DISOCONT Tersus gradually replaces the older DISCONT Units with Profibus communication. The new Dosing Units communicate via PROFINET and can be accessed via TCP/IP.
1 Pre-Adjustment[edit | edit source]
1.1 Mechanical Checks[edit | edit source]
Make sure that all transportation locks are removed, all load cells are not locked anymore and every compensator has to be free of tension. It’s also important that there is no force closure at all load cells. Also take care that for the Grounding of the Loadcells only High-Flexible Groundingcables are used.
1.2 Electrical Checks[edit | edit source]
Make sure no cables touch any feeding Hoper or Dosing Units at the measuring part. Check if every wire including shield is connected well. Wires which are connected to the measuring part must be in a as low as possible tension. Any tension will have influence!
1.2.1 Schenck Unit in Switchboard and long cableing[edit | edit source]
Attention When having the Schenck Units not right next to the Dosing Units but in the +SR21 or in any central Switchboard Room there are several things requiring special care.
Make sure only shielded cables are used!
Of course the extra wiring occurs additional swaps and wiring mistakes, for example one shaker is connected to a different VCU.
Therefore be careful when switching on the Exitor the first time not to overload a smaller one if mixed.
When having a centralized Schenck Controller Position also the structure numbers are different.
To compensate the long wiring (50 to 300 meters) Schenck is delivered with electromagnetic coils, installed directly on the VVC. This is necessary for VVC 29150 with a device serial number before 15901848 (March 2022). After that, coils are not any longer needed.
Attention Not only the wiring up to the tower next to the Motor cables cause a problem, but the short distance between the terminal and the VCC Shake Control inside the cabinet. This wires should be shielded as well and pulled as far as possible from Frq`s and Power cables.
2 Connection Settings[edit | edit source]
2.1 TCP/IP Configuration[edit | edit source]
In order to assign the TCP/IP address to the Dosing Unit you need to know the serial number of the unit which is written on the control board module.
The serial number starts with “EI” followed by six numbers.
- Disconnect the network from the Scalance switch and remove the PROFINET-TCP/IP bridge at the last station
- Connect your notebook to the third port of the TCP/IP module
- Start Schenck Process EasyServe and go to "Connection -> Ethernet (Scanner)" and run the scan
- If the scan was succesfull, you will see all Dosing Units; on the very right the serial number is displayed
- Perfrom the configuraion for each Dosing Unit via the "Configure" button and set the data according to your line (name, IP address, subnetmask and default gateway)
- Choose the IP address as follows: TCP/IP ADDRESS = PROFINET ADDRESS + 1 (e.g. PROFINET Addr. 10.xx.yy.15 -> TCP/IP Addr. 10.xx.yy.16) (IPC 4.0 address range: Template:KomIp200..231)
- Subnetmask: 255.255.255.0, Default Gateway: Template:KomIp190 (IPC 3.9) / Template:KomIp71 (IPC 4.0)
- Be aware, that for new line we use a 23 Subnet (255.255.254.0) -> The 3. octet of the Profinet Address (YY) will probaply differ by 1 to the Gateway (YY-1)
- Give the dosing its standardized device name. This device name can be also adjusted later on in parameter P02.03. "WinCC-Tag_PI-number" (example SilMexDos001_QN410)
- Press button "Apply"
After this it should be possible to connect online to each unit
- Go to "Connection / Ethernet manually" or "Ethernet scanner" and get connected to each Dosing Unit
- Adapt communication parameters as follows:
Template:Image
Template:Image
Template:Image
Note: All modified parameters will be saved online
- If all parameters are modified, you can disconnect your notebook from the TCP/IP loop
2.2 PROFINET Configuration[edit | edit source]
- Connect your notebook to the PROFINET loop where the cable from the Scalance switch is normally attached
- Open the HWconfig, select the PROFINET path and go to “PLC -> Ethernet -> Edit Ethernet Node”
- Click "Browse" and wait until the scan is finished - the device type of Tersus is “TPS-1”
Template:Image Template:Notice bms
- Start with the first one and click "OK" and reassign the name if not already set
- Enter and assign the PROFINET configuration
Note: It’s important to set the right gateway
- Restart the units and reinstall the PN-TCP/IP bridge
- Perform a scan with the Primary Setup Tool and check if all Units are online
- Disconnect your notebook and reconnect the cable to the Scalance switch
- Check if all Dosing Units are online in PVSS
3 Explanation of Scale Operation Mode[edit | edit source]
Activate Scale Operation Mode: View → Scale Operation 1
| Abbreviation | Explanation |
| Template:Image | Start / Stop Dosing Unit |
| Template:Image | Lock / Unlock Easy Serve User Interface |
| Template:Image | By entering a setpoint to P you can adjust the actual feeding rate in kg/h |
| Template:Image | I shows the value of the actual feeding rate in kg/h |
| OP Mode | Start / Stop Keyboard Mode |
| VSM Type: A | Switching between “Volumetric” or “Gravimetric” Mode |
| Deviation | Difference between Setpoint P and the actual value I in percent |
4 Commissioning[edit | edit source]
Attention: In fact we have two different types of Dosing Units - units with a dosing screw and units with a vibro feeder - they have to be adjusted in different ways
4.1 Parameter Adjustment Chart[edit | edit source]
- Open the Parameter panel
- Parameters to be set as following - detailed explanation see below
| Parameter | Explanation | Default-Value | Example Dosing Screw Main Dosing | Example Vibro Feeder | Example Fluff Dosing with screw (Simplex) |
| P 01.01 | Analog Channel A10 | NO | NO | NO | NO |
| P 01.01 | Analog Channel A10 | NO | NO | AI1 (Analog In 1) if function variant Temp./Slide applies | NO |
| P 01.02 | Analog Channel A11 | NO | NO | NO | NO |
| P 01.02 | Analog Channel A11 | NO | NO | AI2 (Analog In 2) if function variant Temp./Slide applies | NO |
| P 01.16 | Vibro Controller VVC | NO | NO | YES | NO |
| P 01.17 | Event: Communication VVC | A | A | A | A |
| P 02.03 | Device Name (WinCC-Tag_PI-number) | DISOCONT Tersus VLW | (e.g. SilMexDos001_QN410) | (e.g. SilCox001Dos002_QN520) | (e.g. SilMexDosFlf_QN420) |
| P 03.03 | Maximum Flow Rate Io | 1000 kg/h | (e.g. 4050 kg/h) | (e.g. 60 kg/h) | (e.g. 2050 kg/h) |
| P 03.04 | Feeder hopper capacity Fo, see below | 100,0% LC | (e.g. 12,0% LC) | (e.g. 21,0 %LC) | (e.g. 6,7 %LC) |
| P 03.05 | Event: Hopper overload | W2 | W2 | W2 | W2 |
| P 03.06 | Flow Rate Units | ----.- kg/h | ----.- kg/h | ----.- kg/h | ----.- kg/h |
| P 03.07 | Fill Weight Unit | ---.-- kg | ---.-- kg | ---.-- kg | ---.-- kg |
| P 03.08 | Counter 1 Unit | -----.- kg | -----.- t | -----.- t | -----.- t |
| P 03.09 | Counter 2 Unit | ------- kg | -----.- t | -----.- t | -----.- t |
| P 04.01 | Feeder Start | FB | FB | FB | FB |
| P 04.01 | Feeder Start | FB | FB | FCB.GP.DO4.HIGH if function variant Temp./Slide applies | FB |
| P 05.06 | LC Characteristic Value | 2mV/V | (e.g. 2,85 mV/V) | (e.g. 2 mV/V) | (e.g. 2,85 mV/V) |
| P 05.07 | LC Rated Capacity | 100 kg | (e.g. 6600kg) | (e.g. 60 kg) | (e.g. 3000 kg) |
| P 06.01 | Volumetric Start up | 0,0s | 10,0s | 10,0s | 10,0s |
| P 06.09 | Filling Controll | MIN/MAX | MIN/MAX | MIN/MAX | MIN/MAX |
| P 06.10 | Threshold filling start | 10,0% Fo | (e.g. 40,0% Fo) | (e.g. 40,0% Fo) | (e.g. 40% Fo) |
| P 06.11 | Threshold filling stop | 90,0% Fo | (e.g. 70,0% Fo) | (e.g. 80,0% Fo) | (e.g. 60,0% Fo) |
| P 06.13 | DO: Gate | DO.VCU1.DO6.HIGH | DO.VCU1.DO6.HIGH | DO.VCU1.DO6.HIGH | n/a (controlled by function variant Simplex-FB |
| P 06.13 | DO: Gate | DO.VCU1.DO6.HIGH | DO.VCU1.DO6.HIGH | DO.VCU1.DO6.HIGH | n/a (controlled by function variant Simplex-FB |
| P 06.14 | Gate Feedback 1 | DI.VCU1.DI7.LOW | DI.VCU1.DI7.LOW | DI.VCU1.DI7.LOW | DI.VCU1.DI5.HIGH |
| P 06.14 | Gate Feedback 1 | DI.VCU1.DI7.LOW | DI.VCU1.DI7.LOW | FCB.GP.DO3.LOW if function variant 2 FLAPS applies | DI.VCU1.DI5.HIGH |
| P 06.15 | Gate Feedback Time | 3,0s | 10,0s | 10,0s | 10,0s |
| P 06.21 | Setting Time | 3s | 5s | 5s | 12s |
| P 06.22 | T_Volumetric | 30s | 60s | 60s | 60s |
| P 06.23 | Event: T_Volum. | W1 | A | A | W1 |
| P 06.24 | Gate Feedback 2 | n/a | n/a | n/a | n/a |
| P 06.24 | Gate Feedback 2 | n/a | n/a | FCB.GP.DO4.LOW if function variant 2 FLAPS applies | n/a |
| P 08.09 | Time Deviation | 20,0s | 60,0s | 60,0s | 60,0s |
| P 09.01 | T-Differential | 3,0s | 3,0s | 3,0s | 3,0s |
| P 09.02 | Filter: Actual Flow Rate | 3,0s | 1,0s | Twin Main 1,0s Twin MB 3,0s, Single 10,0s | 3,0s |
| P 09.03 | Filter: Actual Flow Rate analog | 3,0s | 3,0s | 3,0s | 3,0s |
| P 09.04 | Filter: Deviation | 3,0s | 3,0s | 3,0s | 3,0s |
| P 09.05 | Fill Weight Display | 3,0s | 1,0s | 1,0s | 1,0s |
| P 09.06 | Display Speed | 3,0s | 3,0s | 3,0s | 3,0s |
| P 09.08 | Band rejection | NO | NO | NO | NO |
| P 09.09 | Frequency band rejection | 0,12Hz | 0,12Hz | 0,12Hz | 0,12Hz |
| P 09.10 | Quality band rejection | 1 | 1 | 1 | 1 |
| P 09.11 | Control speed adaption TDIFF | NO | NO | NO | NO |
| P 09.12 | Standard deviation (calibration program TD: Control speed adaption) | 0,0000kg/h | (e.g. 0,4162kg/h) | (e.g. 0,4162kg/h) | (e.g. 0,4162kg/h) |
| P 09.13 | Material factor TDIFF | 1 | 1 | 1 | 1 |
| P 10.02 | Event: Actual Flow Rate MIN | W1 | IG | IG | IG |
| P 11.01 | Range Correction (calibration program CW: Span Calibration) | 1 | (e.g. 1,0025) | (e.g. 1) | (e.g. 1,0004) |
| P 11.02 | Calibration Weight (calibration program CW: Span Calibration) | 10,0000kg | must be set according to the weight | must be set according to the weight | must be set according to the weight |
| P 11.03 | Tare (calibration program TW: Tare) | 0,0000kg | (e.g. 833,6310 kg) | (e.g. 18,1952 kg) | (e.g. 865,2153 kg) |
| P 12.01 | P-Component KP | 0,93750 | 0,65 | 0,65 | 0,65 |
| P 12.02 | I-Component TN | 6,9s | 7,0s | 7,0s | 7,0s |
| P 12.03 | Bypass (calibration program CV: Vol. Discharge Adaption) | 11,00mA | 12,00mA (fixed value) | (e.g. 9,98mA) | 12,00mA (fixed value) |
| P 12.04 | Controller Magnitude Offset | 4,00mA | 4,00mA | (e.g.0,15mA) | 4,00mA |
| P 12.05 | Lower Limit | 4,00mA | 4,00mA | 0mA | 4,0mA |
| P 12.06 | Upper Limit | 20,00mA | 20,00mA | 20,00mA | 20,00mA |
| P 12.07 | Contr. Magn. at STOP | 0 | Lower Limit | 0 | Lower Limit |
| P 12.19 | Controller Adaptation | NO | YES | NO | YES |
| P 12.20 | Correction Meas. Time | 30s | 15s | 30s | 15s |
| P 13.01 | Linearization ON | NO | NO | YES | NO |
| P 13.02 | Linearization Y1 (calibration program Linearization P1) | 10% | - | (e.g. 7,61% ) | - |
| P 13.03 | Linearization I1 | 10% Io | - | 5,0% Io | - |
| P 13.04 | Linearization Y2 (calibration program Linearization P2) | 20% | - | (e.g. 17,47%) | - |
| P 13.05 | Linearization I2 | 20% Io | - | 10,0% Io | - |
| P 13.06 | Linearization Y3 (calibration program Linearization P3) | 30% | - | (e.g.52,60%) | - |
| P 13.07 | Linearization I3 | 30% Io | - | 30,0% Io | - |
| P 13.08 | Linearization Y4 (calibration program Linearization P4) | 50% | - | (e.g. 77,03%) | - |
| P 13.09 | Linearization I4 | 50% Io | - | 60,0% Io) | - |
| P 14.01 | DAE ON | NO | YES | YES | YES |
| P 14.02 | Adaptive DAE | NO | YES | YES | YES |
| P 14.03 | Fuzzy Min ( calibration program DAE calibration) | 10,0000kg/h | (e.g. 9,1998kg/h) | (e.g. 20,0781kg/h) | (e.g. 5000kg/h) |
| P 14.08 | Fuzzy Tracking | 1,5s | 3,0s | 3,0s | 3,0s |
| P 14.09 | Event: DAE active | W2 | W2 | W2 | W2 |
| P 14.10 | Event: DAE Fault | W1 | W1 | W1 | W1 |
| P 14.11 | DAE Monitoring Time | 6,0s | 10,0s | 10,0s | 10,0s |
| P 15.16 | AO: Contr. Magn. Y | AO.VCU1.AO1 | AO.VCU1.AO1 | AO.VCU1.AO1 | AO.VCU1.AO1 |
| P 15.16 | AO: Contr. Magn. Y | AO.VCU1.AO1 | AO.VCU1.AO1 | n/a if function variant Temp./Slide applies and a servo sliding element is installed | AO.VCU1.AO1 |
| P 16.01 | Event: External Event 1 | A | A | A | A |
| P 16.01 | Event: External Event 1 | A | A | W1 if function variant Temp./Slide applies and a servo sliding element is installed | A |
| P 16.02 | DI: External Event 1 | DI.VCU1.CI1.LOW | n/a | n/a | n/a |
| P 16.02 | DI: External Event 1 | DI.VCU1.CI1.LOW | n/a | DI.VCU1.CI1.LOW if function variant Temp./Slide applies and a servo sliding element is installed | n/a |
| P 16.03 | Event: External Event 2 | A | A | A | A |
| P 16.03 | Event: External Event 2 | A | A | W1 if function variant Temp./Slide applies (for temperature montioring) | A |
| P 16.04 | DI: External Event 2 | n/a | n/a | n/a | n/a |
| P 16.04 | DI: External Event 2 | n/a | n/a | FCB.GP.DO2.HIGH if function variant Temp./Slide applies (for temperature montioring) | n/a |
| P 16.05 | Event: External Event 3 | IG | IG | IG | IG |
| P 16.05 | Event: External Event 3 | IG | IG | A if function variant Temp./Slide applies (for temperature montioring) | IG |
| P 16.06 | DI: External Event 3 | n/a | n/a | n/a | n/a |
| P 16.06 | DI: External Event 3 | n/a | n/a | FCB.GP.DO3.HIGH if function variant Temp./Slide applies (for temperature montioring) | n/a |
| P 21.01 | Protocol Type | NO | PROFINET IO | PROFINET IO | PROFINET IO |
| P 21.02 | Timeout Host | 10s | 10s | 10s | 10s |
| P 21.03 | Event: Cyclic Communication | A | A | A | A |
| P 21.04 | Event: Acyclic communication | W1 | W1 | W1 | W1 |
| P 21.05 | Check in Keyboard Mode | YES | NO | NO | NO |
| P 21.24 | Configuration | PARA_ID_6_15 | FIXED_8_16 | FIXED_8_16 | FIXED_8_16 |
| P 22.24 | ID Read Value 16 | --- | --- | FCB_AO 03 if function variant Temp./Slide applies (for temperature monitoring) | --- |
| P 24.04 | DO: PLC 4 | n/a | n/a | DO.VCU1.DO4.HIGH (if knocker installed) | n/a |
| P 25.01 | Bin Weigher Active (see chapter "Enable additional hopper weight cell" below) | NO | YES (if applies) | YES (if applies) | YES (if applies) |
| P 27.13 | FCB_AO_04 | n/a | n/a | AO.VCU1.AO1 if function variant Temp./Slide applies and a servo sliding element is installed | n/a |
| P 27.14 | Offset FCB_AO_04 | 4,00 mA | 4,00 mA | 0,00 mA if function variant Temp./Slide applies and a servo sliding element is installed | 4,00 mA |
| P 27.15 | Range FCB_AO_04 | 20,00 mA | 20,00 mA | 20,00 mA | 20,00 mA |
| P 27.16 | Reference FCB_AO_04 | 1000,00 | 1000,00 | (e.g. 100,00) if function variant Temp./Slide applies and a servo sliding element is installed | 1000,00 |
| P 28.01 | FCB_DO 01 | n/a | n/a | DO.VCU1.DO5.HIGH if function variant Temp./Slide applies | DO.VCU1.DO5.HIGH (Function variant Simplex-FB) |
| P 28.01 | FCB_DO 01 | n/a | n/a | n/a | DO.VCU1.DO5.HIGH (Function variant Simplex-FB) |
| P 28.01 | FCB_DO 01 | n/a | n/a | DO.VCU1.DO6.HIGH if function variant 2 FLAPS applies | DO.VCU1.DO5.HIGH (Function variant Simplex-FB) |
| P 28.02 | FCB_DO 02 | n/a | n/a | n/a | DO.VCU1.DO6.HIGH (Function variant Simplex-FB) |
| P 28.02 | FCB_DO 02 | n/a | n/a | DO.VCU1.DO5.HIGH if function variant 2 FLAPS applies | DO.VCU1.DO6.HIGH (Function variant Simplex-FB) |
| P 35.17 | Material Parameter 17 | --- | --- | Bypass Adaption | --- |
| P 35.20 | Material Parameter 20 | --- | --- | Reference FCB_AO 4 if function variant Temp./Slide applies and a servo sliding element is installed | --- |
| P 35.24 | Material Parameter 24 | --- | --- | --- | Controller Index (Function variant Simplex-FB) |
| P 42.09 | Oscillation Amplitude MEMS | 1,50 mm | 1,50 mm | (e.g. 1,85 mm, maximum 2,00 mm) | 1,50 mm |
| P 42.13 | Current Max | 5,0 A | 5,0 A | (e.g. 7,0 A, depends on exiter coil size and if coil cooling is installed) | 5,0 A |
- Set parameter P 03.03 "Nominal Flow Rate" to maximum feed rate of the Dosing Unit. For example, if the maximum flow rate of the dosing unit is 280 kg/h, then write this value into parameter P 03.03
- Parameter P 03.04 "Nominal Amount Fo" indicates the maximum material capacity of the hopper (100% Level Max [kg]) in dependence of the load cell capacity.
The correct value "Nominal Amount Fo" can be calculated as follows:
Template:Notice bms
Example:
100% Level Max [kg] = 660kg
LC Rated Capacity [kg] = 3 * 2200kg = 6600kg
According to the formula, the Nominal Amount Fo has to be set to 10,0%
- Set parameter P 05.06 “LC Characteristic Value” (Cn) according to value on the load cell
- Set parameter P 05.07 “LC Rated Capacity” (Emax) according to values on the load cell. For example, if there are 2 load cells connected parallel and each load cell has an Emax of 150 kg, the Parameter P 05.07 has to be set to 300 kg.
Note: These two Parameters are written on a label on the load cell.
- The filling sequence starts after it reached Level Min which you can adjust with Parameter P 06.10 “Threshold filling start” and stops after it reached Level Max which is adjustable with Parameter P 06.11 “Threshold filling stop”.
- Start filling: Level Min (kg) = (100% Level Max * Threshold filling start) / 100
- Stop filling: Level Max (kg) = (100% Level Max * Threshold filling stop) / 100
- The filling sequence starts after it reached Level Min which you can adjust with Parameter P 06.10 “Threshold filling start” and stops after it reached Level Max which is adjustable with Parameter P 06.11 “Threshold filling stop”.
Note: Filling level of big Dosing Units should be as high as possible to have long gravimetric time periods (but not more than 75 % of the maximum hopper capacity). Filling level of small Dosing Units should be less high to prevent adherence of the granulate (e.g. antistatic). To check if the hopper becomes not filled up with too much or too less material start filling sequence (Scale Operation Mode / Press Button “Filling Start”) and check how much material is inside the hopper. Template:Notice bms
- Select "TW: Tare" program in Tools -> "Calibration Programs"
- Start Calibration Program “TW Tare”
- Wait until calibration is done and the new tare value is displayed, then press button apply
- Check calibration by putting a weight on 3 different points on the hopper and see if PVSS shows the right value. If not, check load cell wiring, transportation locks and start calibration again.
4.2 Templates of parameters for the different types customized for BMS, usually installed allready from Schenck at delivery[edit | edit source]
Readme Media:ReadMe_Brückner_Parameter_2024-07-23.pdf Vibro Standard Feeder: Media:Brueckner_Template_Vibro_2024-01-26.zip Vibro TEMP SLIDE Feeder (280 size): Media:Brueckner_Template_Vibro_TEMP_SLIDE_2024-01-26.zip Vibro 2 FLAPS Feeder (fast product change): Media:Brueckner_Template_Vibro_2_FLAPS_2024-01-26.zip Simplex-FB with alternating filling flaps (fluff dosing): Media:Brueckner_Template_SIMPLEX_FB_2024-04-24.zip
Old/Obsolet, just for historical reference: File:190924 Dosing Schenck BMS-Standard Parameter Liste .xls Old/Obsolet, just for historical reference: BMS-Tersus Parameter
4.3 Enable additional hopper weight cell[edit | edit source]
It is possible to evaluate the weight of the second Hopper by use of the auxiliary port x92 on the Schenk unit.
Following steps are nessacery to activate the auxiliary port:
- 1. select from dropdown menu tab 25 "Bin Weigher"
- 2. Set P25.01 "Bin Weigher Active" to yes
- 3. Set P25.02 "Load Measurement" to LC.VCU1.LC2.-
- 4. Set the other parameters according the name plate of the Load cell
- 5. Select from dropdown menu tab 22 "Fixed mode configuration"
- 6. set P22.23 "ID Read Value 15" to BIN:Fill Weight
- 7. select in the Calibration Programm "TB:Tare" for zeroing the actual displayed weight.
4.4 Dosing Unit with a vibro feeder[edit | edit source]
- Check refill flap
- Open Scale Operations and Unlock Easy Serve User Interface.
- Press button “Filling Start” - Refill flap should open.
- Press button “Filling Stop” - Refill flap should close again.
- If the refill flap is not opening, check wiring, check pneumatic and make sure that Parameter P 06.13 “DO: Gate” is “DO/VCU1/DO6/HIGH”
- Adjustment of Parameters
- Open the Parameter panel
- Parameters to be set as following - see chart in chapter before
4.4.1 Knocker Valve[edit | edit source]
On the really small Schenck-Units we often find a knocker-valve.
This Valve knocks against the bin during the start of a dosing unit to loosen the bridges of the material in the small outlet of the unit.
Comissioning:
- Configure the PLC-Signal: P24.04 to the output where the knocker Valve is connected (usually DO4)
- Tick the box "Knocker" in the WinCC panel of the Dosing-Unit
- Configure the desired Values for "Knocker Time Setpoint" and "Knocker Pulse Setpoint"
4.4.2 Calibration of the External Controller[edit | edit source]
4.4.2.1 FRS 00052 controller (obsolete from year 2018 on, replaced by VVC 29150 controller)[edit | edit source]
- Set operation mode to “Volumetric”
- Start Dosing by pressing Button “Start”
- Set P to Nominal Flow Rate (Value Parameter P 03.03)
- Adjust Poti R1 (See figure 4) of the External Controller until the value of the actual feeding rate I is around the same as the set point P
- Set P to zero
- Increase Parameter P 12.04 "Controller Magnitude Offset" in small steps (e.g.: start with 0.1 mA and step up with 0.05 mA) until the vibro feeder just starts moving the material a little bit. Then take 10 % off the adjusted value and write the new value into Parameter P 12.04
Template:Notice bms
Template:Image
- Set again set point P to Nominal Flow Rate (P03.03) and adjust Poti R1
- Stop Dosing by pressing Button “Stop”
4.4.2.2 Shake Control VVC 29150[edit | edit source]
At the end of 2017 the old FRS 0052 controller was replaced by the new VVC 29150 controller.
Modifying the oscillation amplitude with the VVC 29150 can only be done via EasyServe anymore.
It's important to know, that the new Vibro Feeder also comes with a new vibration sensor named VME 29150-2GD.
This sensor measures the acceleration instead of the velocity which was done by the previous sensor VRS 20300(-1D3G).
Please make sure that you have at least EasyServe v28 installed on your notebook and that Schenck Tersus runs firmware version vlw20172_003 or higher.
For detailed information about the new vibro controller goto: Schenck ShakeControl VVC29150
4.4.2.2.1 Connection of engineering notebook (obsolete, just in case that you are on line which got the first VVCs)[edit | edit source]
Template:Notice bms
Obsolete: RS232 connection to access online parameters to the controller with this first versions like P01.11 Oscillation Amplitude MEMS of the Vibro Controller and P01.15 Current Max.
Obsolete: the parameters of the new Vibro Feeder can only be modified via a serial connection – modifying parameters of the dosing unit still works via Ethernet.
| Contact on X102 (VVC 29150) | RS232 serial port on the PC |
| 1 (GND) | 5 (GND) |
| 2 (Tx) | 2 (Rx) |
| 3 (Rx) | 3 (Tx) |
Obsolete: Connect notebook like shown above
Obsolete: Open EasyServe v28 or higher and configure your COM port (Connection / Serial)
Obsolete: Once the connection has been established you will see a parameter list like this:
Obsolete: The parameters are saved in an independent PAR-file and need to be added in the SVN.
4.4.2.2.2 Commissioning and parameters of VVC 29150[edit | edit source]
In order to activate the new Vibro Controller please make sure that P01.16 Vibro Controller VVC at the parameter set of the Dosing Unit is activated (enter expert mode first).
Carry out Calibration program “Vol. Discharge Adaption”
- View "Scale Operation 1"
- Set "Gravimetric Mode"
- Start Dosing Unit
- Set P to Maximum Flow Rate
- Start Calibration Program "Vol. Discharge Adaption"
- Wait until Deviation is around zero and for control magnitude and set/act value to stabilize on display
- Press "Apply" - value will be taken over into Parameter P 12.03 Bypass
Adjust mechanical setup of the Vibro Feeder or modify VVC 29150 parametrization if determined Bypass value is too high
If for whatever reason the determined Bypass value after the Volumetric Discharge Adaption is outside of the recommended range (10-12mA for dosings with low flow rate and 14mA for dosings with high flow rate) there are two possibilities to change that:
- Change mechanical setup of the Vibro feeder
- Adjust P42.09 Oscillation Amplitude MESM of the VVC 29150
Note: P42.07 (Gain (Index) 1 only works in combination with sensor VRS 20300 (obsolete) and P42.09 only with VME 29150.
P42.07 defines with which factor the system amplifies the actual value of the vibration amplitude. In other words, this value affects the maximum possible vibration amplitude – the higher the value, the higher the amplitude.
P42.09 specifies the maximum vibration amplitude. By default this parameter is set to 1.5mm – if required it’s possible to set it up to 2.0mm.
P42.13 Current Max: depends on the size of the exciter coil. Can be increased, but only if a coil cooling is installed.
For detailed information about the new vibro controller goto: Schenck ShakeControl VVC29150
Continue with Calibration Program „Optimize Controller“, “DAE Adjustment” and so on…
4.4.3 Calibration of Vol. Discharge Adaption, Optimization Controller and DAE Adjustment[edit | edit source]
- Open Scale Operations (View/Scale Operation)
- Set operation mode to “Gravimetric”
- Start Dosing by pressing Button “Start”
- Set P to the Nominal Flow Rate
- Start Calibration Program “Vol. Discharge Adaption”
- Wait until Deviation is around zero and for control magnitude and set/act value to stabilize on display
- Press Button “Apply” - value should be taken over into Parameter P 12.03 "Bypass"
- Start Calibration Program “DAE Adjustment“
- Wait until Deviation is around zero and maximum disturbance and standard deviation to be displayed
- Press Button “Apply”
4.4.4 Linearization of P1-P4[edit | edit source]
Note: The vibro feeder discharge characteristic is non-linear. To improve the assignment of set points to actual values and the control quality in gravimetric mode, linearization has to be performed.
Note: Useful values are, for instance, P1 = 5%, P2 = 10%, P3 = 30%, P4 = 60% of the Nominal Flow Rate
For example:
If the Nominal Flow Rate of the Dosing Unit is 280 kg/h, we are going to set P1 = 14 kg/h, P2 =28 kg/h, P3 = 84 kg/h, P4 = 168 kg/h
We start with the calibration of P1, so the Nominal Flow Rate has to be set to P= 14 kg/h
- Enter feed rate to P in percent of the nominal feed rate (Parameter P 03.03).
- Open Calibration Programs
- Start Program Linearization P1
- Wait until deviation value is around zero
- Accept result by pressing apply
- Call up Linearization Program P2 and repeat steps a) to e) (don’t forget to change P to P2)
- Call up Linearization Program P3 and repeat steps a) to e) (don’t forget to change P to P3)
- Call up Linearization Program P4 and repeat steps a) to e) (don’t forget to change P to P4)
- Set Parameter P 13.01 Linearization to “On”
- Set all set points from P1 to P4 again and check if actual feeding rate I reaches the Setpoint P more smoothly.
Template:Notice bms Template:Image
4.4.5 Function Test[edit | edit source]
For the function test start Dosing Unit over PVSS and set different set points for the feeding rate. Open Scale Operations and check if the actual value of the feeding rate I changes properly. If it takes to long until the actual value I reaches the set point P you can adjust it by changing Parameter (P 12.01 "P-Component KP" of controller). Furthermore, check if refilling is working correctly.
4.5 Dosing Unit with a Dosing Screw/Spiral, type Coniflex (Main Dosing with mixed granulate and fluff together), not standard any longer[edit | edit source]
4.5.1 Check refill flap and cleaning unit[edit | edit source]
- Open Scale Operations (View/Scale Operation)
- Press button “Filling Start” -> Refill flap should open and cleaning should start
- Press button “Filling Stop” -> Refill flap should close again
- If the refill flap is not opening or cleaning doesn’t start, check wiring, check pneumatic and make sure that Parameter P 06.13 “DO: Gate” is “DO/VCU1/DO6/HIGH”
4.6 Fluff Dosing Unit with a Dosing Screw, type Simplex (Direct Fluff Dosing DFD), actual standard[edit | edit source]
4.6.1 Hopper calibration[edit | edit source]
- Select "TW: Tare" program in Tools -> "Calibration Programs"
- Start Calibration Program “TW Tare”
- Wait until calibration is done and the new tare value is displayed, then press button apply
- Check calibration by putting a weight on 3 different points on the hopper and see if PVSS shows the right value. If not, check load cell wiring, transportation locks and start calibration again.
4.6.2 Calibration of Vol. Discharge Adaption, Optimization Controller and DAE Adjustment[edit | edit source]
- Open Scale Operations and start the Keyboard Mode
- Set operation mode to “Gravimetric”
- Start Dosing by pressing Button “Start”
- Set P to the nominal feed rate
- Start Calibration Program “Vol. Discharge Adaption”
- Wait until Deviation is around zero and for control magnitude and set/act value to stabilize on display.
- Press Button “Apply”. Value should be taken over into Parameter P 10.03 Bypass
- Start Calibration Program “Optim. Controller"
- Wait until Deviation is around zero and for P-Component KP and I-Component TN to be displayed
- Press Button “Apply”
- Start Calibration Program “DAE Adjustment“
- Wait until Deviation is around zero and maximum disturbance and standard deviation to be displayed
- Press Button “Apply”
4.6.3 Function Test[edit | edit source]
For the function test start Dosing Unit over PVSS and set different set points for the feeding rate. Open Scale Operations and check if the actual value of the feeding rate I changes properly. If it takes to long until the actual value I reaches the set point P you can adjust it by changing Parameter (P 12.01 "P-Component KP" of controller). Furthermore, check if refilling is working correctly.
5 Final Function Test[edit | edit source]
- Start all Dosing Units and set different set points for the feeding rate.
- Check if everything is working correctly.
6 Parameter File Handling[edit | edit source]
- Save the parameter files in the server (\_engineering\public\dosing\Schenck\) and use the standardized file name : XXXXKOM_WinCC-tag_PI-number_IP address (example: 2047KIK_SilMexDos001_QN410_10.20.161.200.PAR).
- Commit the files into SVN.
7 Troubleshooting[edit | edit source]
7.1 Unexpected Consumption Reset[edit | edit source]
Template:Image
If you observe a unwanted reset of a dosing unit's actual consumption, you need to check P03.08 "Counter 1 Unit".
Make sure that it is tons [t] with one digit after the decimal point.
7.2 Firmware Check[edit | edit source]
old/obsolete, just for historical reference Schenck has informed us that faulty firmware releases can cause freezing of the electronics if the units have been powered up for approx. 200 days.
old/obsolete, just for historical reference Firmwares listed below must be updated: • VLW 20172-002 (released 2016-11-24) to VLW 20172-005 • VWF 20172-001 (released 2017-08-11) • VMC 20172-001 (released 2018-03-05) and VMC 20172-002 • VIO 20170-006 (released 2018-01-23)
8 Archive of *.ndb-Files to view Parameter Backups[edit | edit source]
If you want to open a backup from a Dosing which was never connected to your computer EasyServe will deny to show the parameters.
To avoid this problem you can download the following file: ndb-Database from Schenck
Schenck download support
This Databas you unpack into C:\Program Files (x86)\Schenck\Database. After that you should be able to view all backup Parameter-files.
