Operating Manual VIBTRONIC-Connector Sets for Magnetic Vibrators Series SA...
Operation and display elements on the VAE-2control board
Intended Use VIBTRONIC connector sets of type SA...-2 and SAE...-2 are designed and constructed as alternating voltage regulators for controlling magnetic vibrators; they operate on the voltage regulation principle (phase regulation). The connector set has been designed for use with mains networks having a frequency of either 50 or 60 Hz and a sinusoidal voltage.
For your safety You will find three different types of symbols in this operating manual which are intended to point out important information: DANGER ATTENTION! NOTE . . DANGER! The DANGER warning describes procedures or conditions which could have dangerous or even life-threatening consequences for the person installing or using the equipment WARNING! You will find this information with procedures in which a danger of damage to equipment exists.
Although we developed the VIBTRONIC connector sets taking into account all safety measures, operational error cannot be completely eliminated. In the interest of your safety and that of your colleagues, observe the following information: DANGER DANGER DANGER! Life threatening voltages are present within the connector set when it is connected to the mains voltage.
© 1996 AVITEQ Vibrationstechnik GmbH COPYRIGHT The VIBTRONIC connector sets, Series SA...-2 and SAE...-2 as well as this operation manual are copyright protected. Any reproduction of the units will be prosecuted. All rights of this operating manual are reserved, including reproduction via photo mechanical, print, data or any other possible medium, as well as in translation.
Chapter Contents General notices regarding this operating manual, our Conditions of Sale, the Warranty and the Intended Use of the connector sets Shipping, storage, delivery contents and disposal Here you learn the fundamentals of the connector set and its selections: The function description Assembly, electrical connection To the point: Commissioning Step by Step Prevention is better: Service and Maintenance Not to be forgotten: Troubleshooting Seek and find: the Index
TABLE OF CONTENTS 1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 3 3.1 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 4 4.1 4.1.1 4.1.2 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.3 4.3.1 4.3.2 We are Partners. 1-1 About this Operating Manual.............................................................................................................. Product Liability and Warranty............................................................................................................
4.3.3 4.3.4 4.4 4.4.1 4.4.2 5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.3 6 4-17 4-18 4-20 4-20 4-21 Commissioning 5-1 Commissioning with AVITEQ magnetic vibrator............................................................................................ Commissioning Procedure .................................................................................................................. ............. Special Notes.............................................................................................
1 We are Partners. 1.1 About this Operating Manual 1.2 Product Liability and Warranty 1.3 Fields of Application and Intended Use 1.4 Maintenance and Repair 1.5 Installation and Operating Personnel Chapter Outline Although you might want to get immediately started with our connector set, we would like you to read this chapter first. It provides a summary of the contents of the operating manual and settles our legal relationship as parties to a contract.
1.1 About this Operating Manual For whom? This operating manual is directed to the • installation technician who installs and commissions the magnetic vibrator. • electrician or engineer who carries out the installation of the connector set, the electrical connection to the mains network and the connection to the magnetic vibrator.
Special Indicators in This Operating Manual You have already learned how safety notices are indicated, or...
1.2 Product Liability and Warranty The connector sets have been designed for a long service life. They correspond to the current state of science engineering and have been tested individually for each of its guaranteed functions prior to delivery. AVITEQ Vlbrationstechnik GmbH continually conducts product and market analyses for further development and improvement.
Moreover, we decline any liability for damages to conveyor and automation systems caused by malfunctions of the product or faults in the operating manual. We are not liable for consequences caused by accessories that were not delivered or certified by AVITEQ Vibrationstechnik GmbH. We are not responsible for the violation of patent rights and other titles of third parties outside of the Federal Republic of Germany.
1.3 Fields of Application VIBTRONIC connector sets, types SA...-2 and SAE...-2, hereafter abbreviated with SA(E)...-2, allow infinite adjustment of the working stroke on the magnetic vibrator and thereby of the conveyor rate from vibration conveyor devices. The connector sets must be used together only with AVITEQ magnetic vibrators or corresponding magnetic vibrators from other manufacturers in accordance with their intended use.
ATTENTION! ATTENTION! If a magnetic vibrator is directly connected to mains or an inappropriate connector set is used, the magnetic vibrator may be destroyed. Use only the appropriate connector set! 1.4 Maintenance and Repair The connector set contains no components which can be serviced or repaired by the installer or the operator. Do not open the units under any circumstances. In case of failure, send it to AVITEQ Vibrationstechnik GmbH, Hattersheim, Germany.
1.5 Installation and Operating Personnel Prior to installation and/or commissioning, you should familiarise yourself with all details of the connector set and with the connection options of the magnetic vibrator. For more information, see the chapter in the operating manual on connecting the magnetic vibrators. Persons involved with installation, commissioning, assembly, disassembly, adjustment or maintenance must have read and understood this operating manual completely; particularly the safety notices.
2 Transport, Delivery, Disposal 2.1 Transport and Storage 2.2 Extent of Delivery 2.3 Disposal Chapter Outline For storage and transport, certain measures must be observed in order to prevent damamge to the units. The extent of delivery must be checked after unpacking. The packing material should be disposed of properly. What to do with the VIBTRONIC connector sets when they are no longer required? The "return guarantee".
2.1 Transport and Storage • Delivery: the connector sets and accessories are delivered in appropriate packing so that they reach their destination without damage.
ATTENTION! ATTENTION! Unauthorised combinations may result in destruction of the magnetic vibrator or connector set! Mains voltage, mains frequency and vibration frequency must be compatible! The nominal current of the connector set must be the same or greater than the peak current of the magnetic vibrator. Connect only compatible devices! 2.2 Disposal 2.3.1 Packing Materials The following materials are used by us for delivering connector sets, depending on the type of transport.
2.3.3 Unit Component Materials In the case of disposal by the customer, and when exchanging components, local effective waste and disposal regulations should be observed. We accept no responsibility for improperly disposed of parts and components! • Regulations regarding the disposal of electronic parts and components apply to the disposal of the connector set. • The power semiconductor (thyristor and diode module) do not contain beryllium and thus can be disposed of as electronic waste.
3 Function Description 3.1 Introduction 3.2 Operating Principle 3.3 Scope of Operation 3.4 Series and Models 3.5 Type Designation Chapter Outline After a description of the operating principle of the connector sets, a discussion of the scope of operation and of the connection options follows in chapter 3.3. The final sections provide you with an overview of the available connection set models and the type designations.
3.1 Introduction AVITEQ magnetic vibrators must be operated with the appropriate VIBTRONIC connector sets. Depending on the application and size of the magnetic drive, AVITEQ Vlbrationstechnik GmbH supplies connector sets from the SA(E)...-2 in size F, G or H, available in cabinet and panel mounting units. 3.2 Operating Principle Oscillation rates and mains frequency Connector sets of type SA(E)...-2 are alternating-voltage regulators and function on the voltage regulation principle (phase regulation).
3.3 Scope of Operation The VIBTRONIC Connector Sets of type SA(E)...-2 are designed for the following regulation types: • Voltage regulation • Working stroke regulation • Voltage regulation with limit protection • Effective working stroke regulation The various regulation types are described below. Voltage-, working stroke- and effective working stroke regulation Connector Sets of the type SA(E)...-2 can be operated with voltage regulation or working stroke regulation with limit monitoring.
3.4 Series and Models 3.4.1 Series Three series of VIBTRONIC connector sets with various characteristics are available: • • • NOTE Type series SU(E)... without voltage regulation in cabinet and panel mounting units for nominal currents up to 6 A. Type series SC(E)... with voltage regulation in cabinet and panel mounting units for nominal currents up to 14 A. Type series SA(E)... with voltage and working stroke regulation in cabinet and panel mounting units for nominal currents up to 43 A.
Table 3-a (Continued) Technical data for Connector Sets SA(E)...-2 SA(E)-FS..-2 SA(E)-GS..-2 SA(E)-HS..-2 Nominal current 25A 23 A 43 A Maximum power loss in switching cabinet 75 W 70 W 85 W NOTE NOTE: The permissible tolerances are, for the mains voltage, ± 10.0 % and, for the mains frequency, ± 0.5 %. NOTE NOTE: The vibration frequency is set at the factory prior to delivery and must not by changed by the customer. 3.4.
4 Installation 4.1 Mechanical Installation 4.2 Binding Post Assignment 4.3 Electrical Connection 4.4 Electrical Connection to the Magnetic Drive Chapter Outline This chapter describes the mechanical and electrical installation of the connector sets up to and including the connection to the magnetic vibrator.
4.1 Mechanical Installation The installation steps for the two versions are described in the following sections: • Panel mounting unit, in Chapter 4.1.1 and • Cabinet unit, in Chapter 4.1.2 4.1.1 Panel Mounting Unit The connector sets are available as installation units for vertical installation in switching cabinets or control cases.
Figure 4.1 Panel mounting unit dimensions and hole pattern for securing to vertical vibration-free switching cabinet walls or installation plates Weight: 3 kg Carry out the installation as follows: Screw the mounting plates (delivered loose) onto the cabinet as shown in Figure 4.2. Use the hole pattern in Figure 4.2 to orient yourself, and drill the necessary holes for the fastening screws. Hand-fasten the mounting plates to a vibration-free vertical wall or frame.
Figure 4.2 Cabinet unit Dimensions and hole pattern for securing to vertical vibration-free walls or frames ATTENTION! Dimensions in mm SA-FS...-2 SA-GS...-2 SA-HS...-2 Depth T 155 210 Height H 300 380 h 244 324 Weight (kg) 12 15 ATTENTION! Connector sets are temperature sensitive! Make certain that the units are not installed near external heat sources, such as direct sunshine or radiators.
4.2 Binding Post Assignment The following sections 4.2.1 to 4.2.6 explain the binding post assignment on the connector sets as well as the available options. Read these sections before you begin wiring, and observe the information regarding electromagnetic compatibility! NOTE NOTE: The symbol for the control board for each connection diagram is located in the left margin. An arrow mark in each installation step helps you locate the binding posts and display or adjustment elements. 4.2.
NOTE NOTE NOTE: For Magnetic Vibrators without a vibration sensor and/or temperature switch, binding posts 13 and 14 must be connected by a wire bridge. If the bridge is missing, the red LED (HOT/ERROR x) lights up and the operational message relay opens. As a result, the vibrator voltage at binding posts 3 and 4 goes to zero; the Magnetic Vibrator ceases to function.
ATTENTION! ATTENTION! Destruction of the vibration sensor/temperature switch by connecting to the false bindingposts! Never connect the two black wires to binding posts 3 and 4! NOTE NOTE: For line lengths longer than 50 m between magnetic vibrator and connector set: use a separate cable for the two black vibration sensor/temperature switch signal lines. NOTE NOTE: Electromagnetic compatibility: if the line lengths are longer than 100 m, the two black signal lines must be shielded. 4.2.
4.2.4 Primary and Fine Fill Rates When using the connector set for dosing and filling processes, we recommend a circuit as shown in Figure 4.6. In this circuit the two relays K1/K2 function as follows: • K2 initiates the filling process. • Kl switches at 95% full weight. • At 100% full weight, both relays return to their rest positions. Figure 4.
4.2.5 External control input The connector sets may be operated with an external command value entry (extraneous control input). The following extraneous command values can be used for setting the working stroke: • 0...10 V DC, resistance approx. 40 kOhm • 4...20 mA DC, working resistance 100 Ohm • 0...
4.2.6 Operational message and actual-value display Operational message relay The Connector Set is fitted with an operational message relay with change-over contact: • Make contact (31 and 30): Vibrator in operation • Break contact (31 and 32): Vibrator standstill, w=0 or START=off or foult (HOT/ERRORx or w>x), the particular condition can be read from the corresponding LEDs. Figure 4.
Figure 4.9 Connecting the actual-value display Note: at 10 V, display shows 100.0 (%) The decimal point is set at the factory for a 100.0 (%) display range. NOTE NOTE: Electromagnetic compatibility: shield the signal lines for the actual-value display if line lengths exceed 5 metres. 4.2.7 Switching On/Off Externally The connector set can be externally switched on or off by means of a switch (relajl buttons or optical coupler. The corresponding binding post assignments are shmj in Figure 4.10.
Figure 4.
NOTE NOTE: To prevent switching faults, use only gold-plated or hermetically sealed contacts. NOTE: With external on/off switches, i.e. when binding posts 21,22 and 23, an assigned, the first switch on the DIP switch block is to be set to OFF (left) (For details on the DIP switch block settings, see Chapter 5.3). NOTE DANGER! NOTE: Shield the signal lines to guarantee electromagnetic compatibility if the lines exceed five metres in length! 4.3 Electrical Connection 4.3.
4.3.2 Connection Diagram For the connector set connection diagram, see Figure 4.11. Hie appropriate connection diagram is delivered with each connector set. Note the minimum binding post assignment (Figure 4.3 in Chapter 4.2.1). Rgure4.
4.3.3 NOTE Vibration-Width Adjuster, Rotary-Type Knob and Scale NOTE: Connector sets of type SA(E)...-2 can be operated without further modifications to the connection assignment with a vibration-width adjuster (linearpotentiometer with limit value between 1 kOhm and 10 kObm). A linear 1 kOhm potentiometer is always included in the delivery from the factor] (see Figure 4.12). The technical data are listed in Table 4-a below. Figure 4.
4.3.4 DANGER Installation of the actual-value display DANGER! Before installing the actual-value display, switch off the current supply to the Connector Set and check that no voltages are present! Protect against unintentional reconnection! The 3 1/2 digit actual-value display operates at a measuring rate of 2.5 measure-ments/s and consists of a red LED display unit (height 14 mm) in a black plastic case.
Dimensions and measurement inputs are to be taken from Figure 4.14. Figure 4.14 Actual-value display (dimensions and connection assignments) Installation Steps Switch off the current supply from the installation area and check that no voltages are present! Fit front cutout (30.
4.4 Electrical Connection to the Magnetic Vibrator A connection diagram is included with each VIBTRONIC connector set. The connection diagram is also included in this operating manual in Chapter 4.3.2 (see Figure 4.11). Make all the connections between mains, connector set, command value circuit, and magnetic vibrator. When working with the available options, note the device-typical peculiarities and the applicable binding post assignments chapters 4.2.1 to 4.2.6 shown earlier in this chapter.
4.4.2 NOTE Line Lengths NOTE: We define the line length as being the distance between vibration conveyor device and main distributor. Smaller line cross sections or longer line lengths could result in faults (see Chapter 7). The maximum permissible line length is 300 m. An appropriate line cross section is to be used for a given vibrator current. The line cross sections (based on length) are given in the operating manual for the magnetic vibrator.
5 Commissioning 5.1 Commissioning with AVITEQ magnetic vibrators 5.2 Commissioning with vibrators from other manufacturers 5.3 Information regarding the DIP switch block Chapter Outline In general, the connector sets can be operated with either original AVITEQ vibration conveyor devices or devices from other manufacturers. This chapter describes the necessary commissioning steps for both options.
5.1 Commissioning with AVITEQ magnetic vibrator 5.1.1 Commissioning Procedure When commissioning with the original AVITEQ magnetic vibrator, you are advised to follow the commissioning steps of the appropriate chapter in the magnetic vibrator operating manual. In the event of malfunction, refer to Chapter 7 located towards the end of this operating manual.
5.2 Commissioning with vibrators from Other Manufacturers 5.2.1 Setting the vibrator Mains Voltage The vibrator mains voltage 1%, which can be measured at binding posts 3 and 4 on the connector set, is set with a fixed value at the factory for use with original AVITEQ devices. If a magnetic vibrator from another manufacturer is to be used, the setting must be checked prior to commissioning and, if necessary, adjusted.
1 NOTE NOTE: It is beyond the scope of this operating manual to predict the behaivor of vibration devices used with magnetic vibrators and/or working units not supplied by AVITEQ Vibrationstechnik.
NOTE NOTE: Even if the maximum setting on the potentiometer (dial value "10") is not used during actual operation, this setting should be tested during commissioning to ensure that the vibration conveyor device functions correctly up to its limits. 6 DANGER NOTE Connect a voltmeter with a suitable measuring range (recommended: 750 V AC) to binding posts 3 and 4 on the connector set. When using a digital voltmeter, select the maximum measuring range (750 V or 1,000 V).
8 NOTE DANGER Use an iron-vane meter or one which is True-KMS in the frequency range from 0 to 500 Hz and compare the values with those specified by the manufacturer for the vibration conveyor device being used! NOTE: When measuring current, only an RMS responsive measurement instrument (iron vane or "True RMS" instrument for 0-500 Hz) must be used. Other measurement instruments with a measuring range not equal to 0-500 Hz (without DC) cannot measure non-sinusoidal values correctly.
5.3 Note on the DIP switch block Introduction The DIP switch block is located approximately in the center of the control board, to the left of the LED bar. The DIP switch block contains a total of 8 miniature switches, located one below the other, which can be set to one of two positions using a small screwdriver: right (=ON) and left (=OFF).
* 400/500V vibrators can be operated with the Connector Set SA(E)...-2 on a 400 V or 500V mains network. A 400/500 V vibrator can be identified by the "400/500V" specification on the type plate.lf only "400V" or "500V" is on the type plate, the firingangle switch must not be switched over! Table 5-b DIP switch 2 to be set by customer Fixed settings of the lower DIP switches 3 to 8 Use Table 5-c to check that the vibration frequency is set in accordance with the type plate.
6 Maintenance Chapter Outline Although the connector sets are maintenance free, it is recommended that they be checked regularly for soiling.
Maintenance All models of the AVITEQ connector sets are, in general, maintenance free. In dusty environments, however, dust can penetrate and collect. This can result in deterioration of the cooling system for the control electronics and short ciruits as a result of soiled strip conductors. Check the following at regular intervals: Has dust penetrated? Determine the cause so that measures can be taken to avoid the problem in the future! Clean the connector set by vacuuming the dust layer, e.g.
7 Troubleshooting 7.1 Fault Causes and Remedies 7.2 Help by Telephone Chapter Outline Problems usually crop up during the installation and commissioning procedures. This chapter provides troubleshooting assistance. Chapter 7.2 includes a checklist which should be completed before telephoning our Service Department.
7.1 DANGER Fault causes and remedies DANGER! Disassembling the connector set is life-threatening and may result in damage to the device. There are no components inside of the connector set which can be repaired or serviced by the user.
1 Faults Cause(s) Remedies Vibration No mains voltage. No LEDs light up. Correct fault source, check fuse(s) conveyor device does not function. Mains fuse blown. No LEDs light up. Replace fuse, check current consumption if necessary Fuse in Connector Set blown. No LEDs light up. Replace fues, check current consumption and consult with AVITEQ Vibrationstechnik if necessary. Supply line interrupted. No LEDs light up.
faults Causo(s) Remedies 3 Vibration conveyor device stops shortly after start-up (approx. 5 30s). Vibration power not reached. Red LED "w>x" lights up. Causes and Remedies, see item 2 4 Vibration Connected temperature switch triggers due to high vibraconveyor tor temperature. device switRed LED "HOT/ERROR x" lights up. ches off during operation. The yellow LED "w=0" lights up. Interruption in command value circuit Allow Magnetic Vibrator to cool for approx. 2 hours.
7.2 Help by Telephone Additional help in the determination and correction of faults is available by telephoning AVITEQ Vibrationstechnik GmbH at (+49) 6145-503 0. We'll be glad to help you if you have any questions! Before you contact us, please go through the following checklist and note the important information; it will help us provide you with faster and more accurate telephone assistance. General Information: 1 .1 Device type (as stated on type plate) 1. 2 Device number 1 .
8 INDEX A actual-value display -Connection Data 4-18 -Installation 4-19 altitude 1-6 ambient temperature 1-6,4-2,4-4 electronic waste 2-4 EMV directive (89/336/EWG) 3-2 enviroments with explosion hazards 1-6 extent of delivery 2-2 external control input 4-9 external release 3-4 B F beryllium 2-4 binding post assignment 4-5 fault causes and remedies 7-2 fuse 4-14 c cabinet unit 1-2,4-3 cleaning interval 6-2 collision mode 5-4 commissioning 5-3,5-5 commissioning flow chart 5-5 conditions of warranty
measurement instrument 5-6, 5-7 mechanical installation 4-2 models 3-5 moderate climatic environments 1-6 N natural frequency 5-7 nominal current 3-6 nominal voltage 3-5 0 operating messages 3-4 operating personnel 1-8 operational message relay -load capacity 4-11 oscillation rates 3-2 P packing materials 2-3 panel mounting unit 1-2,4-2 pit gas environments 1-6 potentiometer 4-17 power loss 3-6 primary and fine fill rates 4-8 Q qualified personnel 1-2,1-8 R repair 1-7 rotary-type knob 4-17 S safety 0-
EC Declaration of Conformity Manufacturer: AViTEQ Vibrationstechnik GmbH Im Gotthelf 16 65795 Hattersheim-Eddersheim Telefon: 06145/503-0 Fax: 06145/503-200 Connector Sets for Magnetic Vibrators Device Types: SA...-2, SAE...
AViTEQ Vibrationstechnik GmbH Im Gotthelf 16 D - 65795 Hattersheim-Eddersheim Telefon: +49 (0)6145/503-0 Fax: +49 (0)6145/503-200 C€ VIB 12.
