranges there is always an
alarm cut-out. This mode can be interrupted at any time by pressing the stop-
key and started again with any new start. In case of an interruption or in case CM-error
of a stop or a disturbance, no values will be stored. After checking of the illogic measuring values, e.g.:
- negative values
max. output, the value that is corresponding to a speed of 75% will be dis-
- 15%-value > 45%- value
played in the menu point checking max. output or the report CM error will be
displayed.
This mode is no independent mode but a special function of the mode gra- gravimetric discharge GD
vimetric feeding. It is possible to switch over from GF to GD with feeding Switchover from GF → GD
being started or stopped. With GD mode there will be no refilling on reaching - Mode selection Kx10
of filling level min but gravimetric feeding will be continued until filling level - Digital input 1
underload has been reached. On reaching underload there will be an alarm - Host computer
report unterload with/without cut-out and a switch-over from GD to GF.
If there is no alarm cut-out in case of underload, mechanical damage

risks to be caused as the screw is not filled with product while the
! speed is constantly rising (controller!). The same goes for to small
underload values. (screws are not turning true)
volumetric feeding VF
With this mode the manipulated variable stays constant (ykon), there is no
control. Otherwise this mode is corresponding to gravimetric feeding mode setpoint
(monitoring of filling level, filling, calculation of actual value etc). y con = 75% ×
output
If maintenance operation is selected with a component, this component will no Maintenance MA

longer be addressed by the Congrav LM2. By selection of this mode a possi-
ble selection will be reset automatically.

Chapter 13
13.3 Component page Kx20: Control parameters
For the gravimetric control of a weight feeder it is possible to configure two con-
troller types: controller 1 that is a PID controller with a 0.5s cycle or controller 2
that is an adjusting controller with a variable cycle.
!
Controllers 1 and 2 function separately from one another. For this reason,
parallel operation of both controllers should only be activated, if it is absolu-
tely necessary. It is generally required to adjust the controllers to the feeding
conditions and to check the controllers.
Recommended values for basic

01 - 03 P-, I-, D-term 1st controller controller setting
The 1st controller is a PID-controller with the following differential equation: Output kg/h P I D
0.5 - 2.5 40 0.15 0
( ∑ ( xd ) + T )
TS TV 1 2.5 - 10 30 0.25 0
yi = K p1 ⋅ xdi + i ( xdi −1 − xdi )
TN 1 s 10 - 50 20 0.5 0
50 - 250 15 0.75 0
yi: change of manipulated variable, xdi: control difference, Ts: scanning time, Kp1: P, TN1: I Tv1: D
250 - 500 10 1.0 0
The controller has the function to control the deviation that appears during 500 - 1000 5 2.0 0
feeding (setpoint - actual value). For this purpose the Congrav LM2 takes an 1000 - 5000 3 4.0 0
actual value from the continuous sequence of the actual value in fixed time 5000 - 25000 1 8.0 0
intervals Ts and calculates the weight difference/cycle (=actual value) and the
control difference xdi. The control difference thus calculated is added to the
control algorithm mentioned above. The result of the control algorithm is the
change of the manipulated variable yi. With this the Congrav LM2 determines
a new variable and transmits it to the setting device of the feeder via the ana-
logue output of the manipulated variable (0 - 10 VDC).
04 Adjusting factor 2nd controller(DDW)

The 2nd controller has the function to guarantee long-time stability. The algo-
rithm of the 2nd controller functions with a variable access time (CP26), it is a Example:
mere adjusting controller. I.e. during the access time that has been adjusted Setpoint = 95 kg/h
(CP26) the absolute loss in weight (=actual value) and the average speed will Actual value = 100 kg/h
be measured. The adjusting regulator calculates a speed difference corre- Speed = 50%
sponding to the existing control difference = (setpoint - actual value), this dif- Adjusting factor = 1
ference will be set to absolute. In order to calculate the precise difference, a new manip. var. = 47,5%
volumetric feeding phase runs down before each measurement. The volumet-
Adjusting factor = 0.75
ric phase permits to take into consideration the average value adjustment new manip. var. = 48.13%
(CP07) and the window/filter- adjustment (CP19). After each start the ad-
justing controller will operate without average calculation for 8 cycles, after a Adjusting factor = 0
setpoint modification or after refilling for 4 cycles. After that its adjusting re- new manip. var. = 50%
action will be calculated from the average value of the last 4 modifications of
the manipulated variable. The adjusting factor permits to adjust the damping.
An input 0 switches off the adjusting controller.
Due to the adjusting controller function safe weight values (access
! time, weight filtering) and an optimum adjustment of the filter limits
have to be absolutely observed for the safety of the operations.

Chapter 13
04 Adjusting factor 2nd controller (DBW)
With a weigh-belt feeder the adjusting controller does not operate with an ab-
solute weight difference but with the average belt load value that has been
Adjusting factor= 0:old control
calculated during the access time. The control difference is calculated on the Adjusting contr. >0:Adjusting
basis of the actual value, that is the product of the average belt load and the controller
average speed, it will then be corrected under consideration of the adjusting
factor.
The so-called belt load regulator of a weigh-belt feeder functions independ-
ently of a PID or adjusting control, this regulator changes the speed in cycles
of 0.5s as a function of the control difference. The belt load regulator is only
activated in combination with the adjusting controller (adjusting factor > 0), if
the belt load difference exceeds the determined control difference (CP11).
13.4 Component page Kx50: Alarm configuration
!
An alarm report with alarm cut-out has the function to protect the weigh-
feeder against damage that might possibly be caused by the alarm (e.g..
overload). Thus, a modification of the alarm configuration always has a ne-
gative impact on the protection of the weigh feeder.
Alarm cut-out (= switch off)
Alarm cut-out
With an alarm cut-out the feeding operation of the component will be stopped 1. LED in the K-key is flash-
immediately after the alarm has occurred. The alarm of this component stops ing red
all selected components, if the option alarm stop has also been selected. A 2. Flashing mode display
start of the component or a collective start of all selected components is only 3. 2nd digital output alarm has
possible after the reset of the alarm. been set in CP13
Alarm report (= report only)

In case of an alarm report without alarm cut-out, the feeding operation of the Alarm report without cut-out
component and the feeding operations of the other selected components will 1. frozen mode display
not be stopped. The frozen mode display is only refreshed after the reset of the 2. 4th digital output alarm
alarm report. The stop of the feeding operation cancels the alarm report and message set (see 13.2)
resets the 4th digital output that has possibly been set.
Overload report only during gravimetric feeding (DDW)
If the hopper filling level exceeds the overload value that has been determined
there is only an alarm report, accompanied by an automatic switch-over to
volumetric feeding. The volumetric feeding operation continues until the hop-
per filling level has fallen short of the overload value. As soon as the hopper
filling level has left the overload range, the gravimetric feeding operation
starts and the alarm message will be reset.
Refill fault report only during gravimetric feeding (DDW)
If the hopper filling level does not exceed filling level minimum (CP17) dur-
ing the max. refill time (CP21), there will be a report about the refill fault and
the feeding switches back to gravimetric feeding operation.

Chapter 14
14 Test functions of Congrav LM2
During a test or a simulation all outputs will be set. Thus, in order to avoid
! functional disorders, all plug connections have to be disconnected.
14.1 Menu page F140: Test of I/O-periphery

Ein-/Ausschalten des Testprogramms
K140 GD GD GD LF PLC V=ein Status der Digitaleingänge 1 - 13
Test der E/A-Peripherie Wenn Test=ein können die Digitalausgänge durch das
Test aus
Drücken der Enter-Taste gesetzt bzw. zurückgesetzt
Dig.Ein. : 0 0 0 0 0 0 0 0 0 0 0 0 0
werden. Mit dem letzten Menuepunkt werden gleich-
Dig.Aus. : 0 0 0 0 0 0 0 0 0 zeitig alle Digitalausgänge gesetzt bzw. zurückgesetzt.
Test Druckerschnittstelle
System-Check Rx Tx Aktivierung des System-Checks und Transferanzeige
der Leitrechnerschnittstelle
14.2 Component page Kx30: The I/O-status of the component

Werte der analogen Eingänge in % bezogen auf 10VDC
K130 GD GD GD LF PLC V=ein 1 = analoge Wägezelle oder analoge Führung
HS-Type Komponente 01 2 = analoge Drehzahl
Ana. Eingaenge 1: 0.00 2: 0.00 3: 0.00 Werte der analogen Ausgänge in %
Ana. Ausgaenge 1: 0.00 2: 0.00 1 = Stellgröße bezogen auf 10VDC
Dig. Eingaenge 0 0 0 0 0 0 0 0 2 = Istwert bezogen auf 20mA (optional)
Dig. Ausgaenge 0 0 0 0 0 0 0 0 Status der digitalen Ein-/Ausgänge
Waegezelle 0 = nicht gesetzt
Status und ppm-Anzeige der seriellen Wägezelle 1 = gesetzt
E no serial data transfer
0E usable weighing range has not been reached because preload is to
small
0X weight value not stable
0Y weight value stable
14.3 Component page Kx40: Test of the I/O-periphery of the component

Ein-/Ausschalten der Simulation
Ein-/Ausschalten des Testprogramms
K140 GD GD GD LF PLC V=ein
HS-Type Komponente 01 Wenn Test=ein können die Analogausgänge
Simulation aus durch das Drücken der Enter-Taste in 12.5%-
Test aus Schritten gesetzt werden.
Ana. Ausgaenge 1: 0.00 2: 0.00
Wenn Test=ein können die Digitalausgänge durch das
Dig. Ausgaenge 0 0 0 0 0 0 0 0 0
Drücken der Enter-Taste gesetzt bzw. zurückgesetzt
Test ser. Waegezelle
werden. Mit dem letzten Menuepunkt werden gleich-
zeitig alle Digitalausgänge gesetzt bzw. zurückgesetzt.
The simulation program permits to test Congrav LM2 without connected feeders. Simulation mode
Speed reading is bridged internally, thus no external speed reading is required. 1. Select simulation
2. Fulfil start conditions
3. Input setpoint
4. Refill

Appendix A
Appendix A: Commissioning of a DDW
Preliminary checks
Commissioning your loss-in-weight feeder should generally be started with a
check whether the DDW is in working order. I.e., the electrical and mechanical
mounting has to be carried through as per the plans and checked.
Static inspection of the weighing system of the DDW

1. Switch on the power supply.
2. Loosen all transport catches.
3. Respect a short warm-up phase of app. 30min.
4. Compare the calibration data with the „test certificate loss-in-weight feeder“
that is also part of the delivery, possibly you have to change them.
5. All start conditions except for weight<min have to be fulfilled.
6. Auto-tare and coarse tare have to be set to zero. GT
7. By a brief loading and unloading of the feeder (add/take off weight) check H corr = ⋅ H act
whether the display is free from changes.
G D − G0
8. Place a defined test weight that is adapted to the weighing range (normally Hcorr = corrected lever arm
app. 30 % of the weighing range) on the hopper of the DDW. The exact GT = test weight
weight value should be displayed now. If this should not be the case, correct GD = weight value with GT
the lever arm (CP15) according to the formula. G0 = weight value without GK
9. The corrected lever factor has to be checked again. Hact = actual lever arm
10.Auto-taring of the DDW. You will possibly have to decrease the weight value
by means of coarse tare (auto-tare max. 5% of the weighing range).
Checking of the drive

1. Select mode discharge and enter the setpoint 10%.
2. Start the DDW and check the sense of rotation of the drive.
3. If required, adjust the speed/vibration amplitude controller.
Commissioning with product

1. First filling as per the mechanical operating instructions.
2. To permit filling of the feeding device, start discharge with 10% for a short
term.
3. Select and start checking of max. output.
4. After completion of checking of max. output enter the required setpoint and
start gravimetric feeding.
5. During the feeding operation the controller setting and accuracy has to be
checked by means of sampling, if necessary the controller has to be optimised.
The above steps only describe the commissioning in general and have to be
adapted for each loss-in-weight feeder.

Appendix B
Appendix B: Commissioning of a DBW
Preliminary checks
Commissioning your loss-in-weight feeder should generally be started with a
check whether the DBW is in working order. I.e., the electrical and mechanical
mounting has to be carried through as per the plans and checked.
Checking of the adjustable drive of DBW

1. Switch on the power supply. Inlet
2. Take off the transport sheet.

rotation of the belt
3. Start discharge mode with 10%. TRANSPORT CATCH
4. Check the sense of rotation and the guiding system of the belt.
5. A tachometer permits to check the adjustment of the speed BELT SCRAPER
BELT GUIDES
controller, correct it if required.
Static inspection of the weighing system of DBW

1. Compare the calibration data of the microcomputer controller with the „test
certificate“ that is also part of the delivery, possibly you have to change them.
2. Reset the tare values auto-tare (Kx10) and coarse tare (CP06) to zero. If the
system has been wired correctly, a positive weight value has to be displayed.
3. The weighing unit will now be relieved from the belt by inserting the red
transport protection sheet.
GT
4. Check whether the display of the weigh-belt feeder is free from changes by a Gcorr = ⋅ Gact
brief loading and unloading of the strain gauge load cell (do not exceed the G D − G0
weighing range!). Gcorr = corr. weight test value
5. Suspend the delivered test weight from below the special screw of the strain GT = test weight
gauge load cell of the weigh-belt feeder. GD = weight value with GT
6. If the weight value is not accurately displayed, correct the weight test value G0 = weight value without GT
(CP34) according to the formula. Gist = act. weight test value
7. Check the corrected weight test value once again.
8. Remove the red transport protection sheet and suspend the test weight once GT
Acorr = ⋅ Aact
again to the load cell. G D − G0
9. If the weight value is not accurately displayed, correct the adaptation (CP35) Acorr = corrected adaptation
according to the formula. Aact = actual adaptation
10.Check the corrected adaptation.
11.Now define the coarse tare value (CP06) in such a way that the remaining
belt load is within the auto-tare range. The static inspection of the weigh-belt
feeder ends with the successful completion of the auto-tare function.
Commissioning with product

1. Material is now to be fed into the inlet shaft, then the weigh-belt feeder with
half of the maximum output. The level slide valve should be set in such a way
that the speed of the belt drive motor is app. 40%.
2. Check the feeding operation by sampling, if necessary correct the weigh-
bridge length (CP33) according to the formula. Set
3. Check the corrected length of the weighing bridge (WBL). WBLcorr = ⋅ WBLact
Act

Appendix B/C
If it is not possible or very convenient to check the weighing bridge with the
original product, this check may also be carried out without the original product.
In such case, a plastic bag, a jute bag or anything similar must be filled with
water or sand, etc., and well sealed so that it can function as a known test weight.
This plastic bag must not be wider than the inlet shaft and not longer than the
stretch between the inlet shaft and the weighing bridge extension. Its weight
should be equivalent to that of an average weigh-belt load. When positioning the
bag take care that the distribution is uniform, that is why a bag of water is the
best. The adjustment is done as follows:
1. After completion of the auto-tare function the mode "discharge" has to be se-
lected.
2. Static adjustment of the feeder as described above.
3. Set the internal counter in (CP08) to the lowest value (enter original value of
(CP08) after adjustment) and reset the throughput counter on page F430.
4. Once the installation has been started place the test weight in front of the
weighing bridge and collect it again at the feeder outlet. After that, the system
can be stopped again.
C
5. The value that is now displayed on page F410 internal counter (total) should WBLcorr = ⋅ WBLact
be identical with the test weight. Should there be a difference between the T
weight and the counter reading, the weigh-bridge length (WBL) (CP33) has to WBLcorr = corrected WBL
be changed according to the equation. C = counter reading
K = test weight
WBLact = actual WBL
Appendix C: Functions of the I/O of Congrav LM2

Digital inputs and outputs of the master controller
Digital inputs Digital outputs
1 installation interlocking 1 all selected components started
2 collective start 2 alarm of one selected component
3 collective stop 3 total throughput-pulse output
4 collective reset 4 start condition of one selected component missing
5 key switch 5 communication error PT03
6 immediate stop of inst. 6-13 free
7 analogue control
Digital inputs and outputs of the I/O-controller

Digital inputs Digital outputs
1 see chapter 13.2 1 started
2 start 2 alarm with cut-out
3 stop 3 refill (DDW) or auto-tare (DBW)
4 reset 4 see chapter 13.2
Analogue inputs and outputs of the I/O-controller

Analogue inputs Analogue outputs
1 weight signal 0-10VDC 1 manipulated variable 0 - 10VDC
2 speed 0-10VDC 2 actual value 0(4)-20mA (optional)

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Program version: HG V2.6/2.

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©Brabender Technologie, April 1999 Operating Instructions LM HG V2.6/2.7 Page 2/39

13.4Component page Kx50: Alarm configuration 35

Appendix A: Commissioning of a DDW 37

©Brabender Technologie, April 1999 Operating Instructions LM HG V2.6/2.7 Page 3/39

Congrav L/M-2A opposite to the other two Congrav L/M-types it is equipped

In order to ensure an optimum feeding operation the Congrav LM 2 has to be

Any modification of the values determined can alter the operating

Please refer to the Technical Manual for a description of the addresses

With the alarm reports „Memory-Card?“ and „MC-Batt empty“ the

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3.1 The front keyboard

• The cursor keys F1 F2 F3 F4 F5 F6 ? HC CR

• The numerical keys

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3.3 The host computer interface

3.4 Functions of the integrated LEDs of Congrav LM 2

Lightning Function of the LED in the start-key

Lightning Function of the LED in the K-keys

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4.1 The status line

4.1.1 The mode displays

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4.2 The parameter inputs

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direct selection by:

F430 Reset throughputs

direct selection by: direct selection by:

F500 Alarm reports F600 Calibration data of components

direct selection by: direct selection by:

direct selection by: direct selection by:

Manipulation functions in the calibration program F600:

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5.2 Mode (of the installation)

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1. An analogue control of the components (single mode) is not possible.

5.4 Host computer operation

5.5 Total output

5.6 Date and time

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With Congrav LM2A it is possible to connect a

or if the alarm is deleted:

3. Printout of calibration data

7.1 Total throughput divisor

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Congrav LM2 stores the feeding parameters on

It has to be absolutely observed that the resetting of a selected memory element

7.2.1 Reset RAM

7.2.2 Reset EEProm 1

7.2.3 Reset EEProm 2

As per software version HG V2.0 and higher no EEProms will be em-

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8.1 The setpoints

8.1.1 The installation setpoint

8.1.2 The component setpoints

* * only valid for selected com-

8.1.3 Setpoint ramp, setpoint threshold (menu page F150)

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9 Menu pages F310,F311: Alarm stop, delay times

9.1 The delay times

9.2 Alarm stop

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