Borger STE-RSM2 User manual

www.boerger.de www.boerger.com
Operating Manual
Börger Reversing Control Unit
Types STE-RS
M
R
U
2
3

Börger Worldwide
2www.boerger.de / www.boerger.com BA-STE-RS, 26.09.2014
Börger Worldwide
Europe
Germany
– Head Office –
Börger GmbH
Benningsweg 24
46325 Borken-Weseke
Germany
Phone [phone] / 91030
Fax [phone] / 910346
[email protected]
www.boerger.de
France
Börger France S.A.R.L.
9 rue des Prés
67670 Wittersheim
France
Phone +33 (0) 3 / 88515468
Fax +33 (0) 3 / 88515413
[email protected]
www.borger.fr
Great Britain/
Ireland
Börger UK Ltd.
East Wing - Old School
Watling St. Gailey
Staffordshire
ST19 5PR, United Kingdom
Phone [phone] / 798977
Fax [phone] / 798979
[e-mail]
www.boerger.com
Netherlands
Belgium
Luxembourg
Börger Benelux
Postbus 78
7630 AB Ootmarsum
Netherlands
Phone +31 (0) 541 / 293687
Fax +31 (0) 541 / 293578
[e-mail]
www.boerger-pumps.nl
Poland
Boerger Polska Sp.z o.o.
ul. Toszecka 101
44-100 Gliwice
Poland
Phone +48 32 / 3356094
Fax +48 32 / 3356095
[email protected]
www.boerger.pl
America
USA
Boerger, LLC
2860 Water Tower Place
Chanhassen, MN 55317
USA
Phone +1 877 / 7263743
+1 612 / 4357300
Fax +1 612 / 4357301
[email protected]
www.boerger.com
Asia and
Australia /
Oceania
Singapore
Boerger Pumps Asia Pte. Ltd.
16 Boon Lay Way
#01-48 TradeHub21
Singapore 609965
Phone +65 / 65629540
Fax +65 / 65629542
[email protected]
www.boerger.com
China
Boerger China
Shanghai Representation Office
Room 2111, No. 58 Yinqiao
Building
Jin Xin Road, Pudong
Shanghai 201206, China
Phone +86 (0) 21 / 51389081
Fax +86 (0) 21 / 51389082
[email protected]
www.boerger.com.cn
India
Boerger Pumps Asia Pte. Ltd.
India Representation Office
German Centre, Office #21
14th floor, Building no. 9, Tower B
DLF Cyber City Phase III
Gurgaon 122002 Haryana, India
Phone +91 (0) 124 / 4636060
Fax +91 (0) 124 / 4636063
[email protected]
www.boerger.com
Africa *
Head Office
Börger GmbH
Benningsweg 24
46325 Borken-Weseke
Germany
Phone [phone] / 91030
Fax [phone] / 910346
[email protected]
www.boerger.de
Your sales
partner:
– Stamp –
* Algeria, Morocco: See France, Börger France S.A.R.L.

Product Specifications
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Product Specifications
Machine:
Product group: Control unit, reversing control unit
Type: STE-RSM, STE-RSR, STE-RSU
2, 3
Manufacturer's address:
Company: Börger GmbH
Address: Benningsweg 24
Town / city: 46325 Borken – Weseke, Germany
Phone: [phone] / 9103 – 0
Fax: [phone] / 9103 – 46
E-mail: [e-mail]
Internet: www.boerger.de
Spare parts orders and customer
service in Germany:
Börger GmbH
Tel. / fax: Spare parts orders – industrial sector:
Tel. [phone] / 9103 – 38
Fax [phone] / 9103 – 49
Customer service – industrial sector:
Tel. [phone] / 9103 – 35
Fax [phone] / 9103 – 49
Spare parts orders and customer
service – agricultural sector:
Tel. [phone] / 9103 – 31
Fax [phone] / 9103 – 47
E-mail: [e-mail]
Spare parts orders and
customer service in other countries:
See separate contact data for your
regional sales partner
Document data:
Document: ZBA-STE-RS_Englisch.docx
Language: English translation of the German
original, available at ser[email protected]
Issue date: 9/26/2014

Contents
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Contents
Börger Worldwide..........................................................................................................................2
Product Specifications..................................................................................................................3
Contents ........................................................................................................................................4
1General Information ......................................................................................................7
1.1 Introduction......................................................................................................................7
1.2 Notes on copyrights and property rights ..........................................................................7
1.3 Information for the operator .............................................................................................8
1.4 Instruction........................................................................................................................9
2Safety ...........................................................................................................................10
2.1 General information .......................................................................................................10
2.2 Notes on signs and symbols..........................................................................................10
2.3 Proper use.....................................................................................................................11
2.4 Residual risk..................................................................................................................12
2.5 Description of the safety equipment...............................................................................14
2.5.1 Fuses ............................................................................................................................14
2.5.2 Emergency stop.............................................................................................................14
2.5.3 Filter ventilator protection ..............................................................................................14
2.6 Marking and signs on the STE-RS control unit ..............................................................15
2.7 Safety instructions for operating personnel ....................................................................17
2.8 Safety instructions for maintenance and rectifying malfunctions on the STE-RS
control unit.....................................................................................................................18
3Product Description ....................................................................................................20
3.1 Construction of the STE-RS reversing control unit.........................................................20
3.1.1 Control cabinet ..............................................................................................................23
3.1.2 Control unit ....................................................................................................................24
3.1.3 Reversing contactor combination...................................................................................24
3.1.4 Motor protection switch..................................................................................................25
3.1.5 Frequency converter......................................................................................................25
3.1.6 Electrical connections....................................................................................................25
3.1.7 Operating terminal .........................................................................................................26
3.1.8 Menu navigation ............................................................................................................27
3.1.9 Options and accessories ...............................................................................................35
3.2 Function of the STE-RS reversing control unit ...............................................................36
3.3 Technical data ...............................................................................................................38
3.3.1 Dimensions....................................................................................................................38
3.3.2 Electrotechnical data .....................................................................................................39
3.3.3 Ambient conditions of STE-RS control unit ....................................................................39

Contents
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3.3.4 System limits .................................................................................................................39
4Transportation, As-delivered Condition, Storage, Installation.................................41
4.1 Transportation ...............................................................................................................41
4.2 As-delivered condition ...................................................................................................42
4.3 Storage / interim storage ...............................................................................................42
4.3.1 Storage..........................................................................................................................42
4.3.2 Interim storage ..............................................................................................................42
4.4 Installation .....................................................................................................................43
4.4.1 Positioning.....................................................................................................................43
4.4.2 Installing the control cabinet ..........................................................................................44
4.4.3 Electrical connections....................................................................................................45
4.4.4 Control cabinet climatization..........................................................................................47
4.4.5 Secure installation / checking fastening screws .............................................................47
5Operation .....................................................................................................................48
5.1 Commissioning..............................................................................................................49
5.1.1 Switching on the control unit and checking the functions ...............................................49
5.1.2 Password customization, password input ......................................................................49
5.1.3 Setting the date and system time...................................................................................52
5.1.4 Checking the direction of rotation ..................................................................................52
5.1.5 Adjusting the control parameters ...................................................................................53
5.2 Normal operation...........................................................................................................56
5.3 Downtimes ....................................................................................................................57
5.3.1 Downtimes in automatic operation.................................................................................57
5.3.2 Downtimes in manual operation.....................................................................................57
5.3.3 Switching off the control unit..........................................................................................57
5.4 Faults ............................................................................................................................58
5.4.1 Reversing when the current consumption is exceeded ..................................................58
5.4.2 Fault messages and troubleshooting .............................................................................59
5.5 Resetting the intermediate meter...................................................................................62
6Maintenance and Repairs ...........................................................................................63
6.1 Machine care.................................................................................................................64
6.1.1 Cleaning the outside of the control cabinet ....................................................................65
6.1.2 Cleaning the outside of the operating terminal during operation ....................................66
6.1.3 Cleaning the inside........................................................................................................66
6.2 Maintenance and inspection ..........................................................................................66
6.2.1 Lamp test ......................................................................................................................67
6.2.2 Insulation measurements...............................................................................................68
6.3 Repairs..........................................................................................................................68
7Disposal .......................................................................................................................69
7.1 Environmental protection...............................................................................................69

Contents
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7.2 Oil, oily waste and grease..............................................................................................69
7.3 Plastics..........................................................................................................................69
7.4 Metals............................................................................................................................70
7.5 Electrical and electronic waste.......................................................................................70
7.6 Final decommissioning ..................................................................................................70
8Accessories .................................................................................................................71
9Appendix ......................................................................................................................71
9.1 Circuit diagrams, complete parts list and data sheets ....................................................71
9.2 Type code......................................................................................................................72
9.3 Checklist for commissioning ..........................................................................................74
9.4 EC Declaration of Conformity ........................................................................................75
9.5 Additional documentation ..............................................................................................76
9.6 Supplier documentation .................................................................................................76

General Information
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General Information1
Introduction1.1
This operating manual is an important aid for the correct and safe
operation of the control unit.
It contains important information for operating the control unit and
the units connected to it in a safe, proper and economical manner.
Adhering to these instructions will help avoid associated dangers,
reduce repair costs and downtimes and increase the reliability and
service life of the control unit and the units controlled by it.
The operating manual must be made available at all times. All
personnel who work on or with the control unit must read and
adhere to the manual. This work includes:
— Operation and troubleshooting
— Maintenance (machine care, maintenance and repairs)
— Transportation
Notes on copyrights and property rights1.2
This operating manual must be treated as confidential. It may only
be made accessible to authorized persons. The manual may only
be passed on to third parties following written approval from
Börger GmbH.
All documents are protected according to the copyright laws. The
distribution and reproduction of documents, in whole or in part,
plus the exploitation and distribution of all associated content is
forbidden unless expressly authorized in writing.
Violations will be prosecuted and may lead to claims for
compensation. All rights for exercising industrial property rights
are reserved by Börger GmbH.

General Information
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Information for the operator1.3
The operating manual is an integral part of the control unit. The
operator (i.e. the responsible party) is responsible for making the
operating personnel aware of this manual.
Additionally, the operator is obligated to ensure the notice and
observance of national regulations for accident prevention and
environmental protection, plus the notice and observance of
supervision and reporting duties taking special operational
aspects into account, e.g. regarding work organization, work
processes and personnel.
Aside from the operating manual and the currently valid accident
prevention regulations in the country of operation and at the
installation site, all recognized special regulations for safe and
proper operation must be observed.
The operator is not permitted to make or arrange for any changes,
modifications or alterations to the control unit without approval
from Börger GmbH. This includes any changes to the
programming beyond the settings described in the following
chapters.
Any spare parts used must comply with the technical
requirements specified by Börger GmbH. This is always
guaranteed when original spare parts are used.
Only original spare parts may be used during the warranty period,
failing which the warranty is void.
Only trained or instructed personnel may be assigned to operate,
maintain, repair or transport the control unit. Clearly define the
personnel responsible for operation, maintenance, repair and
transportation.

General Information
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Instruction1.4
As the operator, you are obligated to inform and, if necessary,
instruct your operating personnel in regard to the applicable legal
and accident prevention regulations, as well as the safety
equipment available on the control unit and the units controlled by
it. The different technical qualifications of the operating personnel
must be taken into account.
The operating personnel must have fully understood the
instructions, and adherence to the instructions must be
guaranteed. Only then can your personnel work safely and be fully
aware of associated risks.
Adherence to instructions must be checked on a regular basis. As
the operator, you should therefore have each instructed staff
member confirm their training participation in writing.
Börger GmbH, their regional subsidiaries or your local sales
partner will be happy to help you regarding staff instruction. On
request, they can also carry out training on the functionality,
commissioning, maintenance and repair of the control unit and the
units controlled by it.
Contact us for a detailed quotation.

Safety
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Safety2
General information2.1
Only high-quality components have been used in the control unit
that have been specifically selected and programmed for the units
controlled by it.
Nevertheless, the operation of the control unit and the units
controlled by it may endanger the operating person and cause
damage to the connected units, the control unit or other material
assets in the following circumstances:
— When operated by untrained or uninstructed personnel
— When not used properly
— When not maintained or repaired properly
Notes on signs and symbols2.2
The following terms, signs and symbols are used in this operating
manual, and indicate particularly important information.
Danger!
Warns of an immediate hazardous situation with unavoidable
serious injuries or death as a result if the instructions shown are
not strictly adhered to.
Warning!
Warns of a hazardous situation with the possible risk of
subsequent serious injuries or death if the instructions shown
are not strictly adhered to.
Caution!
Warns of a possible hazardous situation with the risk of
subsequent moderate or light injuries and material damage if
the instructions shown are not strictly adhered to.

Safety
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Notice
Indicates a possible hazardous situation or unsafe, dangerous
work processes that may lead to damage to the machine or
surrounding area.
Note
Offers useful information on safe and proper operation.
Bullet points describe work and / or operational steps. These●
steps must be carried out from the top down.
— Indents indicate lists.
All instructions and symbols attached directly to the control unit
and the units controlled by it (e.g. warning signs, operational
signs, all component designations etc.) must be strictly adhered
to.
They may not be removed and must be kept completely legible.
Some of the diagrams used in this operating manual, which are
only used to illustrate a particular work step, show a different type
of control unit. However the work step is the same.
Proper use2.3
The STE-RS reversing control unit serves the purpose of
preventing and removing slight blockages of a connected
macerator caused by fiber materials.
An integrated motor protection protects the motor of the
connected macerator from damage through overload. In the event
of an overcurrent, the STE-RS switches off the connected
macerator.
An emergency stop switch additionally allows the operator to bring
the macerator to an immediate standstill.
It is possible to connect an external control unit (optional for some
versions).

Safety
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Proper use includes compliance with the instructions on
— safety,
— operation,
— repairs and maintenance,
which are described in this operating manual as well as in the
operating manuals of the connected components.
Any other use or use over and above these specifications is
deemed as improper use. The operator is solely liable for any
resulting damage.
Residual risk2.4
Even when all safety instructions are adhered to, there are
residual risks involved in operating the control unit as detailed
below.
All persons that work on and with the control unit must be aware
of these residual risks and observe the associated instructions to
avoid accidents or damage caused by these residual risks.
It may be necessary to open or remove on-site safety equipment
during installation and modifications. This causes a residual risk
and potential danger that each operating person must be aware
of:
Danger!
Risk of fatal injury due to electric shock!
Electrical connections may only be installed by qualified
electricians.
Pay particular attention to all instructions and safety
regulations contained in the operating manuals for
electronic components in the appendix.

Safety
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Danger!
Danger of serious injury or death from electric shock!
For protection against contact, secure the power supply with an
AC/DC sensitive residual current device (RCD Type B)
according to the circuit diagram.
Switch off the STE-RS control unit using the main switch
before performing any repair or maintenance work.
Ensure that it cannot be switched back on unintentionally, e.g.
by applying a U-lock to the main switch or by disconnecting the
plug from the power supply.
Protect the STE-RS control unit from moisture, heat, and frost.
In particular, ensure that water cannot enter when the control
cabinet is open.
Ensure that all electric connections have been properly
reconnected before switching the unit on and that the cables
used are undamaged and have not been sharply bent.
Make sure that the control cabinet is always closed and locked
before switching on and during operation, and that no
unauthorized persons have access to the key.
Disconnect the unit during thunderstorms or a prolonged
absence from the power supply.
Warning!
The following applies to versions with a frequency converter:
The frequency converters may carry a dangerous contact
voltage for up to 10 minutes after disconnection from the
power supply.
Only open the control cabinet 10 minutes after shutdown.

Safety
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Description of the safety equipment2.5
The control unit is equipped with the required safety equipment
according to the applicable legal guidelines in the country of
manufacture, current state-of-the-art technology and recognized
safety regulations.
Fuses2.5.1
The circuit breakers (automatic fuses) indicated on the electric
circuit diagrams protect the electric circuits from being damaged
by overcurrent.
Emergency stop2.5.2
An emergency stop switch for the connected units is located at the
front of the control cabinet door. This switch must always be
accessible.
Filter ventilator protection2.5.3
In the version with control cabinet climatization, a cover, a filter
and a protective mesh protect the rotating axial ventilator fan from
contamination and from anyone reaching into it.
The air inlet opening in the cover may not be blocked. The cover
may not be removed.

Safety
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Marking and signs on the STE-RS control unit2.6
(The data provided are for illustrative purposes only. Here,
they refer to a Multichopper P150 control unit.)
Meaning:
The control unit manufacturer’s nameplate
Location:
In a
clearly visible position on the control
cabinet door inside the control cabinet
1)
Different address possible, e.g. when delivered through a
subsidiary.
Meaning:
The control cabinet manufacturer's nameplate
Location:
In a clearly visible position on
the inside of the
control cabinet door
Meaning:
The filter fan hood manufacturer’s nameplate
Location:
In a clearly visible position on the filter fan
hood
Meaning:
Marking of electronic components
/ circuits
(the first number marks the page in the
circuit
diagram)
Location:
In a clearly visible position on the relevant
components in the control cabinet
Meaning:
Emergency stop switch (red on yellow)
Location:
At the front of the control cabinet

Safety
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Meaning:
Warns of dangerous electrical voltage
Location:
On the control cabinet and on individual
components
Meaning:
Protective ground connection
Location:
On all connecting points to the protective
ground wire
Attention!
Check that all terminal screws are properly
tightened before commissioning the system
Meaning:
Warning:
The electrical connections must be checked
before commissioning the STE
-RS control
unit and the components connected to it. In
particular, it must be ensured that the terminal
screws are tight.
Location:
In a clearly visible
position on the inside and
outside of the control cabinet
Meaning:
Warning: Components marked with this label
carry voltage even after switching off the
control unit via the main switch.
Location:
In a clearly visible position on the relevant
components
in the control cabinet
Additional markings on electronic
components
Meaning:
See the manufacturer’s operating manual
Location:
On the individual components

Safety
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Safety instructions for operating personnel2.7
The control unit and the components controlled by it may only be
operated while they are fully assembled, in perfect working
condition and only for their intended purpose, in a safe and risk-
conscious manner having regard to this operating manual.
All malfunctions must be rectified immediately and professionally,
especially those affecting safety. This applies particularly to
defects such as loose electrical connections, frayed, burnt, kinked
or otherwise damaged cables etc.
Every person assigned with commissioning, operation or
maintenance work must have fully read and understood this
operating manual beforehand – specifically chapter 2, Safety.
Consulting the manual during work is already too late. This
applies especially to personnel that only work occasionally on the
control unit.
The operating manual must always be kept accessible next to the
control unit.
No liability will be assumed for any damage and accidents caused
by non-compliance with the operating manual.
Adhere to the applicable accident prevention regulations and all
other generally recognized safety regulations and guidelines for
occupational health at work.
Clearly specify the responsible parties for the various
maintenance and repair tasks and adhere thereto. Only then can
handling errors be avoided, especially in dangerous situations.
If the control unit or the connected components malfunction:
Use the emergency stop switch to shut down the control unit●
and the connected components immediately.
Turn the main switch to OFF.●
Ensure that the control unit cannot be switched on again, e.g.●
by locking the main switch with a U-lock.
Take all necessary measures in order to shut down the●
connected devices (e.g. close the valves).
Report the malfunction to the responsible department/person.●

Safety
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This especially applies to safety-related alterations to the control
unit or connected components.
Observe the maintenance instructions in the relevant operating
manuals when carrying out maintenance on the connected
components.
Work on the control unit may only be carried out by trained,
reliable personnel. Personnel in training or requiring instruction, as
well as persons currently in vocational training, may only operate
the control unit under the constant supervision of an experienced
staff member.
Safety instructions for maintenance and rectifying malfunctions on2.8
the STE-RS control unit
The control unit may only be opened, maintained and repaired by
qualified electricians, while having proper regard to the attached
electric circuit diagrams.
Adhere to the prescribed intervals for regular maintenance and
inspections or those specified herein and in the operating manuals
of the components.
Modifications, repairs and maintenance on the control unit may
only be carried out when the control unit is switched off.
Accidental restarting of the unit must be prevented completely.
To the extent necessary, amply secure the surrounding area when
performing maintenance. Cordon off the working area with a red
and white safety chain and a warning sign.
Large assemblies and components must be carefully attached
and secured to hoists when they are removed or replaced so that
associated dangers are minimized. Only appropriate hoists and
lifting media in technically perfect working condition with sufficient
load capacities may be used.
Never stand under suspended loads.
Protect the electronic components from moisture and impurities.
Do not use aggressive cleaning agents to clean the outside. Use
lint-free cleaning cloths. Only clean the electronic components
with suitable agents according to the manufacturers' operating
manuals.

Safety
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Dispose of any replacement parts in a safe and environmentally-
friendly manner.

Product Description
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Product Description3
Construction of the STE-RS reversing control unit3.1
Outside of the control cabinet, front view
1 Control cabinet with lock (S)
2 Main switch
3 Emergency stop
4 Operating terminal
5 Red LED indicator lamp, is lit in the event
of malfunctions
6 Yellow LED indicator lamp, is lit during
automatic operation
7 Blue LED illuminated pushbutton for
restoring readiness for operation after an
emergency stop
8 Start button / stop button
for connected components, with indicator
light for trouble-free operation
Options:
12 Control cabinet climatization with filter fan
hood (supplied as standard in version with
frequency converter)
13 UV cover, lockable