RNA ESR 2500 User manual

Operating Instructions
Controller for vibrating motors
ESR 2500
ESR 2800

Rhein-Nadel Automation GmbH 2
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Table of Contents
1. About this document............................................................................................................4
2. Safety directives..................................................................................................................4
2.1. Design of safety directives ..................................................................................................4
2.2. Fundamental safety directives.............................................................................................4
2.3. Personnel............................................................................................................................4
2.4. Intended use........................................................................................................................5
2.5. Residual hazards.................................................................................................................5
2.5.1. Device.................................................................................................................................5
2.5.2. Motor protection ..................................................................................................................5
2.5.3. Degree of protection - Protection of persons and equipment ..............................................6
3. Product information.............................................................................................................6
3.1. Functional description .........................................................................................................6
3.2. Standard features................................................................................................................6
3.3. Applied standards................................................................................................................7
4. Installation and commissioning............................................................................................7
4.1. Sequence of operations for installation and commissioning................................................7
4.2. Mechanical installation........................................................................................................8
4.3. Electrical installation............................................................................................................8
4.4. Commissioning....................................................................................................................9
4.5. Choice of the right current range.........................................................................................9
4.6. Sensor connection.............................................................................................................12
4.7. Connection diagram..........................................................................................................13
4.8. Voltage change .................................................................................................................14
5. Operator panel and display of the controller......................................................................15
5.1. Operator panel - Display ...................................................................................................15
5.2. Navigating through the menus...........................................................................................16
5.3. Main menu ........................................................................................................................16
5.3.1. The "Status" screen:..........................................................................................................16
5.3.2. The "Info" screen:..............................................................................................................17
5.3.3. The "Extended" screen:.....................................................................................................17
5.3.4. Summary of ESR 2500, ESR2800 main menu..................................................................18
6. The set-up menu...............................................................................................................18
6.1. List of set-up menu items ..................................................................................................18
6.1.1. Accumulation checker (sensor inputs)...............................................................................19
6.1.2. Ramps...............................................................................................................................19
6.1.3. Display calibration.............................................................................................................20
6.1.4. Communication / connector XS3.......................................................................................20
6.1.5. Analogue speed input........................................................................................................21
6.1.6. High / Low speed...............................................................................................................21
6.1.7. Multiple settings.................................................................................................................21
6.1.8. Active braking....................................................................................................................22
6.1.9. Changing the password.....................................................................................................22
6.1.10. Activation code..................................................................................................................22
7. Calibration menu...............................................................................................................22
7.1. List of calibration menu items............................................................................................22
7.1.1. Start calibration .................................................................................................................22
7.1.2. Fine tuning ........................................................................................................................23
7.1.3. Current sensor configuration.............................................................................................23
7.1.4. Set max. current................................................................................................................23
7.1.5. Mode.................................................................................................................................23
7.1.6. Changing the password.....................................................................................................23
7.2. Calibration process............................................................................................................24
8. Memory Reset...................................................................................................................28

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9. Technical data...................................................................................................................28
9.1. Accessories.......................................................................................................................29
10. Alarm messages................................................................................................................29
10.1. Alarm message and troubleshooting.................................................................................29
10.1.1. Short-circuit protection active............................................................................................29
10.1.2. Overload protection active.................................................................................................30
10.1.3. No feeder or low current....................................................................................................30
10.1.4. Frequency error.................................................................................................................30
10.1.5. Vibration restricted ............................................................................................................31
10.1.6. Resonance frequency not found........................................................................................31
10.1.7. Resonance maximum not found........................................................................................31
10.1.8. PWM measurement offset error ........................................................................................31
10.1.9. Voltage measurement offset error.....................................................................................31
10.1.10. Current measurement offset error .................................................................................31
10.1.11. Offset error refusing common mode, distance measurement........................................32
10.1.12. Magnet core saturation not found..................................................................................32
10.1.13. Field bus error ...............................................................................................................32
11. General errors...................................................................................................................32
Declaration of Conformity
According to the Low-Voltage Directive 2014/35/EU
and Electromagnetic Compatibility Directive 2014/30/EU
We hereby declare that the product meets the following requirements:
Low-Voltage Directive 2014/35/EC
Electromagnetic Compatibility Directive 2014/30/EU
Applied harmonised standards: DIN EN 60204 T1
EN 61439-1
Remarks:
Rhein-Nadel-Automation
---------------------------------
Managing Director
Jack Grevenstein

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1. About this document
The information given in this document reflects the following version:
Document description:
This document provides assistance in choosing your product. You will also find information on mechanical and electri-
cal installation, operation, product extensions and accessories.
Non-observance may cause trouble with the product or the environment, reduce the product lifetime or lead to other
damage.
2. Safety directives
2.1. Design of safety directives
2.2. Fundamental safety directives
Non-observance of the following fundamental safety measures and directives may lead to severe injury and damage to
property!
Meeting the requirements given in the related documentation is a precondition for safe and trouble-free operation and
for achieving the product properties specified. Further additional safety directives in the other sections must be observed
as well.
2.3. Personnel
Only qualified professionals are allowed to work on or with the product. IEC 60364 or
CENELEC HD 384 define the qualification of these persons:
•They are familiar with set-up, installation, commissioning and operation of the product.
•They possess the qualification required for performance of their work.
•They know all regulations for the prevention of accidents, directives and laws applicable to set-up, installation and
commissioning on site, and they are able to apply the same.
•They have knowledge and skills of First Aid.
Attention
Read this document carefully and observe the safety directives before commencing any work.
Product
from software version
Date
ESR2500
V1.2.7
2019-03-01
ESR2800
V1.2.7
2019-03-01
Notice
This notice identifies useful tips for use of the controller.
Attention!
This symbol identifies hazardous situations.
Non-observance of such warnings may cause irreversible injury or even death!
Attention!
Any work on electrical equipment of the machine/system shall be carried out exclusively by a professional
electrician, or by instructed persons working under the direction and supervision of a professional electri-
cian, according to electrotechnical rules.

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2.4. Intended use
Please observe the following directives for intended use of the controllers:
•The devices herein described must only be stored, fitted and operated under the conditions specified in this doc-
umentation.
•Here you are not concerned with domestic devices! They are solely intended to be used as components for
commercial or professional applications pursuant to EN 61000−3−2.
•They satisfy the protection requirements of 2014/35/EU: Low Voltage Directive.
•They do not constitute a machine as defined by 2006/42/EU: Machinery Directive.
•A machine comprising the product must not be commissioned or put into operation for the intended use until it
has been declared to be in conformity with the EC Directive 2006/42/EU: Machinery Directive; Observe EN
60204−1.
•Commissioning or starting operation for the intended use is only permitted in compliance with the EMC Directive
2014/30/EU.
•Use of the product in living areas may lead to EMC disturbance. The user is responsible for taking interference
suppression measures.
•They are optimised for operation of RNA bowl feeders and linear feeders. Observe the limits indicated in the
technical specification.
2.5. Residual hazards
Residual hazards may remain even if all directives have been observed and protective measures taken.
Such residual hazards must be considered by the user in the risk assessment of his machine/equipment. Non-ob-
servance may lead to severe injury and damage to property!
2.5.1. Device
Pay attention to the warning signs fitted to the device!
Symbol
Description
Hazardous voltage:
Prior to commencing any work on the product check for absence of voltage on all power con-
nections.
Leakage current:
Make fixed installation and PE connection according to EN 60204−1!
Attention
Before opening the controller, pull the mains plug and wait for the periods shown below, allowing the DC
link circuit capacitors to discharge down to a safe voltage level.
Discharge period:
ESR 2500
10 minutes
ESR 2800
15 minutes
2.5.2. Motor protection
Certain device parameter settings may overheat the connected drive magnet, e.g., by prolonged operation with the
wrong current range set.
Attention!
•Prior to start-up make sure that the protective earth conductor is connected and in proper condi-
tion. Make the PE conductor test with approved test devices only.
•Never start up despite detected damage.
•Do not make any technical modifications to the device, except as described in this document.
•Never start up in an incompletely installed state.
•Never operate the device without the required guards in place.
•Connect, disconnect or change any electrical connections only in the absence of voltage.

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2.5.3. Degree of protection - Protection of persons and equipment
•All specifications relate to installed condition ready for operation.
•All slots not used must be closed by protection caps or dummy plugs in order not to reduce the protection
against accidental contact.
3. Product information
3.1. Functional description
This fully automatic controller has been developed specifically to operate RNA bowl feeders or linear feeders with a
high feed rate.
The intelligent controller continuously monitors the mechanical conveyor movement and uses this signal for active
control of the vibration amplitude and thus the feed rate. This makes sure that the set fed rate is maintained irrespec-
tive of conveyor load, ambient temperature, supply voltage and supply frequency, etc.
The drive frequency is automatically controlled in a PLL circuit so that the feeder is run under optimum conditions at all
times, i.e. exactly at the resonance frequency.
The controller adapts to the connected feeder by means of an automatic calibration sequence which largely eliminates
the often laborious mechanical adaptation to the feeder.
These controllers allow vibrating motors to be operated at different mains frequencies without the need for changing
the magnets or re-adjusting the feeder mechanically.
The controller is self-protected which makes sure that neither the drive magnets nor other components will be over-
loaded. The parameters of all mechanical and electrical components are permanently monitored. In case of significant
deviations the monitoring function will output alarm messages before serious consequences can occur, i.e., it identifies
a defective spring or loose nut before further damage occurs.
This controller as two 24V DC sensor amplifiers.
Moreover, there are two optocouplers and a relay output for status messages as well as an external enabling input of
24 V DC for remote control.
3.2. Standard features
•Dynamic electronic protection covering output short-circuits and output overloads.
•Active protection of magnets and motor.
•Permanently controlled speed which ensures stable running and repeatable speed setting.
•Low maintenance of the drive system.
The automatic frequency adjustment to the changes in drive characteristics reduces the need for frequent fine
tuning of the drive springs.
•Reduced power consumption (approx. 50 %).
Motor requires less power as it runs in the resonance range.
•Flexible choice of frequency (25-150 Hz).
Drive frequency can be perfectly fine-tuned for a specific application, irrespective of the mains frequency.
•Not affected by mains fluctuations (voltage / frequency).
•Control over the entire feed system.
•2 sensor amplifiers.
oTwo independent 24V DC sensor inputs for monitoring the feeder (accumulation check).
•Speed can be set by analogue setpoint entry.
•Communication
oElectrically isolated 24V input for start/stop by external signal.
oReadiness message (optocoupler, 24VDC, 20mA)
oActive message (optocoupler, 24VDC, 20mA)
oActive message via relay contact. 250VAC, 1A
•Firmware upgrade via USB port.
•Immediate stop function by active brake monitor.
oThis optional feature stops the motor immediately in response to a stop command. This prevents a
'stop delay' and slow stoppage of the vibrating motor.This option is particularly useful where counters
are involved, i.e., where an exact number of parts is to be counted without excess parts dropping off
the feeder when the right number of parts is reached.
•Multiple calibration
•One device can be calibrated for up to 11 different motors.
•Electrically isolated 24V input for speed switching.

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3.3. Applied standards
EC - Conformity
The controller is compliant with the following standards:
EC EMC Directive 2014/30/EU
EC Low-Voltage Directive 2014/35/EU
Applied harmonised standards:
DIN EN 60204, part 1
EN 61439-1
4. Installation and commissioning
This chapter deals with the mechanical and electrical installation of the controller.
The controller is designed for quick and easy installation by following the sequence of operations below.
4.1. Sequence of operations for installation and commissioning
Attention
Read the safety instructions in Chapter 2 prior to installation of the device.
Mechanical installation
•Mechanical installation
Electrical installation
•Connection to supply mains and protective earthing
•Load connection
•Control connection
Commissioning
•Calibration
•Programming

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4.2. Mechanical installation
Planning the place of installation:
Choose the best possible position taking the following into consideration:
•Ambient temperature
•Low-vibration mounting
•Operator access to controller
•Controller location near the vibrating motor
•Cable routing
Physical dimensions
Fix the ESR2500 - 2800 controller in place by inserting two M8x40mm screws through the two holes in the heat sink
beneath the housing.
You can fix the device either directly to the feeder base plate or to the base frame of the machine.
A controller fitted directly to the feeder is exposed to strong vibration which may shorten its lifetime. It is highly recom-
mendable, therefore, to mount the controller on a non-vibrating, mechanically rigid structure such as the base frame of
a machine.
4.3. Electrical installation
Fuses
The device is internally protected by a 4A 5x20mm time-lag fuse in the mains supply line.
Mains supply must be protected by overload protection with C 16A fusing.
Earthing and supply mains
Notice
Check that supply voltage is in accordance with the data on the device rating plate.
Check if controller setting has been changed to another supply voltage or magnet voltage.
The ESR2500 / 2800 controllers are devices of protection class 1 which have to be connected to earth accord-
ing to regulations.
Attention
The cable connecting the controller with the vibratory feeder must be shielded and both ends of the shield
connected to protective earth.
The maximum admissible cable length is 3 m.
166,00
173,00
156,00
173,00
190,00
193,00
14,00
227,50
166,00

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Attention
Before you connect the controller to power supply and switch it on, it is mandatory to check the following:
• Is the controller in a good, safe operating state and closed with all screws tightened?
• Are the connectors screwed in place/locked?
• Are all cables and glands in proper condition?
• Is operation for the INTENDED USE made sure?
• Does the supply voltage specified on the controller match the local supply voltage?
Do not start up the controller unless you can answer a clear YES to all the above questions.
Attention
Before starting operation after maintenance work or after controller replacement, set the output power on
the controller to minimum before switching on. Check if the system works properly as you increase the out-
put power.
4.4. Commissioning
To prevent mechanical and/or electrical damage to the controller or connected devices, strictly observe all parameters
specified under item 4.3. If you do not find your specific type in the table of drive units please contact Rhein Nadel Au-
tomation. We will be happy to advise you.
Attention
In order to ensure smooth and stable operation of the drive unit it is necessary to have a well-tuned drive
system. Please also see the operating instructions of the feeder connected.
4.5. Choice of the right current range
In order to achieve the optimum feeding performance the current range of the controller must be selected to suit the
maximum load current of the vibrating motor according to Table 1 current setting of S301.
For information on the maximum current for the feeders please refer to the rating plate on the feeder motor and to Ta-
bles 2 and 3.
Current setpoint
2500
2800
100%
5.53 A*
9.00 A*
50%
2.75 A
4.50 A
33%
1.83 A
3.00 A
25%
1.37 A
2.25 A
Table 1 Connection table for max. current setpoint of S301
Always choose the lowest possible current range.
Example for ESR2500: The current input of the feeder is 2.5 A; use the 2.75 A current setpoint.
Notice
Set the correct current range also in the controller parameters.
(See under 7.1.3.)
For setting the correct current range you must open the controller. For this be sure to observe the safety instructions in
Chapter 2.
Attention!
Any work on electrical equipment of the machine/system shall be carried out exclusively by a professional
electrician, or by instructed persons working under the direction and supervision of a professional electri-
cian, according to electrotechnical rules.

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Attention
Before opening the controller, pull the mains plug and wait for the periods shown below, allowing the DC
link circuit capacitors to discharge down to a safe voltage level.
Discharge period:
ESR 2500
10 minutes
ESR 2800
15 minutes
Circuit Diagram / Installation Guide
Active
S301 Max. current setting = 100%
S301 Max. current setting = 50%
S301 Max. current setting = 33%
S301 Max. current setting = 33%
S403 supply voltage connected
after main switch