MRW Vib-Control 04 User manual

Operating Manual
MRW Vib-Control 04
Doc ID: Vib-Control 04-DE
Read the manual prior starting all tasks!

© MRW C.M. Fuisting GmbH & Co. KG
Osterwiesenstr. 31
D-73574 Iggingen-Brainkofen
Tel.:[phone]
Fax:[phone]
E-Mail: [e-mail]
Internet: www.mrw-fuisting.com

MRW Vib-Control 04
Table of contents
27. Oktober 2014 3 v. 34
Table of contents
1General........................................................................................................................................................5
1.1 Note for the importer...........................................................................................................................5
1.2 About this operating manual...............................................................................................................5
1.3 Explanation of the symbols and signal words in the operating manual .............................................5
1.4 Limitation of liability ............................................................................................................................6
1.5 Copyright ............................................................................................................................................7
1.6 Spare parts.........................................................................................................................................7
1.7 Guarantee terms.................................................................................................................................7
1.8 Service................................................................................................................................................7
2Safety ..........................................................................................................................................................8
2.1 Responsibility of the owner.................................................................................................................8
2.2 Ambient conditions .............................................................................................................................8
2.3 Use for the intended purpose.............................................................................................................9
2.4 Foreseeable misuse ...........................................................................................................................9
2.5 Special dangers................................................................................................................................10
2.6 Signage.............................................................................................................................................11
3Technical data...........................................................................................................................................12
3.1 General specifications ......................................................................................................................12
3.2 Connection ratings............................................................................................................................12
3.3 Operating conditions.........................................................................................................................12
3.4 Serial number ...................................................................................................................................12
3.5 Dimension sheet...............................................................................................................................13
4Structure and function...............................................................................................................................14
4.1 Operating elements ..........................................................................................................................14
4.2 Menu list ...........................................................................................................................................15
4.3 Deactivating the lock code................................................................................................................17
4.4 Explanation of special menu functions.............................................................................................18
4.5 Status messages in the display........................................................................................................20
4.6 Fault messages in the display..........................................................................................................20
4.7 Defaulting to factory settings............................................................................................................21
5Installation and commissioning .................................................................................................................22
5.1 Safety................................................................................................................................................22
5.2 Connections prepared by the factory ...............................................................................................22
5.3 Prepared X15 connector...................................................................................................................22
5.3.1 Connection variant 1.....................................................................................................................23

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General
5.3.2 Connection variant 2.................................................................................................................... 23
5.4 Prepared X16 connector.................................................................................................................. 24
5.4.1 Connection variant 1.................................................................................................................... 24
5.4.2 Connection variant 2.................................................................................................................... 25
5.5 X17 screw terminal connection in the device .................................................................................. 26
5.5.1 Connection variant backup control and external power regulation.............................................. 27
5.5.2 Connection variant external power regulation via PLC................................................................ 29
5.6 X18 terminal connection in the device............................................................................................. 30
6Spare parts and accessories.................................................................................................................... 31
7Dismantling and disposal.......................................................................................................................... 33
7.1Safety............................................................................................................................................... 33
7.2 Dismantling...................................................................................................................................... 33
7.3 Disposal ........................................................................................................................................... 33
8Declaration of conformity.......................................................................................................................... 34

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General
1 General
1.1 Note for the importer
Before the product is placed on the market the importer must adapt
this documentation to the national law applicable in the country in
which the product will be placed in service.
1.2 About this operating manual
This manual enables safe and efficient handling of the control unit.
The operating manual is a component of the control unit and must
be kept in the vicinity of the system where it is available to
personnel at all times. Personnel must have carefully read and
understood this manual before performing any tasks. The basic
prerequisite for safe work is compliance with all specified safety
instructions and handling instructions.
In addition the applicable local accident prevention regulations and
general safety regulations must be complied with for the machine’s
implementation.
The graphic illustrations in this manual are provided for purposes
basic understanding and can deviate from the actual version of the
machine.
1.3 Explanation of the symbols and signal words in the operating manual
Safety instructions
Safety instructions are indicated by symbols in this operating
manual. The safety instructions are introduced by signal words that
express the scope of the hazard.
The safety instructions must be strictly complied with, you must act
prudently to prevent accidents, personal injury, and property
damage.
DANGER!
indicates an imminent dangerous situation that can
result in death or serious injury if it is not avoided.
WARNING!
indicates a possible dangerous situation that can result
in death or serious injury if it is not avoided.

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General
CAUTION!
indicates a possible dangerous situation that can result
in minor or slight injury if it is not avoided.
CAUTION!
indicates a possible dangerous situation that can result
in minor or slight injury if it is not avoided.
Tips and recommendations
NOTE!
... indicates useful tips and recommendations, as well
as information for efficient and trouble-free operation.
Special safety instructions
The following symbols are used in safety instructions to alert to
special dangers:
Danger!
... indicates electrical shock hazards. If the safety
instructions are not complied with there is danger of
severe or fatal injury.
1.4 Limitation of liability
All information and instructions in this operating manual have been
provided under due consideration of applicable norms and
regulations, the current state of technology, as well as our many
years of insight and experience.
The manufacturer assumes no liability for damage due to:
Failure to comply with the instructions in the manual
Non-intended use
Deployment of untrained personnel
Unauthorised modifications
Technical modifications
Use of non-approved spare parts
The actual scope of delivery can deviate from the details and
presentations described here for special designs, utilizing additional
order options or based on the newest technical changes.
The obligations agreed in the supply agreement, the general terms
and conditions, as well as the delivery conditions of the
manufacturer and the statutory regulations valid when the contract
was concluded, apply.

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General
We reserve the right to make technical changes in the interests of
improving performance characteristics and further development.
1.5 Copyright
This manual is protected by copyright and is provided exclusively
for internal purposes.
Delivery of the operating manual to third parties, duplication in any
form - including excerpts - as well as exploitation and/or
communication of the content, are not permitted except for internal
use without written approval from the manufacturer.
Actions to the contrary make damage compensation mandatory.
We reserve the right to enforce additional claims.
1.6 Spare parts
WARNING!
Safety risk if the wrong spare parts are used!
Incorrect or defective spare parts can cause damage,
malfunction, or total failure; they can also impair safety.
Therefore:
Only use manufacturer's original spare parts.
Only purchase spare parts from authorized dealers or direct from
the manufacturer. See page 2 for the address.
The spare parts list is found in the appendix.
1.7 Guarantee terms
The guarantee terms are included in the manufacturer’s General
Terms & Conditions.
1.8 Service
Our customer service department is available for technical
information. See page 2 for the contact details.
In addition, our employees are always interested in new information
and experiences associated with the application which could prove
valuable in improving our products.

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Safety
2 Safety
This section provides an overview of all the important safety
aspects for optimal protection of personnel, as well as for safe and
trouble-free operation.
Failure to comply with the handling instructions and safety
instructions cited in this manual can result in significant hazards.
2.1 Responsibility of the owner
The control unit is used in industrial applications. The owner of the
control unit is therefore subject to legal occupational health and
safety obligations.
In addition to the safety instructions in this operating manual,
generally occupational health and safety, accident prevention, and
environmental protection regulations must be complied with for the
area of implementation of the machine. Particularly in this regard:
The owner must inform himself of applicable occupational
health and safety regulations, and in a hazard analysis
identify additional hazards that may exist at the installation
site of the control unit due to the special work conditions.
The owner must implement these in the form of operating
instructions.
The owner must ensure during the entire implementation
period of the control unit that the operating instructions
drawn up by the owner correspond to the current state of
legislation, and if necessary the owner must adapt these
operating instructions.
The owner must clearly regulate and specify responsibilities
for installation, operation, and testing.
The owner must ensure that all personnel who handle the
control unit have read and understood the operating
manual.
The owner is also responsible for keeping the control unit in
perfect technical condition at all times
2.2 Ambient conditions
The control unit is designed for use in dry, heated rooms.
The temperature range should be between 15° and 40°C.
The relative humidity may not exceed 60%.

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Safety
2.3 Use for the intended purpose
The control unit has been designed and manufactured exclusively
for the intended use described here.
The MRW VIB-CONTROL 04® regulates the drive pulses of all
electromagnetically driven vibratory drives with a coil current of up
to 10 amperes.
2.4 Foreseeable misuse
Any use that extends beyond the intended use, or any other use of
the control unit is considered to be misuse and can cause
dangerous situations.
WARNING!
Danger due to misuse!
Misuse of the machine can cause hazardous
situations.
Particularly refrain from the following uses of the
machine:
Operation with other energy sources
Operation in explosive atmospheres
Operation in wet-duty rooms

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Safety
2.5 Special dangers
Residual risks that have been determined on the basis of a risk
assessment are cited in the following section.
Comply with the safety instructions cited here and with the warnings
in the subsequent chapters of this manual to reduce health hazards
and to avoid dangerous situations.
High voltage
Danger!
Life-threatening danger due to electric shock!
There is an imminent, life-threatening danger due to
electric shock if live components are touched. Damage
to insulation or individual components can pose a life-
threatening hazard.
Therefore:
If there is damage to insulation, immediately
switch off the power supply and have the fault
repaired.
Only qualified electricians should perform
tasks on the electrical equipment.
De-energise the electrical equipment and
ensure that it is de-energised for all tasks.
Before conducting any maintenance, cleaning
and fault repair work, switch off the power
supply and secure it from accidentally turning
back on.
Do not bypass any fuses or render them
inoperable. When replacing fuses maintain the
correct amperage specification.
Keep moisture away from live components.
Moisture can cause a short circuit.
Vibration
WARNING!
Long-term health impairment due to strong vibrations!
Strong vibrations can cause significant health
impairment in the long term.
The vibration source is decoupled from the
environment via vibration dampers.
Therefore:
Do not render the vibration dampers
inoperable.
Never position yourself within the vibrating
area during operation.

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Safety
Noise emission
WARNING!
Hearing loss due to noise!
The noise level that occurs in the work area can cause
severe hearing loss.
Therefore:
Always wear hearing protection when working
with the machine.
Only be in the danger zone to the extent
required.
2.6 Signage
WARNING!
Danger of injury due to illegible symbols!
Over time, stickers and signs can be become fouled or
can become illegible in some other manner.
Therefore:
Keep all safety, warning, and operating
instructions that are affixed to the control unit
in legible condition.
Replace damaged signs or stickers
immediately.
Unplug the plug before opening!
Unplug the power plug before opening the housing.
Do not pull the plug out of the power outlet by the cable but by the
power plug itself.
CAUTION!
Residual voltage
A minimum waiting period of 5 minutes must be observed after
disconnecting the control unit from the power and before opening it
so that the charge of the capacitators can decrease to a safe level.

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Technical
data
3 Technical data
3.1 General specifications
Dimensions
Specification
Value
Unit
Housing dimension
H x W x D
198x98x81
mm
3.2 Connection ratings
Connected loads, electric
Specification
Value
Unit
Input voltage
110-250
V
Power frequency
50-60
Hz
Power consumption
2,5
A
Max. power consumption for 0.2
sec.
5
A
Output current
8
A
External power supply 24V DC
0,2
A
Fuses (slow blow)
2,5
A
Protection class
IP 54
3.3 Operating conditions
Specification
Value
Unit
Temperature range
15 –40
°C
Relative humidity, maximum
60
%
3.4 Serial number
6
Fig. No. 1:
The serial number can be found on the right-hand side of the
housing.
Fig. No. 2:
The software version is shown when the device is switched on. The
device must first be switched off until the text in the display no
longer appears –this can take up to 5 minutes

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Technical
data
3.5 Dimension sheet

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Structure
and function
4 Structure and function
Fig. No. 3:
1. Display indicates 16 numbers
2. Keypad (membrane keypad)
3. 2.5A slow blow fuse
4. On/off switch
4.1 Operating elements
Fig. No. 4:
Button
Function
Opens the menu
Starts the vibratory bowl feeder
Stops the vibratory bowl feeder
Selects the menu items and opens the submenus
Runs upward through the menu lines
Runs downward through the menu lines
1
2
3
4
Menu
SEL
Start
Stop

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Structure
and function
4.2 Menu list
,
Status display
Contin
ue
with
button
Display
Navig.
button
Description
Save/ac
tiv.
button
Any time
STOP button
In order to get to the top level of the
menu, always press the “Stop” button
STOP button
Freq. Automatic
v
v
Lock code
All the submenus can be selected by
pressing the button “Up” or “Down”.
Activate the submenu with “SEL”
NOTE!
All the values highlighted in yellow in the following
table are factory settings and can be defaulted to
using the “General Reset” function
Menu display
Activ.
button
Display
Navig.
button
Description
Save
button
Freq. Automatic
Frequency search
After “Start”
147Hz > 17Hz
Press the “Start” button to start the
frequency search.
Press the “Stop” button to stop the
frequency search.
Once the frequency search is successful,
the status “STOP buttons” is displayed.
See also Chap. Fehler! Verweisquelle
onnte nicht gefunden werden.
Freq. Pre-
selection xxx.x Hz
y.y A xxx.x Hz
The required vibration frequency can be
set here.
The current power consumption by the
magnetic coils is displayed. See also
Chap. Fehler! Verweisquelle konnte
icht gefunden werden.
Type of control
Freq+speed contr
Quiet / Contr off
Only speed contr.
The required type of control can be set
here. See also Chap. Fehler!
erweisquelle konnte nicht gefunden
werden.
Display
Frequency/Hertz
Current/Output
Current/Mains
The output values to be shown as
information during automatic operating
mode can be set here.
Stop
Start
Stop
Menu
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL

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Structure
and function
Menu display
Activ.
button
Display
Navig.
button
Description
Save
button
Speed input
Internal/Buttons
External 0-10V =
xx V
External
potentiometer=
xx%
Whether the speed is to be controlled via
the control unit or via external inputs is
set here. The status of the external inputs
is displayed.
Start/Stop
Internal/Buttons
+24V Stop = xxV
+24V Start = xxV
Whether the vibratory drive is to be
activated by the buttons or via an
external input can be set here.
The input can be inverted.
The applied voltage at the input is
displayed.
MAX sensor
+24V Stop = xV
0V Stop = xV
The vibratory drive can be stopped here
via a MAX sensor.
The input can be inverted.
The applied voltage at the input is
indicated in the display.
MIN sensor
+24V Start = xV
0V Start = xV
The vibratory drive can be started here
via a MIN sensor.
The input can be inverted.
The applied voltage at the input is
indicated in the display.
Gentle start
Gentle start x.xs
0.5s
The delay for the gentle start can be set
here for between 0.1 and 9.9 seconds.
During this time, power is slowly
increased up to a preset target value.
Gentle stop
Gentle stop x.xs
0.5s
The delay for the gentle stop can be set
here for between 0.1 and 9.9 seconds.
During this time, power is slowly reduced
to a stop.
Stop delay
Time xx.s
0.5s
How long the signal on the MAX sensor
must be at “high level” before the
vibratory drive is stopped is set here.
Start delay
Time xx.s
0.5s
Without MIN sensor: How long the signal
on the MAX sensor must be at “low level”
before the vibratory drive is stopped is
set here.
With MIN sensor: how long the signal on
the MAX sensor and on the MIN sensor
must be at “low level” before the vibratory
drive is stopped.
Max speed xx%
Max speed xx%
90%
The maximum permissible speed of the
vibratory drive in % is set here.
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL

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Structure
and function
Menu display
Activ.
button
Display
Navig.
button
Description
Save
button
Max speed xx%
Min speed xx%
0%
The minimum permissible speed of the
vibratory drive in % is set here.
Current limitation
Current max X A
5A
The highest permissible power
consumption by the vibratory drive can
be set here.
Languages
Italian
German
English
French
Flemish
Spanish
Portuguese (Bra)
The required language is set here.
Button block
Yes
No
The bottom block can be activated here
with “Yes” and deactivated with “No”.
Lock code
(only when block
is activated)
XXX1
A value between 0-999 can be set as a
lock code here.
The smallest value is “1”
All functions except for Start / Stop are
now locked.
4.3 Deactivating the lock code
Lock code
NOTE!
If a lock code is entered, the indicator “Lock code”
appears when a button other than the Start and Stop
buttons is pressed.
Menu display
Activ.
butto
n
Display
Navig
butto
n
Description
Save
button
Lock code
XXX1
Enter the lock code and press the “SEL”
button here.
The device is now unlocked and must be
locked again via the “Button block” menu,
if required.
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL

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Structure
and function
4.4 Explanation of special menu functions
Freq. Automatic
Each vibratory driver has a natural frequency. It is mostly set to
50/60 Hz (mains frequency) or the respective double value by the
manufacturer.
This natural frequency changes if superstructural parts and loads
are placed on the vibratory drive.
Instead of bringing in the natural frequency to the target value again
with time-consuming work by means of spring configuration,
gyrating mass and clearances, the Vib-Control 04 control unit can
search for the new natural frequency and operate the device with
the new optimal frequency.
After starting the frequency search, the software of the Vib-Control
04 tests the frequency band of 147 - 17 Hz and measures the
power consumption of the vibratory drive. The optimal frequency for
operating the “vibratory drive and superstructure” unit is determined
in this way.
A prerequisite for a successful frequency search is a fault-free
vibratory drive (clearances, coils and springs in perfect condition)
and a firm connection between the vibratory drive and the
superstructure. Loose parts on the superstructure interfere with the
frequency search.
Tips and recommendations
NOTE!
If the magnets strike their counter-bearings during the
frequency search, the maximum feed performance can
be limited in the “Max speed” menu before the
frequency search.
Frequency preselection
For vibratory drives with unstable superstructures, the optimal
vibration frequency can be set manually.
It is best to start with the rated frequency of the drive (this can
mostly be found on the type plate).
The power consumption of the drive is always displayed as a guide.
The lower the power consumption, the closer it is to the natural
frequency or the harmonised frequency (double / half value) and the
system is protected.
If one observes the parts to be fed in the superstructure of the
vibratory drive at the same time, the optimal compromise between
power consumption and feed performance can be found.

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Structure
and function
Type of control
Three different control types can be set.
“Freq+speed contr”:
If the frequency was determined via automatic search, the control
unit then regulates the frequency automatically when the
superstructure is loaded.
The feed speed set is then also maintained if the loads are
changed.
This option can only be selected after the automatic frequency
search. If the frequency is set manually, the control type “Only
speed contr.” is then is set automatically here.
“Only speed contr.”:
If this control type is already set in the menu, the control unit then
only regulates the speed when loading the drive. The frequency
remains unchanged.
“Quiet / Contr off”:
If this control type is set in the menu, then the device works with a
sinusoidal frequency at the output.
The drive is significantly quieter and light parts no longer jump in
the superstructure of the drive.
The maximum output current should be limited to 5 A as heat
generation is higher here.
An automatic readjustment in the event of higher loads is not
possible here.

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Structure
and function
4.5 Status messages in the display
53 % 52.2 Hz
Alternative
53% 4.3 A Output vibratory drive
53% 1.8 A Input control unit
Standard display in automatic operating mode
Specification of power in %. Vibratory drive work frequency
Alternative setting
Specification of power in %. Power consumption at input or output
Stop buttons!
The vibratory drive was stopped via the “Stop” button
External Stop!
The vibratory drive was stopped via the control input for the PLC or
the MRW RoboPot System.
Backup Stop!
The vibratory drive was stopped via a directly connected backup
sensor or MAX sensor
4.6 Fault messages in the display
Danger!
Fault messages in the display always indicate an
electrical problem. The fault must be remedied by a
qualified electrician.
“Short-circuit”
This message is displayed when there is a short-circuit at the output
of the control unit to the vibratory drive. Magnetic coils or cables are
defective.
The feed speed is then set to 0%.
After the fault is rectified by an electrician the value must be reset.
“Overload”
This fault occurs when the power consumption of the drive is higher
than the permitted value set in the menu. This function serves to
protect the drive.
Check the air gap and coils of the vibratory drive and/or, if
applicable, increase the permitted power consumption of the drive.
The highest possible value is 8A.