835204-008 kneter-b50-eht ba-01-e - brabender · edition 0712 instruction manual no....

... where quality is measured.

Instruction Manual

Brabender® GmbH & Co. KG •••• Kulturstr. 51-55 •••• 47055 Duisburg •••• Germany �� Phone - 49 - 203 - 7788 - 0 •••• �� Fax - 49 - 203 - 7788 - 101

�� E-mail: [email protected]

Agencies all over the world Brabender GmbH & Co. KG 2012 Copyright protection DIN 34 Edition 0712 Instruction Manual No. 835204-008_Kneter-B50-EHT_BA-01-e

Measuring Mixer Type B 50 EHT

Ident no. 8 352 04.008

for drive units Plasti-Corder® Lab-Station

REGISTRATION CARD Brabender® GmbH & Co. KG

Important! Please complete and return to: Important! Veuillez compléter et retourner à: / Wichtig! Bitte ausfüllen und zurücksenden an: /

Importante: Voglia completare e rispedire a: / Importante: Haga el favor de completar y devolver a:

Brabender GmbH & Co. KG, Kulturstr. 51-55, 47055 Duisburg, Germany Tel. No: ++ 49 - 203 - 7788 - 0

Fax. No.: ++ 49 - 203 - 7788 - 100 E-mail: [email protected]

Please state the Brabender order no. of your equipment: Inscrire ici le numéro de commande Brabender de votre appareil / Bitte hier die Brabender Order-Nr. Ihres Geräts eintragen /

Iscrivere qui il numero d'ordine Brabender dell'apparecchio / Inscribir aquí el número de pedido Brabender del aparato

USER OF EQUIPMENT Utilisateur / Benutzer / Utente / Utilizador

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ATTENTION

Due to the high leakage current (> 3.5 to 300 mA), Residual Current operated Circuit Breakers (RCCB) are not permissible.

The application of conventional RCCBs may lead to the following problems:

1. The high leakage current of frequency inverters and AC servo-controllers may cause unwanted activation of the RCCBs when the instruments are switched on or off.

2. In case of faults, the electronic circuits used in the frequency inverters and AC servo-controllers may cause DC fault currents which do not release conventional RCCBs.

If the application of RCCBs is imperative due to in ternal regulations, we recommend to use

Universal RCCBs of Messrs. Doepke Typ: DFS 4 B (DFS 4 040-4/0.03 BSK)

Doepke Schaltgeräte GmbH/Co. KG Stellmacherstraße 11 26506 Norden Germany Phone +49-(0)4931/1806-0 www.doepke.de

Measuring mixer type B 50 EHT for Plasti-Corder ® Lab-Station 5

Contents

1 GENERAL INFORMATION................................ .....................................7

1.1 Symbols and abbreviations ............................................................................................................7

1.2 Application......................................................................................................................................8

1.3 Disclaimer of liability.......................................................................................................................8

1.4 Noise measurement .......................................................................................................................8

2 SAFETY ..................................................................................................9

2.1 Due application...............................................................................................................................9

2.2 Target groups.................................................................................................................................9 2.2.1 Mounting, modification, disposal.........................................................................................9 2.2.2 Operation, cleaning, maintenance ......................................................................................9 2.2.3 Repair .................................................................................................................................9

2.3 Safety instructions for the user.......................................................................................................9

2.4 Safety devices ..............................................................................................................................10 2.4.1 Emergency motor stop button at the drive unit .................................................................10 2.4.2 Auto-identification and torque limitation ............................................................................10 2.4.3 Safety device.....................................................................................................................11 2.4.4 Two hand control device ...................................................................................................11

2.5 Remaining risks............................................................................................................................12 2.5.1 Hot surfaces - danger of burning ......................................................................................12 2.5.2 Rotating blades - risk of injury...........................................................................................12

3 TRANSPORT AND STORAGE .............................. ...............................13

3.1 Packing.........................................................................................................................................13

3.2 Transport ......................................................................................................................................13

3.3 Unpacking ....................................................................................................................................13

3.4 Scope of supply............................................................................................................................13

3.5 Notification of damage .................................................................................................................13

3.6 Storage.........................................................................................................................................14

4 FEATURES AND OPERATING PRINCIPLE................... ......................15

4.1 Measuring principle ......................................................................................................................15

4.2 Measuring mixer...........................................................................................................................16

4.3 Docking station Universal-Docking-Station ..................................................................................17

4.4 Docking station (year of construction until 2008) .........................................................................17 4.4.1 Connections and control elements....................................................................................17 4.4.2 Temperature controller .....................................................................................................18

4.4.2.1 Displays and control elements of the temperature controller .............................18 4.4.2.2 Functions of the individual keys of the temperature controller ...........................19 4.4.2.3 Keys and displays...............................................................................................19 4.4.2.4 Language setting at the controller ......................................................................21 4.4.2.5 Controller configuration ("Device configuration") ................................................22 4.4.2.6 Alarm setting for the heating zones of the measuring head ...............................23 4.4.2.7 Setting the alarm values for the activated alarms of the heating zones .............24 4.4.2.8 Self-optimization of the temperature controller...................................................25

6 Measuring mixer type B 50 EHT for Plasti-Corder ® Lab-Station

4.5 Additional equipment....................................................................................................................26 4.5.1 Quick loading chute* .........................................................................................................26 4.5.2 Pressure ram ....................................................................................................................26 4.5.3 Pressure ram with bore* for dosing liquids .......................................................................27 4.5.4 Pneumatic loading chute* .................................................................................................27 4.5.5 Precision metering pump*.................................................................................................27 4.5.6 Sealing cover ....................................................................................................................27

5 TECHNICAL DATA ..................................... ..........................................28

6 INSTALLATION ....................................... .............................................29

6.1 Basic requirements ......................................................................................................................29

6.2 Set-up and assembly....................................................................................................................29 6.2.1 Mounting the measuring mixer to the docking station* (year of construction until 2008)..30 6.2.2 Mounting the mixer docking station* to the Lab-Station* ..................................................32 6.2.3 Mounting the mixer blades................................................................................................33 6.2.4 Mounting of additional equipment*....................................................................................33

7 START-UP AND OPERATION............................. .................................34

7.1 Manpower requirements ..............................................................................................................34

7.2 Preparations .................................................................................................................................34

7.3 Test procedure .............................................................................................................................35 7.3.1 Preparations prior to test start...........................................................................................35 7.3.2 Filling the sample into the mixer .......................................................................................36

7.3.2.1 Loading with the quick loading chute* ................................................................36 7.3.2.2 Loading with the pressure ram*..........................................................................37 7.3.2.3 Loading with the pneumatic loading chute* ........................................................37

7.3.3 Checking the filling level of the mixer................................................................................38 7.3.4 Test end and cleaning of the measuring mixer.................................................................39

7.4 Evaluation of the test results ........................................................................................................40 7.4.1 Evaluation criteria..............................................................................................................40 7.4.2 Accuracy and reproducibility .............................................................................................40

8 MAINTENANCE ........................................ ............................................41

8.1 Cleaning .......................................................................................................................................41

8.2 Lubrication of the gear unit...........................................................................................................44

8.3 Exchange of bushings..................................................................................................................44

8.4 Abrasion check.............................................................................................................................44

9 TROUBLE-SHOOTING................................... ......................................45

10 ACCESSORIES ....................................................................................46

11 SPARE PARTS ........................................ .............................................46

12 ANNEX..................................................................................................46


1 GENERAL INFORMATION

Brabender® instruments/software are of a high technical standard and comply with the demand for simple and safe handling. At the same time, they are designed for universal application and, thus, for handling manifold technical tasks. It is strongly recommended to study this instruction manual very carefully before putting the instrument into operation in order to become familiar with the manifold possible applications and to use the instrument/software in an optimum way.

This instruction manual has been supplied together with the instrument/software and is intended for operation in practice. It is to make the user familiar with the instrument/software and to inform him about functional details and maintenance.

Safety instructions and precautions have to be obs erved in order to avoid accidents due to improper handling and operation.

The information contained in this instruction manual will also be useful for the detection and repair of any possible troubles. This instruction manual is, thus, to be considered part of the instrument/software and must be available to the operating personnel.

Within the scope of legal regulations, Brabender® refuses any liability for direct or indirect damage caused in connection with the delivery or use of Brabender® instruments. This is especially true for improper use of Brabender® instruments.

Maintenance and service instructions have to be observed for reasons of safe operation and durability.

For safety reasons beware of unauthorized operatio n, any modification of Brabender instruments or any other unauthorized interference.

At the same time, it should be considered that war ranty will expire as a consequence of improper use and unauthorized operation and/or modi fication and/or any other unauthorized interference.

If there are any inquiries to Brabender® - e.g. relating to handling of instruments/software, ordering of spare parts, accessories, additional equipment or to sending back instrument parts for maintenance or repair - please always state completely all data and complete numbers given on the name plate.

For questions concerning the software, please also state the number of your software version in addition to the software ident no.

Brabender will, of course, always be at your disposal for any information going beyond the scope of this instruction manual.

1.1 Symbols and abbreviations

Some of the elements of the instrument system mentioned in this instruction manual are optional or additional equipment. They are marked with a * within the text.


1.2 Application

The Brabender measuring mixer type B 50 EHT with electrical heating is a measuring head designed for being mounted to a Brabender Universal Docking Station* (or any other suitable docking station*) and for being connected to the Brabender Plasti-Corder® Lab-Station*.

Only a single communication line between docking station* with the measuring head and basic unit Lab-Station* is required for data recording, control, and pre-setting of nominal value. All system components are part of a network with a continuously information exchange between the individual system components based on the field bus technology.

The measuring mixers serve for testing thermoplastics, thermosets, elastomers, and similar materials with regard to the combined influence of temperature and shear. The measuring values are transmitted to the computer* to be recorded and displayed graphically and/or numerically on the monitor* already during the running test, so that the measuring process can be followed directly. Subsequently, the measuring data are evaluated automatically according to the most recent criteria and printed in the form of diagrams, tables, and graphics on a separate printer*.

1.3 Disclaimer of liability

Within the scope of legal regulations, Brabender® GmbH & Co. KG refuses any liability - for whatever legal argument - for direct or indirect damage caused in connection with the delivery or use of the Brabender® instrument/software. This is in particular true for - but not limited to - improper use and/or improper operation and handling of the Brabender® instrument/software.

In this context, Brabender explicitly excludes any warranty for wear parts, in particular for those with product contact.

Under no circumstances, Brabender® GmbH & Co. KG can be made liable for any damage or injuries caused by non-observance of the safety regulations included in the data sheets of the producer of substances, e.g. polymer(s), to be tested or processed with the Brabender® instrument. This is also valid if a recommendation was made concerning the application of certain substances and/or if the provision of test material (polymers) is part of the scope of supply and service.

The Brabender instrument is subject to modifications of color and design as well as to technical modification without prior notice.

1.4 Noise measurement

Noise measurement was made under normal operating conditions within the speed range of the instrument at a distance of approximately 1 m and at a height of approximately 1.6 m.

The equivalent continuous sound pressure level measured is Leq < 70 dB(A) .


2 SAFETY

2.1 Due application

The instrument may only be used with the designated drive unit Lab-Station for testing suitable free-flowing substances. The instrument may not be used for testing or processing explosives.

The instrument may only be used when completely assembled.

2.2 Target groups

2.2.1 Mounting, modification, disposal Mounting, modification, and disposal of the Brabender® measuring mixer may only be carried out by technically skilled personnel with the corresponding qualification. Electric work is only allowed to be carried out by skilled electricians.

2.2.2 Operation, cleaning, maintenance Routine operation, cleaning during routine operation, and maintenance of the Brabender® measuring mixer may be carried out by unskilled personnel.

However, the personnel in charge of operation, cleaning, and maintenance of the Brabender® measuring mixer must have been instructed by a skilled person.

2.2.3 Repair Repair work at the Brabender® measuring mixer is only allowed to be executed by Brabender® service technicians or by skilled personnel authorized for this work by Brabender®.

2.3 Safety instructions for the user

Prior to operation, the user must make sure of the correct condition and set-up/assembly of the instrument.

The carrier of the Brabender® measuring mixer has to make sure within his organization that the persons named in chapter 2.2 "Target groups" only carry out work at the measuring mixer they are authorized to do.

The carrier of the Brabender® measuring mixer has to furnish proof of training of the personnel in charge of operation, cleaning, and maintenance of the Brabender® measuring mixer.

The carrier of the Brabender® measuring mixer has to make sure that the operating personnel, prior to testing and processing any test material with the Brabender® measuring mixer, read and understood the instruction manual of the Brabender® measuring mixer as well as the safety data sheets of the respective producer of the test material and will observe them. The measures listed in the respective safety data sheets of the producer of the test material for avoiding any possible danger when handling the corresponding material must strictly be observed

Disregard of the safety instructions may cause dan ger for the operating personnel. This is also true for arbitrary, unauthorized, and improper modifications to the instrument.

Under no circumstances, Brabender can be made liable for any damage or injuries cause d by non-observance of such safety regulations.


2.4 Safety devices

The instrument shall be protected by pre-setting alarm and limit values (see also separate instruction manuals of the software). This also increases safety for the operating personnel.

2.4.1 Emergency motor stop button at the drive unit

The Brabender® Plasti-Corder® Lab-Station* used as a drive unit for the Brabender measuring mixer is equipped with an emergency motor stop button located on the top surface of the Brabender® Plasti-Corder® Lab-Station* in the front right corner (front view, see fig. below).

Pressing down the emergency motor stop button immediately stops the motor of the drive unit*.

Emergency motor stop button at the Lab-Station Fig. 2-1

2.4.2 Auto-identification and torque limitation

The Brabender measuring mixer is equipped with an encoder box for automatic instrument identification and torque limitation.

The 8-pole cable of the measuring mixer must be connected with the socket "Torque limit key" on the left top of the control side of the drive unit* used.

The drive unit* automatically recognizes the measuring mixer connected and the max. admissible torque for this mixer. If the max. admissible torque is exceeded, the motor of the drive unit* is stopped immediately.

Socket "Torque limit key" at the Plasti-Corder® Lab-Station* Encoder box at the measuring mixer

Fig. 2-2


2.4.3 Safety device The measuring mixer itself is equipped with a safety device (see fig. below). This prevents unintentional operation of the mixer when the mixer bowl is open and serious hand injuries due to rotating mixer blades.

At the front side of the mixer, a plug is fixed via a chain. When the mixer is closed, this plug is connected to a counterpart at the mixer rear wall. The drive motor can only be started when the plug is connected to its counterpart.

If the mixer front is removed, the plug connected to the rear wall is drawn out of the receptacle and the drive motor stops immediately.

Safety device at the measuring mixerr

Fig. 2-3

2.4.4 Two hand control device Sometimes, the mixer can only be emptied by drawing off the bowl while the blades are running. As the instrument stops immediately when the front plate is opened (see 2.4.3), the mixer bowl is equipped with a two-hand control device consisting of a switch button at each of the two mixer handles (see fig. below).

The cables of the two mixer handles must be connected to the sockets "2 Hand Safety Device" of the docking station*.

When the mixer is open, the drive motor can be started with a crawling speed of 4 min-1 by simultaneously pressing these buttons. This facilitates drawing off of the mixer bowl for cleaning purposes after a test.

Never clean the mixer while the rotor is still run ning. Danger of most serious injuries!

Never have two persons work simultaneously on the mixer. Otherwise, the drive might be switches on unintentionally while the mixer is open or during cleaning of the mixer.

Two-hand control device

Socket for cable of the left mixer handle

Socket for cable of the right mixer handle (on top of the docking station*)

Fig. 2-4


2.5 Remaining risks

2.5.1 Hot surfaces - danger of burning

Due to the high processing temperatures of the materials tested with the Brabender measuring mixer, the entire measuring mixer may reach very high temperatures during operation.

Risk of severe burning during start-up, operation, and during maintenance and cleaning work due to the high temperature of the mixer surfa ces!

Always wear suitable protective gloves when workin g at the hot measuring mixer!

2.5.2 Rotating blades - risk of injury When the feed opening of the measuring mixer has not yet been or is no longer closed by the loading chute* or by the pressure ram* (e.g. during material feeding with the pneumatic loading chute*, after removal of the loading chute* for observing the mixing process, during cleaning, etc.), the rotating mixer blades are no longer secured against access.

Risk of serious injury in case of uncovered feed o pening when the drive unit* is switched on.

Never put your hands into the feed opening when th e drive unit* is switched on!

Risk area feed opening

Fig. 2-5


3 TRANSPORT AND STORAGE

3.1 Packing

The instruments are thoroughly packed into wooden crates. Small parts and accessories are packed into cardboard boxes or bags in the crates. Additional equipment is packed either in the same crate as the instrument or in a separate crate, depending on the scope of the order.

3.2 Transport

On the outside of the crate, there are signboards which always must be observed by all means:

This side up!

Fragile, handle with care!

Keep dry!

3.3 Unpacking

First remove the cover of the crate, then take off the lateral walls. Take care of braces and supports within the crate as well as of bolt connections to the bottom of the crate, etc.

When unpacking the equipment, take care that no small parts or accessories which are not fixed to the instrument remain in the packing material. Parts of the equipment may have loosened during transport and may be hidden between the packing material. Therefore, the whole packing material has to be searched very carefully before disposal.

Instructions on labels and stickers are carefully to be observed.

Covering hoods and films should not be removed until set-up and commissioning, respectively.

3.4 Scope of supply

The scope of supply must be compared with the shipping documents immediately after arrival at the place of destination. If there is any discrepancy, Brabender® must be notified immediately.

3.5 Notification of damage

Inspect the instrument immediately after unpacking for any signs of damage. Should any damage be evident, regardless of whether it apparently occurred during carriage or not, notify the delivering carrier immediately and claim damages with him. If necessary, the delivering carrier must be given the opportunity to inspect the shipment. Brabender also must be notified immediately.

If, in the order, the risks of carriage were agreed to be taken by the buyer or by the receiver, the buyer or the receiver has to observe the regulations of the insurance policy.


3.6 Storage

Residual product, in particular residues of aggressive products like e.g. ceramics, distilled water, etc. may cause wear such as abrasion and/or corrosion up to pitting within very short time.

Likewise, storage in humid or aggressive environment may cause corrosion and, in extreme cases, pitting corrosion.

� Thoroughly clean and dry all machine parts before storage, in particular those with product contact.

Particular care must be taken for clean and dry edges, angles, and grooves (e.g. with grooved screws*).

� Prior to storage, disassemble all parts with product contact such as screws*, screw elements*, mixer blades*, etc. and thoroughly clean and dry them.

� Apply a thin (!) film of machine oil (multi-purpose oil) on all parts with product contact.

� Screws*, screw elements*, mixer blades* and similar parts must be packed individually in protective nets.

� Store the Brabender® instrument and all parts thereof in dry rooms only.

� Put the Brabender® instrument on a support which is at least 200 mm high in order to protect the instrument from ground humidity.

� Arrange storage areas so that moisture can escape and periodical inspections are possible.

Extreme temperature variations or long exposure to direct sun may cause damage to the instrument or machine.

� Do not expose the Brabender® instrument or parts thereof to extreme temperature variations or direct sun.

The admissible limit values of ambient temperature and humidity for storage and for operation are included in the list of technical data.


4 FEATURES AND OPERATING PRINCIPLE

The movable Brabender measuring mixer docking stations, series 30/50 EHT consist of a measuring mixer and a temperature controller located in the docking station. The instruments are only to be used in combination with the drive unit Lab-Station.

4.1 Measuring principle

The measuring principle is based on making visible the resistance which the sample material opposes to the rotating blades. A dynamometer is moved out of its zero position. In compliance with the existing standards and test specifications, a typical "PLASTOGRAM®" (torque and stock temperature versus time) is recorded for each sample material. The diagram shows the relationship between torque (viscosity) and temperature/time in consideration of structural changes of the material. The measuring data are displayed during the running test on the monitor* of the computer*. They can be stored and printed on a connected printer*.


4.2 Measuring mixer

The measuring mixer consists of the following main components:

• Mixer back stand with gear unit • Detachable mixer front • Detachable mixer bowl • Mixer blades

Cooling air connection for gear unit

(continuous cooling only)

Bayonet nipple for control thermocouple

Rear wall heating


Bowl heating

Cooling air connection for mixer bowl (continuous air supply or via a solenoid

valve controlled by a 2. temperature controller)

Front wall heating


Mixer backstand with gear unit

Rear wall Mixer blades

Two-hand control device

Mixer bowl Melt temperature thermocouple Plug of safety device Fig. 4-1

The mixer docking station is connected to the Brabender Lab-Station through a spiral tooth gear clutch. The measuring mixers of the series 30/50 EHT can easily be interchanged at the drive unit.

Exchange of the mixers may imply a readjustment of the temperature controller and a repetition of the self-optimizing procedure (see chapter 4.4.2.8).

The blades made of corrosion-proof and wear-resistant steel are fixed through a bayonet locking and held by thrust bearings. Different blades can be mounted at choice for handling a great variety of materials:

• Roller blades • Cam blades (only series 50) • Banbury blades (only series 50) • Sigma blades (only series 50)

Heating/cooling of the measuring mixers is done electrically with air cooling. The cooling of the gear and the mixer bowl is done by compressed air. For controlled cooling of the mixer bowl the instrument is equipped with a solenoid valve. The solenoid valve is triggered separately by the temperature controller. The temperature of the mixer is measured through control couples. The stock temperature is recorded by a thermocouple screwed from the bottom into the mixer bowl.


4.3 Docking station Universal-Docking-Station

Concerning the control elements and connections of the Universal-Docking-Station*, please refer to the separate instruction manual of the Universal-Docking-Station*.

4.4 Docking station (year of construction until 200 8)

4.4.1 Connections and control elements

On the right side of the docking station*, the following control elements are arranged (see fig. below):

• Main switch • Control elements and displays of the temperature controller

Control elements and displays of the temperature controller

Main switch

Fig. 4-2

On the left side of the docking station the following elements are arranged (see fig. below):

• Connection electric heating of mixer zones 1 - 3 • Lead-throughs for control and melt temperature thermocouples • Cooling air connections for mixer bowl • Socket two-hand control device (cable from left mixer handle) • Socket for peripheral units* (37-pole) • CAN-bus socket • CAN-bus connecting cable • Connection metering pump • Cooling air connection gear unit

37-pole socket for

peripheral units

Cooling air for gear unit

CAN-bus connection cable

CAN-bus socket

Connection metering pump

Lead-throughs for control and melt temp. thermocouples Sockets for electric heating zones 1 - 3

Cooling air connections for mixer bowl

Socket for two-hand control device

Fig. 4-3: Connections on the left side of the docking station


4.4.2 Temperature controller The temperature controller is mounted in the docking station* under the mixer. The display and control elements are arranged at the right side of the docking station*.

4.4.2.1 Displays and control elements of the temper ature controller The temperature of the individual zones of the measuring head (e.g. front, bowl, and rear wall of a mixer) is measured by separate control thermocouples and displayed and set by the temperature controller. Normally, during the tests, the nominal temperature value is set by the computer*. Nevertheless, the nominal values can be set manually through the control elements of the temperature controller (operation without PC).

The temperature controller is equipped with a high-contrast LCD display. Upon switching on and initialization of the instrument, the actual values of all control zones connected are shown. The individual instrument parameters are mostly shown in clear text.

Zone number

Actual value

Fig. 4-4

Language selection :

• Press keys "P" and "E" simultaneously for approx. 3 s

• Select the desired language with "�"/"�"

• Press key "E" for saving your language setting

Contrast setting :

• Press key "E" and, at the same time, key "�" or "�"

All other parameters have been factory set according to the order.


4.4.2.2 Functions of the individual keys of the tem perature controller

Zone selection, zone information Display of the actual and nominal values of the selected zone

Parameter selection in the selected zone

Increases the value displayed (e.g. nominal value, control parameter). The new setting must be confirmed by pressing the "E" key.

Modified values that have not yet been confirmed are marked by a flashing "E"

Decreases the value displayed (e.g. nominal value, control parameter). The new setting must be confirmed by pressing the "E" key.

Modified values that have not yet been confirmed are marked by a flashing "E"

E = Enter Confirms the settings and safes them so that they are power-fail save

Displays the trend curve of all zones (overview), as a function of the nominal value, incl. the alarm states.

Simultaneous display of the actual values of all zones connected

Recorder function (shows the actual value curve of a zone)

4.4.2.3 Keys and displays

For details concerning the individual displays and settings of the temperature controller, please also refer to the separate instruction manual of the temperature controller in the annex.

Large display of the actual values of all zones con nected

• Display Er.H:

• Display Er.L:

• No display:

Range overflow or sensor failure

Range underflow or sensor failure

The corresponding control zone has been switched off

With the measuring mixer, only 3 zones are displayed.

Fig. 4-5: Overview

• For selecting a certain control zone: Press key "zone"

• For selecting the tendency display: press key "trend"

trend

zone

P

�

act

fct

E

�

act


Zone information: Display of actual and nominal val ues and of alarms of a zone

Fig. 4-6

• Set the nominal value with the arrow keys "�"/"�".

• A modified value not yet confirmed is marked by a flashing "E".

• Confirm your setting by pressing the key "E".

SET: nominal value no. 1 is active SET SP2: nominal value no. 2 is active Setpoint no. 2 can be set in the menu

"Control parameters"

Further displays :

• Heater current in Ampere, if this option has been configured

• Alarm displays , alarm A active: A ֠

• Status displays: - Self-optimization active OPT - Ramp function active RAMP - Error messages E.xx

• For selecting another control zone: Press key "zone"

• For selecting the tendency display: Press key "trend"

• For selecting the recorder function: Press key "fct"

• Back to display of all actual values Press key "act"

Tendency and alarm state display

This display gives a quick survey over the temperature conditions of all control zones connected

Fig. 4-7

The bars show the deviation from the nominal value :

• deviation ≤ ± 1 % of meas. range

• deviation = ± 1.5 % of meas. range

• deviation ≥ ± 3 % of meas. range

Further displays :

• Line A: if alarm A is active, a ֠ is shown under the corresponding zone

• If the option "Heater current monitoring" is active and a continuous current flow is detected (shortening of semiconductor switches), the message "Current failure alarm" appears

• For selecting a certain control zone: Press key "zone"


zone

trend


Recorder function

This display shows the actual value curve of a control zone as a function of time .

This function permits to observe the settling time and the control behavior of the controller of the selected zone without any additional instruments and to set the parameters accordingly.

In case of a failure, this function permits to observe the actual value curve within a certain time range before the failure occurred.

Fig. 4-8

Proceeding :

• Press "zone" to show the "zone information" or to select the desired zone

• Press "fct" in order to show the actual value curve of this zone

The time axis is determined by the parameter "Sample time".

The actual value range is always drawn symmetrically around the current nominal value which is shown in this window above the key "P".

• To exit the recorder function: Press key "fct"

• Key "�": Decrease display section based on current nominal value (precise display)

• Key "�": Increase display section based on current nominal value (approximate display)


4.4.2.4 Language setting at the controller

In the overview of the controller (fig. 4-5), press keys "P" and "E" simultaneously for approx. 3 s in order to open the menu "Device configuration". The following page is shown:

Fig. 4-9

Press key "�" or "�" in order to set the desired language.

Press "E" in order to save your setting.

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4.4.2.5 Controller configuration ("Device configura tion") The menu "Device configuration" serves for setting various parameters for controller operation.

When the machine is supplied, the parameters have already been factory set according to the order. Usually, these parameter should not be changed.

In the overview of the controller (fig. 4-5), press keys "P" and "E" simultaneously for approx. 3 s in order to open the menu "Device configuration". The following page is shown:

Fig. 4-10

For selecting the different configuration parameters, press key "P" repeatedly until the parameter is shown.

If no entry is made within approx. 15 seconds, the display returns automatically to the overview (see fig. 4-5).

Various configuration parameters can be set, e.g.:

• Language (see 4.4.2.4)

• Type and number of temperature feelers (Pt 100 [RTD] or thermocouple)

• Alarm settings

• Key locking

Use the arrow keys "�" / "�" to set the selected parameter as required.

Confirm your setting by pressing "E" .

Press "E" after each modification of a configuration parameter, even if you want to change further parameters afterwards - otherwise the modification will not be taken over.

After having made and confirmed all settings, press "act" in order to return to the overview.

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4.4.2.6 Alarm setting for the heating zones of the measuring head

Connect the heater cables of the heating zone(s) of the measuring mixer to the corresponding socket(s) at the terminal board of the docking station*.

Mount the control thermocouple(s) of the heating zone(s) and connect them.

In the overview of the controller (fig. 4-5) press keys "P" and "E" simultaneously for approx. 3 s in order to open the menu "Device configuration".

Press key "P" repeatedly until "Alarm A: Configuration" is shown:

Fig. 4-11

Use the arrow keys "�" / "�" in order to set "Heater current monitoring co:9".


Press "P" once. The following page is shown:

Fig. 4-12

Use the arrow keys "�" / "�" in order to set the parameter "Switching behaviour" to "Direct".


Press "P" once. The following page is shown:

Fig. 4-13

Use the arrow keys "�" / "�" in order to set the parameter "Current detection cycle time" to "45".


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Press "P" twice. The following page is shown:

Fig. 4-14

Use the arrow keys "�" / "�" in order to set the parameter "Leakage current min. limit value" to "0.3 A".


4.4.2.7 Setting the alarm values for the activated alarms of the heating zones

In the controller overview (fig. 4-5), press key "zone" until the zone number of the heating zone for which the alarm is to be set is shown in the top left corner of the controller window.

Number of the heating zone Current consumption of the zone displayed (example) Fig. 4-15

Note the current consumption value shown (see fig. above).

Press "P" repeatedly until the page "Control parameters" is shown with the parameter "Alarm value":

Control parameter "Alarm value" Alarm value current consumption of the zone indicated (example) Fig. 4-16

Use the arrow keys "�" / "�" in order to set the alarm value indicated as follows:

Alarm value = current consumption noted minus 15 %


Make this setting separately for each additional heating zone.

An active alarm in a heating zone is indicated in the tendency and alarm state display of the respective zone by the sign ֠ (see fig. 4-7).

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4.4.2.8 Self-optimization of the temperature contro ller

In case of a modification of the system configuration, it may be necessary to run a self-optimization of the temperature controller of one or several zones.

Self-optimization must be done separately for each control zone.

Self-optimization must be done in the nominal valu e range to be used lateron for the measurements.

Press the "zone" key in order to select the corresponding zone.

Set the desired nominal temperature with "�"/"�" and confirm with "E".

The difference between the current actual temperature and the desired nominal temperature must be at least 5 % of full measuring range (at least 80°C .

Press the "P" key until the parameter "Self-optimization" is shown.

Press "�"/"�" to activate self-optimization.

During self-optimization, "OPT" is shown in the status line of the corresponding zone.

When "OPT" is not shown any more, self-optimization for this zone has been completed.

Repeat this process for all control zones.

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4.5 Additional equipment

For the ident numbers of the additional equipment, please refer to the list "Additional Equipment" in the annex of this instruction manual. For some additional equipment separate instruction manuals are available.

4.5.1 Quick loading chute* The quick loading chute* facilitates and accelerates feeding of powdery substances into the measuring mixer. Certain tests e.g. the determination of the fusion time of rigid PVC dry blends can only be executed with the help of a quick loading chute*.

The quick loading chute* is made of corrosion-proof steel. It can be mounted and detached very easily. The individual components of the quick loading chute* are screwed and pinned together.

The quick loading chute* is mounted onto the measuring mixer only just before the material is fed into the measuring mixer. The sample material id fed from the top into the loading chute* while the mixer blades are running. As soon as the whole material has been filled into the quick loading chute*, the plunger is put onto the loading chute*, weighted with the loading weight*, and pressed down evenly and as quickly as possible by the operator. Thus, uniform and quick feeding of the sample into the measuring mixer is ensured.

Fig. 4-17

4.5.2 Pressure ram The pressure ram* facilitates and accelerates feeding of non-powdery substances into the measuring mixer. It also serves for feeding materials which e.g. become gluey already at low temperatures or are compressed that strongly already under low pressures that they cannot be pressed into the mixer by means of the loading chute* (see 4.5.1 and 4.5.4).

Subsequently, the pressure ram is loaded with the loading weight*.

Fig. 4-18


4.5.3 Pressure ram with bore* for dosing liquids A pressure ram with bore* for absorption tests is also available. It is connected to an automatic burette* or a precision metering pump* so that the liquid can be dosed through the bore into the closed mixing chamber.

4.5.4 Pneumatic loading chute* The pneumatic loading chute* permits quick and well-defined feeding of pourable substances into the measuring mixer. Certain tests like e.g. the determination of the fusion time of rigid PVC dry blends can only be executed with the help of a loading chute*.

The piston of the pneumatic cylinder which is mounted on the top of the pressure ram, is pressurized with compressed air. On the top of the pneumatic cylinder, there is a manometer for monitoring the closing pressure, a pressure reducing valve for changing the pressure, and a throttle valve for changing the lifting and lowering speed of the piston. The loading chute* is equipped with a feed hopper.

Before a test is started, the air pressure required ha to be adjusted at the pressure reducing valve. While the blades are running, the sample is filled in through the feed hopper, and the piston is lowered immediately by actuating the two hand safety switch. When the sample material has plasticated, the loading chute* usually is removed.

Fig. 4-19

4.5.5 Precision metering pump* An automatic precision metering pump is available for feeding liquids into the measuring mixer. The dosing rate can be adjusted.

4.5.6 Sealing cover The sealing cover* permits to run tests under inert gases in the measuring mixer. Moreover, gases or vapors accumulating in the mixer bowl during the test can be discharged through one or two valves in the sealing cover*.

The sealing cover* is made of corrosion-proof steel. It is equipped with two valves for the connection of flexible tubes. Mounting and detachment are very easy. The bottom of the sealing cover* has a strong PTFE sealing.


5 TECHNICAL DATA

Mixer W 50 EHT

N 50 EHT B 50 EHT S 50 EHT

Volume of mixer bowl, approx. [cm 3] 55 80 70 85

Sample weight 1) [g] 40 - 70 40 - 80 40 - 70 40 - 70

Torque max. [Nm] 200 200 200 200

Speed ratio

(driven : idle blade)

2 : 3

2 : 3

2 : 3

2 : 3

Operating temperature max. [°C] 500 500 500 500

Dimensions of the mixer (W * H * D) [mm]

approx. 500 * 200 * 450

Dimensions of the docking station with mixer (W * H * D) [mm]

approx. 600 * 1200 * 450

Mains connection 1 * 230 V + N + PE, 50/60 Hz, 16 A

Environmental conditions

Storage: Temperature: -25°C ... +55°C

Humidity: 5 % ...95% rel. hum. max.

Operation: Temperature: +5°C...45°C

Humidity: 5 % ...95% rel. hum. max.

1) depending on the specific weight and bulk density of the sample material


6 INSTALLATION

6.1 Basic requirements

The intended base for the installation of the instrument has to be clean and plane and strong enough to carry the instrument system.

The unpacked instrument is recommended to be carried very carefully to the place of installation. Hard touch-downs must be avoided absolutely.

In case lifting tools are used, they must be fixed as near as possible to the centre of gravity of the instrument and care must be taken not to damage any sensitive parts like control buttons, sockets, etc. by straps and cables.

The connection and adaptation points for the power supply of the instrument are recommended to be located as near as possible to the place of installation of the instrument.

The Brabender measuring mixers are connected to a Plasti-Corder® Lab-Station*. The electric energy required for heating is provided by the temperature control unit in the docking station*. Concerning the required connection data for the drive unit* and the docking station*, please refer to the separate instruction manuals of the drive unit* and of the docking station*.

Requirements:

Electric energy: see technical data and separate instruction manuals of the Lab-Station and of the additional equipment

Compressed air: 1.5 bars

In the annex, please find a list of the special tools supplied with the instrument. Apart from these, normal tools like screw-drivers, etc. are required.

Assembly is recommended only to be effected carefully by competent technical staff.

Electric work is only allowed to be executed by co mpetent electricians.

6.2 Set-up and assembly

Cover hoods and foils should only be removed at th e final place of installation, when all remaining packaging has been removed. Information o n labels and stickers are to be noticed exactly.

If the measuring mixer is supplied together with the corresponding docking station*, all connections between the mixer and the temperature controller are already mounted. For working with the mixer docking station, the instrument is only to be connected to the drive unit Lab-Station, and the mixer blades are to be mounted.

If the measuring mixer is supplied without docking station*, it must be mounted and connected to the docking station* (see chapter 6.2.1).

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6.2.1 Mounting the measuring mixer to the docking s tation* (year of construction until 2008)

The following instructions only apply if the measu ring mixer is supplied without docking station*.

For mounting the measuring mixer to the Universal-Docking-Station*, please refer to the separate instruction manual of the Universal-Docking-Station*.

Make sure that the mounting surface of the docking station* is clean and free from any tools or residues.

Open the knurled nuts on the two stud bolts on the mounting surface of the docking station* until they are in line with the top surface of the stud bolts.

The measuring mixer* may overturn - Danger of inju ry, danger of damage to the mixer!

Secure the measuring mixer* with your hands as lo ng as it has not yet been fixed tightly on the docking station.

Put the measuring mixer* from the front side of the docking station* onto the mounting surface of the docking station* and push it towards the rear side so that the stud bolts on the mounting surface of the docking station* fit completely into the recesses of the two mixer feet.

Fig. 6-1

Tighten the knurled nuts on the stud bolts by hand.

Firmly tighten the knurled nuts on the stud bolts using the cam wrench from the accessory kit of the docking station*.

Mount the safety device fixed at the docking station* to the right side (front view) of the measuring mixer at the cover hood of the gear unit.

Screw the melt temperature thermocouple* fixed at the docking station* from below into the threaded bore on the underside of the mixer bowl so that it reaches approx. 1...2 mm into the mixer bowl.

Mount the control thermocouples fixed at the docking station* according to their numbers into the corresponding bayonet nipples of the measuring mixer* and lock them.

Danger of damage to the heaters due to control thermocouples* mounted wrongly or not at all! Make sure for correct allocation of the control thermocouples* to the serial order of heating zones:

Control thermocouple no. 1 �� to zone no. 1 (front plate) Control thermocouple no. 2 �� to zone no. 2 (mixer bowl) Control thermocouple no. 3 �� to zone no. 3 (rear wall)

Bayonet nipple for control thermo-couple of mixer bowl (zone no.3)

Bayonet nipple for control thermocouple of mixer bowl (zone no. 2) Bayonet nipple for control thermocouple of front plate (zone no. 1)

Fig. 6-2

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Make sure that all control thermocouples have been mounted and connected properly.

Connect the cables of the three heater zones of the measuring mixer* according to their position in the measuring mixer* to the corresponding round sockets "Zone 1 - 3" terminal board of the docking station*.

CAN-Bus socket

Sockets for electric heating zones 1 - 3 Socket for cable of left mixer handle

Fig. 6-3

Connect the cables of the two-hand control device from the mixer handles to the sockets "2 Hand Safety Device" on the terminal board of the docking station* (cable of left mixer handle) and on top of the docking station* (cable of right mixer handle).

CAN-OUT socket at the docking station*:

1. If the docking station* is the last CAN module of the system (usual with mixers):

• Plug the terminal resistor onto the CAN-OUT socket.

2. In case of subsequent CAN modules (e.g. measuring mixer with conductivity measuring device*):

• Plug the CAN connection cable onto the CAN-OUT socket of the docking station*.

• Connect the other side of the CAN connection cable to the CAN-IN socket of the subsequent CAN module.

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6.2.2 Mounting the mixer docking station* to the La b-Station*

For mounting the docking station* to the Lab-Station*, please refer to the separate instruction manual of the Lab-Station*.

For mounting the Universal-Docking-Station*to the Lab-Station*, please refer to the separate instruction manual of the Universal-Docking-Station*.

Prior to any mounting the mixer docking station* to the Lab-Station*, switch off both instruments at the respective main switches.

If the locking wheel of the Plasti-Corder® Lab-Station* is in "Locked" position, pull out the handle of the locking wheel and turn it to "Open" position.

Push the coupling sleeve onto the clutch of the Brabender® Plasti-Corder® Lab-Station*.

Push the docking station* with the measuring mixer mounted towards the Plasti-Corder® Lab-Station* so that the locking bolts of the docking station* fit into the location holes of the Plasti-Corder® Lab-Station* and the coupling sleeve completely embraces the clutch of the measuring mixer.

If there is a difference in height so that the locking bolts of the docking station* do not match the location holes of the Plasti-Corder® Lab-Station*, adjust the height of the docking station* by means of the adjustable foot screws.

Push the docking station* with the measuring mixer towards the Plasti-Corder® Lab-Station* up to the limit stop.

Turn the locking wheel of the Plasti-Corder® Lab-Station* to "Locked" position in order to lock the docking station* at the Plasti-Corder® Lab-Station*.

Connect the 8-pole cable of the encoder box mounted at the measuring mixer to the socket "Torque limit key" on the control side of the Plasti-Corder® Lab-Station*.

See point mark on plug and socket!

Connect the 12-pole cable from the terminal side of the docking station* to the socket "Communication" on the control side of the Plasti-Corder® Lab-Station*.

See point mark on plug and socket!

Connect the air input flange of the measuring mixer to the compressed air net (0.5...1.5 bars).

For cooling air connection in combination with the Universal Docking Station*, please refer to the separate instruction manual of the Universal-Docking-Station*.

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6.2.3 Mounting the mixer blades

For opening the mixer, loosen the two hexagonal socket screws on the front plate and open the swivel tie-bar.

Draw off the front plate of the mixer and put the plate onto the support.

Draw off the mixer bowl and put it onto the corresponding support at the docking station*.

The Universal Docking Station* can be equipped with a supporting module* with drawer for putting down the individual parts of the mixer.

Disassembled mixer bowl

Disassembled front plate Fig. 6-4

Mount the blades:

1. Insert the right blade and lock it by turning it clockwise by approx. 30°.

2. Insert the left blade and lock it by turning it counter-clockwise by approx. 30°.

Make sure that the two blades are fixed correctly.

Check position of the melt temperature thermocouple in the mixer bowl: The melt temperature thermocouple should penetrate approx. 1...2 mm from below into the mixer bowl.

Fig. 6-5

Mount the mixer bowl and the front plate onto the two stud bolts and fix them by means of the swivel tie-bar and the two hexagon socket screws M 10.

Tighten the screws evenly in order to avoid any di splacement of the mixer bowl and possible danger resulting thereof.

Connect the safety control switch at the front of the mixer to the socket at the mixer back stand.

6.2.4 Mounting of additional equipment* For installation and connection of any further additional equipment*, please refer to the separate instruction manuals of the individual units.

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7 START-UP AND OPERATION

For computer-aided systems, please also see instruction manuals for the individual software programs.

7.1 Manpower requirements

Only trained and competent personnel shall be assig ned to operate the instrument.

During operation, one person usually suffices for operating the instrument.

7.2 Preparations

Check all fixtures and connections of the individual units of the system.

Check all connections between the Lab-Station* and the docking station* (check CAN-Bus connecting cable and locking lever for positioning bolts).

Make sure that the safety device, the encoder box, and the two-hand control device are connected properly.

Make sure that the mixer bowl is perfectly clean and dry.

If necessary, connect the air inlet flanges to the cooling air system and turn on the compressed air supply.

The gear unit of the mixer must be cooled if the m ixer bowl temperature exceeds 200°C.

Before a test is started, the mixer must be heated up to the processing temperature required for the material to be tested.

For this purpose, start the temperature controller* (docking station*) according to the separate instruction manual.

Heating/cooling of the mixer must always be done i n a controlled manner, i.e. the control thermocouples must be mounted correctly bef ore test start.

Do not start the temperature controller* without having mounted the control thermocouples in the respective heating zones.

Make sure for proper seat of the control thermoco uples.

Start the Lab-Station* according to the separate instruction manual.

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7.3 Test procedure

7.3.1 Preparations prior to test start Before a test is started, always make sure whether all test conditions have been set correctly and are displayed and recorded properly.

In order to get familiar with the instrument, it is recommended first to run tests with low viscosity, non-curing compounds and to observe the torque and the temperature development very carefully.

Make a preliminary test in order to determine the optimum conditions for your test, i.e. sample weight, mixer temperature, speed, torque measuring range, and damping.

For initial tests select a large torque measuring range and a low speed, e.g. 20...30 min -1.

On the basis of the documentation of the raw material supplier, determine

• type

• density

• softening and melting points

of the material to be tested.

Determine the sample weight as follows:

m V cm g cm KM= • •( ) ( / )3 3ρ

with:

m = mass of the test material

V = mixer volume: 55 cm3 (type 50) with roller blades

80 cm3 (type 50) with cam blades

70 cm3 (type 50) with Banbury blades

85 cm3 (type 50) with Sigma blades

ρM = density of the sample material at ambient temperature

K = constant 0.7...0.8

The constant K is a non-dimensional coefficient which considers the optimum filling level for different dynamic loads. Usually, this factor is < 1. For initial tests, we recommend to use K = 0.7.

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7.3.2 Filling the sample into the mixer

Always use a suitable Brabender loading chute* or pressure ram* for loading the sa mple material into the measuring mixer.

Never use your hands for directly loading the mate rial into the mixer - danger of most serious injury!

In order to prevent an overload of the system and to guarantee a good reproducibility of the results, the following points are to be noticed:

Always carefully observe the torque signal when loa ding the material into the mixer!

High piston pressure during loading of very viscous materials or when loading very large sample weights may cause high torque loads exceeding the admissible maximum load of 200 Nm and causing shear element failure in the mixer coupling.

In order to prevent such overload and possible shear element failure, the material should be screened and coarse particle should be crushed, if necessary.

Load the material as quickly as possible, take care for uniform loading times.

Quick loading implies that the sample material is free-flowing or is available as strips or flakes which can easily be fed into the mixer.

Reproducibility of the measuring results implies uniform loading times.

Make sure for uniform starting temperature of the l oading device.

In order to obtain reproducible results, the loading device* always needs to have the same starting temperature. Pellets with a high melting point may require preheating of the sample material.

Loading of liquids

Liquids should be filled into small PE bags which are bonded and then loaded into the measuring mixer. By means of suitable metering pumps*, liquids can also be fed through the bore of a special pressure ram* (see additional equipment).

Cross-linking materials

In case of cross-linking (curing or vulcanizing) materials, it is recommended to remove the loading weight* and the pressure ram* or the loading chute* as soon as the torque minimum, i.e. the lowest melt viscosity before cross-linking has been reached.

7.3.2.1 Loading with the quick loading chute*

The quick loading chute* should be mounted onto the mixer only just before the test is started in order to prevent heating up of the loading chute* in advance by radiation heat which would impede loading of the material into the mixer.

When mounting the quick loading chute*, take care to keep a sufficient distance of your hands to the feed opening of the mixer - danger of most serious injury!

Fill the material into the loading chute* while the blades are running.

Put the piston into the loading chute* and weight it with the loading weight*.

Press the weight* down manually.

Always carefully observe the torque signal during this procedure.

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7.3.2.2 Loading with the pressure ram*

When mounting the pressure ram*, take care to keep a sufficient distance of your hands to the feed opening of the mixer - danger of most seri ous injury!

As the feed opening of the measuring mixer is opene d again and again when loading material with the pressure ram*, always take care t o keep a sufficient distance of your hands to the feed opening of the mixer.

Never reach with your hands into the feed opening of the measuring mixer - danger of most serious injury!

If strips are to be fed into the mixer, take care to always load same number and size of strips in order to obtain reproducibility.

Fill the material into the loading chute* while the blades are running.

Use the hinged pressure ram* for pressing the material completely into the mixer.

Weight the ram with the loading weight*.

7.3.2.3 Loading with the pneumatic loading chute*

Please also refer to the separate instruction manual of the pneumatic loading chute*.

The chute of the pneumatic loading chute* should be mounted only just before the test is started in order to prevent heating up of the pneumatic loading chute* in advance by radiation heat which would impede loading of the material into the mixer.

When mounting the pneumatic loading chute*, take c are to keep a sufficient distance of your hands to the feed opening of the mixer - danger of most serious injury!

Fill the material into the feed hopper of the pneumatic loading chute* while the blades are running.

Actuate the two hand control device at the pneumatic loading chute* in order to lower the piston (max. pressure: 2.5 bars).

Always carefully observe the torque signal during this procedure.

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7.3.3 Checking the filling level of the mixer

Attention, residual danger: When the feed unit* is removed, the rotating mixer blades are no longer secured against access!

Never put your hands into the running mixer - dang er of most serious injury!

Reloading of material, if necessary, is only admis sible to be done by means of the loading chute* or pressure ram*.

Never use your hands for directly loading the mate rial into the mixer - danger of most serious injury!

When remounting the loading chute* or pressure ram * and during loading of material with the pressure ram*, always take care to keep a suffi cient distance of your hands to the feed opening of the mixer - danger of most serious injur y!

Never insert any objects into the running mixer - danger of destruction of the entire machine system!

Improper filling of the measuring mixer affects the reproducibility of the measuring results.

When the sample material has molten in the measuring mixer, remove the piston of the loading chute or the pressure ram*, and check the filling level as follows:

a) by looking into the mixer: The blades must be completely covered by the material, and the material layers must be compounded and shifted continuously from one blade to the other.

However, no material may emerge through the feed opening of the mixer!

b) by observing the torque curve: The optimum filling level is indicated by the material being in contact with the closing plunger of the loading chute* or pressure ram*. As soon as the plunger or the ram is removed, there should be an almost immediate decrease of the torque curve (which must, however, not exceed 1 ... 2 % max.).

For comparative tests with different materials, this decrease must always be the same!

No torque decrease at all indicates insufficient filling of the mixer. Excessive torque decrease (> 1 - 2 %) means overloading of the mixer.

If material samples are to be taken out of the mix er during the measurement, always stop the drive unit before! Danger of most serious injuries!


7.3.4 Test end and cleaning of the measuring mixer When the test has been completed or when the torque has passed the maximum in case of crosslinking (curing) materials, stop the drive unit in order to prevent unnecessary wear.

Remove the sample material immediately after the test.

Never leave any hardened material in the mixer while the blades are still running as this may damage the blades and the bearings.

Do not have the material cool down in the mixer bo wl!

Sometimes, the mixer can only be emptied by drawing off the bowl while the blades are running.

Utmost care has to be taken when drawing off the m ixer bowl while the blades are running!

After having removed most of the material, completely clean the blades and the bowl when the blades have stopped (see detailed description in chapter 8).

Cleaning should be done as quickly as possible in order to prevent solidification of the material at the blades and in the mixer bowl!

After cleaning, correct temperature conditions must be created before starting a new test. The mixer temperature and the mixer bowl temperature (starting temperature) should be constant for 3 minutes. Before starting the next test, the loading device* (if any) must have cooled down to ambient temperature. Otherwise, the loading process may be impeded, particularly in case of powders with a low melting point.

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7.4 Evaluation of the test results

In many cases, the mixing process is stopped when stationary conditions have been reached, i.e. when the torque and the stock temperature curves have become nearly constant as a function of time. In case of curing or hardening materials, the process usually is not stopped before a second torque increase is observed or a second torque maximum has been passed (see also corresponding literature available from Brabender®).

7.4.1 Evaluation criteria 1. The starting temperature (= temperature signal of the stock temperature thermocouple) should have

remained constant for at least 3 minutes before the test material is fed into the mixer. Usually, this temperature is somewhat lower than the mixer temperature.

2. The material should be fed into the mixer as quickly as possible, preferably within 5...20 seconds (reproducible).

3. When stationary conditions have been reached, the stock temperature should be at least as high as the temperature of the mixer bowl (guiding value: stock temperature = mixer temperature + max. 20 °C at th e end of the test).

If the stock temperature is too low, this may indicate

• underfilling of the mixer, i.e. increase K to 0.75 or 0.8, and/or • insufficient blade speed.

Excess stock temperature may due to

• overloading of the mixer, or • excessive blade speed, or • unsuited blade geometry

4. A very large band width of the torque curve suggests insufficient damping. Excessive damping, however, impedes any additional evaluation of the torque curve, e.g. if slip additives were used for the test material.

5. A torque curve near to the zero line signifies that a wrong torque range was selected. In this case, select a smaller torque range, e.g. 0...100 Nm or smaller instead of 0...200 Nm.

7.4.2 Accuracy and reproducibility Brabender® measuring instruments are manufactured and calibrated according to the state of art. Nevertheless, failures after a long operation time cannot be excluded. Very often, such failures are promoted by insufficient maintenance and non-observance of the daily checks of the operating conditions. Failures of the heating/cooling system, the thermocouples, or the hoses, etc. may occur.

We therefore recommend to check the instrument system upon receipt under suitable test conditions (see above) by means of a reference material which is not sensitive to humidity and can be stored for a long time (e.g. high-molecular polyethylene). File the reference curves obtained from this test and run comparable tests after a certain operating time of the instrument, e.g. every three or six months.

Accuracy and reproducibility are influenced by:

• sample weight • nature of the sample material (temperature, pellet size, pourability, moisture, etc.) • heating / cooling of the measuring mixer • cleanness of the mixer, operability of all system components • speed • wear of blades and bushings, cracking of heating / cooling oils, failure of heating cartridges • observation of test specifications

Tests the results of which are to be compared with each other must run under identical test conditions.


8 MAINTENANCE

8.1 Cleaning

Risk of property damage!

Residual product which hardens or cross-links withi n the machine or instrument involves the risk of automatic speed limitation or motor shu t-down by the automatic torque limitation.

Humidity, in particular distilled water, or residue s of other aggressive products, cause wear such as abrasion and/or corrosion up to pitting.

IMPORTANT NOTE: All parts with product contact are wear parts, i.e. warranty for such parts is generally excluded!

� Empty the instrument or machine completely after ea ch test!

� Thoroughly clean all parts with product contact in regular time intervals or after each test, if necessary, depending on the product processed.

Particular care must be taken for clean and dry sea ling surfaces, angles, and grooves (e.g. with grooved screws*).

� Thoroughly dry all parts after cleaning!

� Never have any cross-linking material cool down or harden within the instrument or machine!

� Never leave any residues of aggressive products suc h as ceramics, distilled water, etc. within the instrument or machine for a prolonged ti me!

� During cleaning, take care for any signs of wear!

All surfaces contacting the sample material must be cleaned very thoroughly while they are still at operating temperature.

Always wear protective gloves when cleaning the in strument! Danger of burning!

Never carry out any cleaning work while the blades are r otating. Danger of most serious injuries!

After tests with materials that are tend to stick to the mixer walls, a substitution with a highly stabilized PVC compounds or with a high-molecular PE is recommended; for temperatures below 150 °C, raw rubber can also be used for this purpos e.

After tests with materials that do not tend to stick to the walls, a substitution is not necessary.

Do not use any rigid or pointed tools for cleaning the blades and the mixer bowl! Only use suitable tools like brass brushes or bronze spatula for this purpose!

All parts that have been disassembled should be placed on wooden or other heat-resistant, non-metallic surfaces in order to avoid unnecessary loss of heat and mechanical damage to the parts. In order to facilitate the storage of hot mixer parts the instrument is equipped with special supports for the front plate of the mixer and the mixer back stand.


Disassembled mixer bowl

Disassembled front plate Fig. 8-1

Cleaning should be done as quickly as possible in order to avoid excessive cooling of the mixer bowl and of the blades.

The more time you take for cleaning, the more time you will need for adapting the mixer to the starting conditions of the previous test!

For opening the mixer, loosen the two hexagon socket screws on the front plate and open the swivel tie-bar.

Take off the front plate of the mixer.

Removal of the mixer bowl is facilitated by starting the drive unit* again. For doing so, press the two buttons at the handles of the mixer.

Never put your hands into the running mixer - dang er of most serious injury!

By the rotation of the blades within the mixer bowl, the mixer bowl is slightly pushed off.

As soon as the mixer bowl can be drawn off, stop the drive unit*.

Carefully and uniformly draw off the mixer bowl with both your hands from the stud bolts and place it onto the deposit.

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Cleaning of the mixer:

It is recommended always to clean the blades and the bushings first and only then the mixer bowl in order to keep loss of heat in the blades as low as possible. All parts of the mixer should be polished with a clean piece of cloth after cleaning.

Blades a) Remove the blades:

Removal of the blades is facilitated by a suitable blade extractor (additional equipment, ident no. 6 19 207 for series 30 and 50 roller blades, ident no. 6 19 257 for cam and Banbury blades).

• Loosen the left blade by turning it clockwise by approx. 30° and remove it.

• Loosen the right blades by turning it counter-clockwise by approx. 30° and remove it.

b) Thoroughly clean both blades with a brass brush and a brass spatula.

Rear wall and bushings Thoroughly clean the rear wall and the bushings with a brass brush and a brass spatula.

Subsequently, immediately remount the blades in reverse order and lock them in order to avoid unnecessary loss of heat in the blades.

Mixer bowl a) Thoroughly clean the mixer bowl with a brass spatula and a brass brush.

b) Immediately mount the clean mixer bowl onto the stud bolts again.

Front plate a) Thoroughly clean the front plate with a brass spatula and a brass brush.

b) Immediately mount the clean front plate onto the stud bolts again and close the swivel tie-bar.

After cleaning, correct temperature conditions must be created before the next test is started. Before starting the next test, the mixer temperature and the mixer bowl temperature (starting temperature, temperature signal of the stock temperature thermocouple) should have been constant for 3 min.

Before starting the next test, the loading device* (if any) must have cooled down to ambient temperature. Otherwise, the loading process may be impeded, particularly in case of powders with a low melting point.

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8.2 Lubrication of the gear unit

In case of everyday use of the mixer, monthly lubrication of the mixer gear unit is recommended. The lubricant "Orapi CT 300" is available from Brabender (see list of accessories).

Before removing the cover of the gear unit, switch off the drive unit*!

Loosen the 3 hexagon socket screws at the protection hood and remove it.

Unscrew the 3 distance sleeves and take off the cover. Now the gear unit is accessible.

Use a paint brush for applying the lubricant "Orapi CT 300" onto the gears and bearings.

In order to ensure even lubrication of all parts, the drive unit* may be started temporarily at a low speed.

Never grasp into the mixer with your hands or inse rt any tools (paint brush, etc.) into the mixer while the blades are running! Danger of most serious injuries, danger of destruction of the entire system!

Remount the cover and the protective hood.

8.3 Exchange of bushings

When the bushings have worn, they must be replaced as follows.

Remove the protection hood from the gear unit.

Unlock the blades and remove them (see 8.1 point 5).

Loosen the two nuts of the stud bolts and remove the stud bolts together with the rear wall.

Loosen the clamping plate between the bushings (on the rear side of the mixer rear wall).

Remove the bushings.

Insert new bushings.

Reassemble the mixer in reverse order.

8.4 Abrasion check

In case of everyday use of the mixer, the mixer, blades, and the thermocouple have to be checked for abrasion once a year. For this purpose, run a test with a simple and reproducible reference material. The results of the abrasion checks must not deviate significantly from the reference curve.

Take care to run these tests under test conditions identical to those of the reference test. Apart from that, a maintenance contract can be made with the Brabender customer service.

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9 TROUBLE-SHOOTING

Failure: Cause: Repair:

Blades have got stuck.

Bushings have been cleaned insufficiently.

Slowly rise mixer temperature up to max. value (do not exceed 250°C!) and start the mixer anew for releasing the blades.

Wrong display of mixer bowl temperature.

Position of the thermocouple is wrong (fig. 9).

Correct position of the thermocouple (it must penetrate 1...1.5 mm into the mixer bowl).

Thermocouple is worn. Replace the thermocouple.

Improper connection to the evaluation unit, evaluation unit defective.

Check all plug connections and cables and replace them, if necessary, check evaluation unit.

Excessive melt temper-ature as compared to the previous measure-ment.

Mixer was not heated through in the previous test.

Repeat the measurement.

Sample weight is too high. Repeat the measurement.

Noise in the gear unit. Insufficient lubrication. Lubricate the gear unit.

Noise in the coupling. Occurs only under load and results from the coupling type.

No action required; possibly lubricate the coupling flanks with ORAPI CT 300.


10 ACCESSORIES

For handling and operating the instrument as well as for cleaning, useful accessories are supplied with the instrument (see accessories list). In case of loss or wear or wastage, the individual parts can be ordered like spare parts at any time.

11 SPARE PARTS

For all inquiries or orders of spare parts or additional equipment for Brabender test instruments, please always state the model number and the serial number of the instrument for which you require the respective spare parts or additional equipment (see spare parts list).

You will find these numbers on the name plates attached to each instrument.

Your order or inquiry cannot be handled without th ese numbers.

By additionally stating the order number under which you once received the corresponding instrument from Brabender, you can facilitate handling of your order/inquiry even more.

All instruments ever supplied by Brabender are registered in a file. They can, however, only be allocated with the help of these numbers.

Spare parts can be ordered from Brabender directly or from any local Brabender representative.

12 ANNEX

Lists: Accessories

Spare parts

Additional equipment

Tables for display and adjusting ranges of the temperature controller

Wiring diagrams

Please also observe the separate instruction manuals for the other instruments working together in a system.


Accessories for

Measuring mixer series 50 EHT for Lab-Station

Qty. Ident no. Description

1 2 11 076 grease "ORAPI CT 300" (50-g tin)

1 6 19 305 round cleaning brush ∅ 25 mm

1 2 97 097 brass wire brush

1 2 97 860 hexagon socket head wrench size 8

1 2 97 590 bronze spatula

1 2 97 122 round brush

Accessories for the measuring mixer only in connect ion with the Universal Docking Station*:

3 6 73 289 control thermocouple with 3000 mm connecting cable

1 6 74 252 stock temperature thermocouple

If a docking station* model up to 2008 is used, the control and melt temperature thermocouples are fixed in the docking station*.


Spare parts for


Ident no. Description

6 94 207.002 Roller blade, short, 1.4312 (for mixer type 50)

6 94 217.001 Roller blade, long, 1.4312 (for mixer type 50)





6 91 229.003 Cam blade, short, 1.4313 (for mixer type 50)

6 94 209.001 Cam blade, long, 1.4313 (for mixer type 50)





6 93 286.001 Banbury blade, short, 1.4301 (for mixer type 50)

6 93 285.001 Banbury blade, long, 1.4301 (for mixer type 50)

6 91 277.003 Sigma blade, short, 1.4312 (for mixer type 50)

6 91 276.003 Sigma blade, long, 1.4312 (for mixer type 50)

6 94 234.004 MB blade, short, 1.8519 (for mixer type 50)

6 94 235.006 MB blade, long, 1.8519 (for mixer type 50)

4 06 260.015 Bushings made of steel/TiN (for standard EHT mixer)

4 06 260.016 Bushings made of steel/TiN (special design for max. 250°C)

2 14 102 O-ring 19 * 1.8 Viton

2 90 006 Inner ring A 6075

2 90 007 Tapered ring A 6157

4 97 239.001 helical gear wheel Z = 18 (for i = 2 : 3/3 : 2)

4 97 240.001 helical gear wheel Z = 27 (for i = 2 : 3/3 : 2)

4 97 285.001 helical gear wheel Z = 20 (for i = 1 : 1.11)

4 97 286.001 helical gear wheel Z = 22 (for i = 1 : 1.11)

4 19 242 feather key 6.7 * 5 * 26.6 with round face (for blades)

4 19 242.001 feather key 6.7 * 5 * 26.6 with straight face (for gear wheels)

2 28 111 heating cartridge 8 * 60 mm, 350 W (mixer bowl)

2 28 088 heating cartridge 10 * 130 mm, 800 W (rear wall, bottom)

2 28 026 heating cartridge 10 * 100 mm, 560 W (front and rear wall)


Supplementary modules for


Ident no. Description

2 97 929 Quick loading chute* for mixers series 50

6 28 364.002 Pneumatic loading chute* for mixers series 50

6 28 204 Pressure ram* for mixers series 50

4 79 123 Loading weight

6 28 206 Pressure ram with bore* for metering pumps (mixers series 50)

2 56 086 Metering pump* for titrating liquids into the measuring mixer

6 28 208 Sealing cover*

6 19 207 Blade extractor for roller blades type 30/50

6 19 257 Blade extractor for cam and Banbury blades (for mixers type 50)

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Format, case: 96 x 96 mm ( 1/4 DIN) Format, face plate: 98 x 98 mm Installation depth: 122 mm

8- Zones Temperature Controller

R2400

Heater current monitoring CANopen interface

DESCRIPTION AND OPERATING MANUAL Nr.: R24-834-BA3-E 01/2007

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1. Contents 1. Contents 2. Type Code 3. Connection Diagram: R2400 - 834 4. Display and Keyboard, general 4.1 Displays 5. Parameter Level: Device Configuration 6. Parameter Level: Zone Configuration 7. Parameter Level: Control Parameters 8. Technical Data 9. Error Displays

10. Installation Instructions Please read this operating manual before starting u p carefully. Observe the installation and connecting instruction s. Take care to the separate interface- and data transmission descriptions. Before operation, the unit must be configured for i ts intended purpose under an expert guidance. (e.g. controller type, sensor type and range, alarm adjustment etc.) See: „Device Configuration“ , „Zone Configuration“ , and „Control Parameters“. Attention: The „heating“- or „cooling“-outputs can be active while programming or configuring the controller.

This can cause a damage either to the plant itself or its contents.

2. Type Code R 2400 - 834 - x - 5 - BAx - d - z 1: power supply: 230 V AC 2: power supply: 115 V AC 3: power supply: 24 V AC 5: power supply: 24 V DC 7: CAN, CANopen Device Profile DS-404 5: with heater current monitoring (only with bist. voltage outputs) 0: sensor programmable: RTD (Pt100-DIN), 2- or 3-wire; Type L (Fe-CuNi), Type J; Type K (NiCr-Ni) 834 8 - zones controller 6 zones heating-off-cooling controller; zones 1-6 2 zones heating-off controller; zones 7-8 control outputs “heating” : bist. voltage signal control outputs „cooling“ : triac

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3. Connection Diagram: R2400 - 834 Zone: Sensor : k5 k4 k3 k2 k1 AC: DC: TC Pt100 40 70 L - 1 8 - 41 71 N + 2 42 72 3 43 73 Out A1 4 Out8H- 17 7 - 44 74 Out A1 5 Out7H- 18 45 75 Out A2 6 19 Triac - 46 L1 76 Out A2 7 Out6C 20 6 47 L1 77 8 Com. 5/6 21 48 L2 78 Out6H - 9 Out5C 22 - 49 L2 79 Out5H - 10 Out4C 23 5 50 L3 80 Out4H - 11 Com. 3/4 24 L3 81 Out3H - 12 Out3C 25 - 60 Out A: + 82 Out2H - 13 Out2C 26 4 61 Out A: - 83 Out1H - 14 Com. 1/2 27 62 Com.H+ 15 Out1C 28 3 - 63 90 64 91 - 65 92 2 66 CAN-H 93 67 CAN-L 94 1 - 68 95 69 CAN 96 It is not permitted to connect the grounds of the sensor-inputs and bist. voltage-outputs with each other. 65: RTD 2. wire RTD 2. wire 66: 3-wire 1. wire 2-wire 1. wire 67: connection 3. wire connection 3. wire = jumper to 2. wire jumper jumper 67: RTD 3. wire RTD 3. wire = jumper to 2. wire 68: 3-wire 2. wire 2-wire- 2. wire 69: connection 1. wire connectio n 1. wire Out 1H … Out 6H: „heating-off-cooling“ – controller, control output “heating” (Com.+: terminal 15) Out 1C … Out 6C: „heating-off-cooling“ – controller, control output “cooling” Out 7H … Out 8H: „heating-off“ – controller, control output “heating” (Com. +: terminal 15) Out A1: Relay contact. Controlled by CAN-bus Out A2: Relay contact. Controlled by CAN-bus Out A (Alarm): Alarm signalisation. See Parameter: Co.A Setpoint Controlling: K1: open = Setpoint 1 (SP1) valid K1: closed = Setpoint 2 (SP2) valid, for all zones Adjustment lock (LOC): K2: open = Adjustment lock only via „software code“ K2: closed = Adjustment locked according to the chosen „software code“. Setpoint changing: K3: open = individual setpoint adjustment for each zone K3: closed = if setpoint has been changed in one zone, this new setpoint is valid (will be overtaken) for all other zones automatically. CAN-Interface: K4: open = CAN: „operational“. Operation only with CANopen protocol. K4: closed = CAN: „operational“ always active. *) „K4“ must be closed, if the instrument is equip ped with a CAN-interface but not used. Heater current monitoring: 1 current – transformer / phase Single phase operation: terminals 76,77: L1 Three-phase operation: terminals 76 – 81: L1, L2, L3

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4.... Display and Keyboard, general

The device is equipped with an LCD-display. After switching on and initializing the device, the actual process values of all connected controller zones are displayed. Zone no.: 1 Process value: 200°C

Most of the individual parameters of the device are displayed in plain text either in English or in German language. See: Device Configuration (press keys „E“ and „P“ simultaneously for approx. 3 seconds).

Key functions :

zone Select individual zone. Zone Information .

Actual process value and setpoint value display of the selected zone.

P Parameter key (parameter preselection of the selected zone).

▲ Adjustment of selected parameter (e.g. setpoint or control parameters) to higher values. When the parameter adjustments have been altered but not entered, a flashing „E“ will be shown in the display.

▼ Adjustment of selected parameter (e.g. setpoint or control parameters) to lower values

When the parameter adjustments have been altered but not entered, a flashing „E“ will be shown in the display.

E Confirmation and storage of the preselected parameter values. E = Enter.

trend Tendency display will be selected. This will give an overview about all connected controller zones and the deviations between setpoint and process value.

Simultaneous a zone dependent alarm signalisation will be shown.

act Display of all actual process values of the connected controll er zones.

fct Recorder function. Display of actual value path over time. First select individual zone with key „zone“. Then press „fct“. To switch off the recorder function: press „fct“ again.

Contrast setting: Press „E“ and keys „▲“ or „▼“ simultaneously.

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4.1 Displays

Key act : Display of all actual process values of the connected controll er zones

Warning Er.H : Measurement range exceeded or sensor fault Warning Er.L : Measurement range undershot or sensor short circuit No indication: Respective control zone is switched off

Select a single zone: Press key „ zone “ Select tendency display : Press key „ trend “

Key zone : Zone Information. Display of process value, setpoint and alarm signal isation of one special zone.

Adjust the setpoint with keys „▲“ and „▼“. When the parameter adjustments have been altered but not entered, a flashing „E“ will be shown in the display. Enter the adjusted value with key „E“. SET: Setpoint 1 active SET SP2: Setpoint 2 active Adjustment of setpoint 2: See: Level „Control Parameters“

Further displays:

- Heater current indication in amps., if this option is installed and configured. - Alarm indications: alarm A active: A ֠ - Status indications: Autotune active: OPT

Ramp function active: RAMP Warnings: E. xx Select other controller zone: Press key „ zone “ Select recorder function for this zone: Press key „ fct “ Select tendency display: Press key „ trend “

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Key trend : Temperature Tendency- and Alarm display

This function shows the temperature trend and alarm status of output A. This display allows a rapid overview of the temperature conditions of the control zones connected.

: Positive or negative temperature deviation between setpoint and actual temp. value: ≤ +/- 1 % of measurement range : Positive or negative temperature deviation between setpoint and actual temp. value: +/- 1.5 % of measurement range

: Positive or negative temperature deviation between setpoint and actual temp. value: ≥ +/- 3 % of measurement range

Line A: if alarm A is active, indication „ ֠ “ is displayed below the respective zone-no.

If the option "Heater current monitoring" is active and if a continuous current flow has been determined (failure of the semiconductor switches) then the following message is reported: "Current failure alarm".

Select further zone: Press key „zone “ Select all actual values: Press key „act “

Key fct : Recorder function

Display of actual value path over time. Select with key „zone “ the„zone information“ display of a wished zone and press key „fct “. The time axis is defined by the "Sample time" This function enables the user to observe the transient response and the timing behaviour of the controller for the respective control zone without the need for any additional devices and to parameterise these accordingly.

In the event of a fault, the course taken by the actual value within a given period of time can be retrospectively examined prior to the occurrence of the fault.

The actual value is always displayed symmetrically around the current setpoint. Above key „ P “ : Indication of the actual process value. Key „▲“ : Decrease cutout based on current setpoint. Precise display. Key „▼“ : Enlarge cutout based on current setpoint. Approximate display. Return to zone indication and leave the recorder function: Press key „ fct “.

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5. Parameter Level: Device Configuration General parameters, valid for the complete device f unctions. This parameters have to be set at first.

Press key „ act “. Display: All actual values. Press keys „P“ and „E“ simultaneously approx. 3 seconds. The first parameter is „Language / Sprache“. Select the language with keys „▲“ and „▼“ and confirm it with the „E“-key. Press key „P“ to select the next parameter. If there is not operation within approx. 30 seconds, the display will return to „all actual values“ (actual value-indication of all zones). If you want to leave this level: press key „E“ appro x. 3 seconds. Language / Sprache English / englisch German / deutsch Sensor mix. Preselection: Zones with PT100(RTD)- or Thermocouple(TC)- sensor ? PT100(RTD) / TC Example for 8 zones: Zo 1 - 8 PT100, only PT100(RTD) sensors Zo 1 - 6 PT100 Zo 7 - 8 TC Zo 1 - 4 PT100 Zo 5 - 8 TC Zo 1 - 2 PT100 Zo 3 - 8 TC Zo 1 - 8 TC, only TC sensors General Information: With the help of the following parameters, the configuration of the kind and the switching behaviour of the alarm relay A takes place. Select: - Temperature- or heater current monitoring - Absolute temperature- or setpoint dependent temperature alarm monitoring Alarm A: Alarm off, no alarm signalisation conf.no.: co.0 (ex works) Configuration Signal contact, setpoint dependent: low - high co.1 (switches output A) Limit contact, process value dependent: low - high co.2 Limitcomparator, setpoint dependent: low - high - low co.3 Signal contact, setpoint dependent: high - low co.4 Limit contact, process value dependent: high - low co.5 Limitcomparator, setpoint dependent: high - low - high co.6 Limitcomparator, with start-up suppression: low - high - low co.7 Heater current monitoring; limit contact: low - high co.8 Heater current monitoring; limit contact: high - low co.9 The individual alarms A of all zones are connected to the main, common output A.

The selected alarm configuration of A is valid for all active controller zones. The alarm values itself (switching points) have to be set for each zone in the parameter level

„Control Parameters“ individual. Adjustment of parameter: “Alarm A”. Please note: Care should be used to ensure, that the setpoints of the alarms are programmed within the selected measuring range. If a setpoint ramp has been programmed, the alarms that are relative to the setpoint (signal contact, limit comparator) follow the setpoint up the ramp. In case of sensor error the alarms will react in the same way as range override. The alarm contacts therefore do not offer protection against all types of plant breakdown. With this in mind, we recommend the use of a second, independent monitor unit.

Alarm A: Direct if alarm signalisation ֠ on: output: high (ex works) Switching behaviour if alarm signalisation ֠ off: output: low Invers if alarm signalisation ֠ on: output: low if alarm signalisation ֠ off: output: high

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The signal contact is adjusted and displayed The limit contact (also heater current monitoring) is relative to the setpoint (deviation alarm). adjusted and displayed as an absolute value. Configuration Configuration co.x co.x low high co.1 low high co.2, co.8 high on co.4 high low co.5, co.9 setpoint process process The limit comparator is adjusted and displayed The alarm relay of the limit comparator with relative to the setpoint. The selected start-up suppression is activated when the controller value is effective below and above the setpoint. is first switched on. It is only then deactivated, when the process value has been within, and left, the o.k. -zone.

Configuration Configuration co.x co.x high low high low co.3 low high low co.7 high low high co.6 setpoint process setpoint process

signal value

limit range

limit value

limit range

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Heater current monitoring (Option) The heater current monitoring function is valid for all connected control zones if selected. The following parameters will only be displayed if the heater current monitoring system is activated as described below: Heater current monitoring via output A: Set parameter „Alarm A - Configuration“ to co.8 or co.9 The heater current to be monitored, has to be programmed as an absolute value. First select zone. Then select alarm value A and adjust the heater current value (ampere). Heater current, actual value: Select zone (zone information). Heater current display: see „current“ ( ampere) Heater current, alarm signalisation: Display: Zone information: A ֠ Display: Tendency display: ֠ to the zone concerned Please note: If the supply voltage is low, the heater current has to be higher than the monitoring value. Otherwise the alarm signal will be activated. If the heater current value falls below the monitoring value, an alarm signal (the relay switches) will be activated. With the help of the parameter „Delay time“ it is possible to program a delay time for this. When switching the power-on, the alarm signalisation will be suppressed until the heating current values for all zones has been scanned and verified. Current detection 1 ... 60 sec. Time between the current measured cycle time (sec.) of two zones following each other.

(ex works Brabender®: 45 sec.)

Attention! The set value must be > 30 sec.! With current detection cycle times of < 30 sec., the measuring head may

heat up to 45°C even if the nominal value has been set to 0°C. In the set cycle time, the heating current is controlled by switching on and

off, one after another, each individual zone for a short moment. A defective SSR is recognized by current flowing during the "off" time. An

interruption of the heating zone is recognized if no current is flowing when the SSR is "on".

Alarm A: 5 steps adjustable (in sec.) Adjustment and display in seconds. Delay time (sec.) off= no delay time The values are dependent on the If alarm relay A is configured current detection cycle time and the for heater current monitoring. number of active controller zones. Leakage current off; 0,0...99,9 A Adjustment of the allowed min. Min. limit value leakage current value.

SSRs (especially if they are combined with RC-combinations) normally have small leakage currents. The sum of the actual leakage current will be displayed as „act. leakage current“.

If a permanent current is detected the alarm relay will be activated.

The status will be displayed as follows: See display „Zone information“: „Er.Cu“ (Error Current) flashes See display „Tendency display“: „Permanent current“ The zone with a permanent current only can be detected by observing the actual

temperate process values (high values). Technical data: Heater current monitoring Current transformer 1:1000: Passive through current transformer with snap-in attachment for DIN rail (Type M2000) mounting (EN 50022, 35 mm). Connections to the controller: 2 x 6,3 mm flat connectors. Heater current detection and indication range: 0...max. 60,0A. Single-phase operation. 0...max. 99,9 A. Three-phase operation. The sum of the current of all three phases of one controller zone will be monitored.

Variations of the power supply voltage have to be considered when the alarm values are programmed.

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Adjustment lock - All parameters adjustable (others are locked) (ex works) - Only setpoint 1 adjustable - Setpoints, alarm values and ramps adjustable - All parameters locked The parameters that have been locked, can be displayed but not altered. This adjustment can`t be changed, if the external contact K2 is closed. Zones offset Zones will be numbered with a preselected offset value. (ex works: off) Co.1 Zone numbering: 1 – 8 Co.2 Zone numbering: 9 – 16 Co.3 Zone numbering: 17 – 24 Co.4 Zone numbering: 25 – 32 The following parameters are only valid, if the unit is equipped with a CANopen interface . CANopen: 1 .... 127 (ex works: 1) Device adress CANopen: 10k, 20k, 50k, 100k, 125k, 250k, 500k, 1000k Baud (ex works: 20) Baud rate CANopen-specification: CANopen Master: no CANopen Slave: yes Extended Boot-up: no Minimum Boot-up: yes COB ID Distribution: yes; default via SDO Node ID Distribution: no; via device keyboard No. of POD´s: 2RX, 2TX PDO Modes: async., sync. Variable PDO mapping: yes Emergency message: yes Life guarding: yes No. of SDO`s: 1RX, 1TX Device Profile: CiA DS-404 See: -Brabender Object Dictionary R2400-834 -Brabender Shortform Object Dictionary R2400-834 -CiA CANopen Device Profile DS-404 Recorder function: 2,5sec. ... 10min. See: Recorder function (Chapter 5.1) Sample time Adjustment of the time difference between two

temperature values. The total time, which can be monitored, will be

displayed. Note: The sample time has to be shorter than the fastest changings of the actual temperature. It is possible to store up to 90 temperature values.

Device code: BB.xx End of this parameter level. Next Display: „Language / Sprache“

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6. Parameter Level: Zone Configuration Adjustable for each controller zone individually. This zone dependent parameters have to be set after programming the device configuration.

Select individual zone with key „ zone “. Press keys „P “ and „E “ simultaneously approx. 3 seconds. The first parameter is „Zone on/off“. Adjust this parameter with keys „▲“ and „▼“ and confirm it with the „E“-key. Press key „P“ to select the next parameter. If there is not operation within approx. 30 seconds, the display will return to „zone information“ (actual value- and setpoint- display) of the selected zone. If you want to leave this level: press key „E“ appr ox. 3 seconds. Zone on/off on Measuring- or controller zone active (ex works)

off Measuring- or controller zone switched off Controller 2-point-controller "heating-off" (ex works) configuration 2-point-controller "cooling-off" 2-point-controller „cooling-off“ with non linear cooling 3-point-controller „heating-off-cooling“ 3-point-controller „heating-off-cooling“ with non-linear cooling Indicator operation: no controller action 2-point- heating 2-point- cool (Air) Sensor selection PT100 (RTD), - 50,0 ... 100,0 °C PT100 (RTD), - 58 ... 212 °F PT100 (RTD), - 90,0 ... 205,0 °C PT100 (RTD), -130 .. 401 °F PT100 (RTD), 0 ... 400 °C (ex works) PT100 (RTD), 32 ... 752 °F PT100 (RTD), 0 ... 800 °C PT100 (RTD), 32 ... 1472 °F Pt 100 (RTD) 0,0 ... 400,0 °C Pt 100.(RTD) 0,0 ... 800,0 °C or, if thermocouple (TC) has been selected (see chapt.: „sensor mix“) TC Type L, FeCu-Ni 0 ... 400 °C TC Type L, FeCu-Ni 32 ... 752 °F TC Type L, FeCu-Ni 0 ... 800 °C TC Type L, FeCu-Ni 32 ... 1472 °F TC Type J, FeCu-Ni 0 ... 800 °C TC Type J, FeCu-Ni 32 ... 1472 °F TC Type K, Ni-CrNi 0 ... 1200 °C TC Type K, Ni-CrNi 32 ... 2192 °F TC Type S, Pt10Rh-Pt 0 ... 1600 °C TC Type S, Pt10Rh-Pt 32 ... 2912 °F TC Type J, FeCu-Ni -50 ... 600 °C TC Type J, FeCu-Ni -58 ... 1112 °F TC Type J, FeCu-Ni -50,0 ... 600,0 °C TC Type J, FeCu-Ni 0,0 ... 800,0 °C Take care: If the Sensor selection is changed, the following parameters will be set as follows

and need to be readjusted: Setpoint 1, Setpoint 2: Setpoint limitation min. Lower setpoint limitation: Bottom range end Higher setpoint limitation: Top range end Setpoint-ramp values: off Alarm values: off Process value offset: off

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Process filter off; 1 …60 sec. Filter time constant (ex works: off) Process value filter Process offset -999... off... 1000 °C/°F (ex works: off) -9,9... off... 10,0 °C/°F This parameter serves to correct the input signal, e.g. for: - the correction of a gradient between the measuring point and the sensor tip, - the line resistance balancing of 2-line RTD (Pt100) sensors and - correction of the control deviation when using P- or PD-action. If for example the offset value is set to +5°C , then the real temperature measured by the sensor (when process is balanced) is 5°C less than the setpoint and the displayed process value. Setpoint limitation : Highest adjustable setpoint value (ex works: 400°C) max. setpoint programming range: setpoint limitation min. ... top range Setpoint limitation : Lowest adjustable setpoint value (ex works: 0°C) min. setpoint programming range: bottom range ... setpoint limitation max. Copy all parameters The „Zone Configuration“ and the following controller-parameters of this zone to programmed in this zone, can be copied to each other zone, if all zones have the destination zone same kind of sensors. Select the target zone number with the keys „ up “ and „ down “.

„All“ : copy to all other zones. The parameters will be copied after the „E “- key has been pressed. While the copy function is active: „COPY“ is shown.

End of this parameter level. Next Display: „Zone on/off “

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7. Parameter Level: Control Parameters Adjustable for each controller zone individually. This zone dependent parameters have to be set after programming the zone configuration.

Select individual zone with key „ zone “. Select the first parameter of this zone (setpoint 1 or setpoint 2) by pressing the key „P“. Adjust this parameter, if needed, with keys „▲“ and „▼“ and confirm it with the „E“-key. Press key „P“ to select the next parameter. If there is not keyboard-operation within approx. 30 seconds, the display will return to „zone information“ (actual value- and setpoint- display) of the selected zone. If you want to leave this level: press key „E“ appr ox. 3 seconds. Setpoint 2 off; Lower setpoint limitation ... Upper setpoint limitation (ex works: off)

Setpoint 2 is valid for all zones, if the external contact K1 is closed. Setpoint2 = Off: Setpoint1 is still valid, if contact K1 is closed. Rising ramp off; 0,1 ...99,9 ° C/min. or °F/min. (ex w orks: off) 0,01...9,99 °C/min. or °F/min. if range with d ec.point is selected Falling ramp off; 0,1 ...99,9 °C/min. or °F/min. (ex work s: off) 0,01...9,99 °C/min. or °F/min. if range with dec.p oint is selected A programmed ramp is always activated when the setpoint is altered or when the mains supply is switched on. The ramp constructs itself out of the momentary process value and the pre-selected setpoint. The ramp can be activated for both setpoint1 and setpoint2. By programming the second setpoint accordingly a setpoint profile can be obtained (please see example below). process SP2 SP1 time K1, open K1, closed K1, open Alarm A: Temperature monitoring: alarm value adjustment / switching point Alarm value if „Signal contact“ is selected: off= -200; -199... 199 °C/°F (ex works: off) (switches output A) if „Limit comparator“ is selected: off= 0; 1...199 °C/°F (ex works: off) if „Limit contact“ is selected: off= Measuring range, bottom end -1 (ex works: off) Adjustment: Measuring range, bottom end ... top end or: Heater current monitoring: alarm value adjustment / switching point Limit contact off=0; 0,1 ...99,9 A (ex works: off)

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Output ratio 0...100% HEATING and COOLING The actual output ratio shows the momentary calculated ratio. It cannot be altered. The display is in percent of the installed performance capability for heating and cooling. Max. output ratio limitation heating 0...100% (ex works: 100) (%) Limitation of the output ratio is only useful if: - the heating or cooling energy supply is grossly oversized compared to the power required, - to turn off a control output (setting = 0%). Under normal circumstances no limitation is needed (setting = 0%). The limitation becomes effective, when the controllers’ calculated output ratio is greater than the maximum permissible (limited) ratio. Warning! The output ratio limitation does not work during autotune. Max. output ratio limitation cooling 0...100% (ex works: 100) (%) The following parameters are only effective, if eit her the configuration “Heating-off controller” or the configuration “Heating-off-cooling controller” has been selected. They are only displayed in one of this modes. Preselection: actual (wished) parameter set no. 1 or no. 2 1 or 2 There are two PID - parameter sets ( for “heating” and “cooling” function) available. This PID-sets are valid for heating and cooling – function. The wished set will be adjusted by this parameter. Parameter set 1: „heating“ and „cooling“ OFF; 0,1...100,0 % (ex works: 3,0) P Proportional band Parameter set 1: „heating“ and „cooling“ OFF; 1...200 sec. (ex works: 30) D Rate time Parameter set 1: „heating“ and „cooling“ OFF; 1...1000 sec. (ex works: 150) I Reset time Normally the controller works using PD/I control action. This means, controlling without deviation and with practically no overshoot during start-up. The control action can be altered in its structure by making the following adjustments to the parameters: a. no control action, on-off (setting P = OFF) b. P-action (setting D and I = 0) c. PD-action (setting I = 0) d. PI-action (setting D = 0) e. PD/I modified PID-action Parameter set 1: Cycle time heating 0,5...240,0 sec. (ex works: 1,0) The switching frequency of the actuator can be determined by adjusting the cycle time. This is the total time needed for the controller to switch on and off once. Bistable voltage outputs: cycle time 0,5...10 secs Parameter set 1: Cycle time cooling 0,5...240,0 sec. (ex works: 1,0)

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Parameter set 2: „heating“ and „cooling“ OFF; 0,1...100,0 % (ex works: 3,0) P Proportional band Parameter set 2: „heating“ and „cooling“ OFF; 1...200 sec. (ex works: 30) D Rate time Parameter set 2: „heating“ and „cooling“ OFF; 1...1000 sec. (ex works: 150) I Reset time Normally the controller works using PD/I control action. This means, controlling without deviation and with practically no overshoot during start-up. The control action can be altered in its structure by making the following adjustments to the parameters: a. no control action, on-off (setting P = OFF) b. P-action (setting D and I = 0) c. PD-action (setting I = 0) d. PI-action (setting D = 0) e. PD/I modified PID-action Parameter set 2: Cycle time heating 0,5...240,0 secs (ex works: 1,0) The switching frequency of the actuator can be determined by adjusting the cycle time. This is the total time needed for the controller to switch on and off once. Bistable voltage outputs: cycle time 0,5...10 secs Parameter set 2: Cycle time cooling 0,5...240,0 sec. (ex works: 1,0)

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The following parameters are only effective, if the configuration 2-point. controller “heating-off” and 2-point. con troller “cooling-off” (Air) has been selected. They are only displayed in this mode. Preselection: actual (wished) parameter set no. 1 or no. 2 1 or 2 There are two PID - parameter sets for the “heating” action available. The wished set will be adjusted by this parameter. Parameter set 1: P Proportional band OFF; 0,1...100,0 % (ex works: 3,0) heating Parameter set 1: D Rate time OFF; 1...200 sec. (ex works: 30) heating Parameter set 1: I Reset time OFF; 1...1000 sec. (ex works: 150) heating Parameter set 1: Cycle time 0,5...240,0 sec. (ex works: 10,0) heating (sec.) Parameter set 1: Cycle time 0,5...240,0 sec. (ex works: 10,0) cooling (sec.) Parameter set 2: P Proportional band OFF; 0,1...100,0 % (ex works: 3,0) heating Parameter set 2: D Rate time OFF; 1...200 sec. (ex works: 30) heating Parameter set 2: I Reset time OFF; 1...1000 sec. (ex works: 150) heating Parameter set 2: Cycle time 0,5...240,0 sec. (ex works: 10,0) heating (sec.) Parameter set 2: Cycle time 0,5...240,0 sec. (ex works: 10,0) cooling (sec.) Cooling controller: P Proportional band 0,1...100,0 % (ex works: 3,0) (%) Cooling controller: D Rate time OFF; 1...200 sec. (ex works: OFF) (sec.) Cooling controller: I Reset time OFF; 1...1000 sec. (ex works: OFF) (sec.) Cooling controller -100...+100 °C / °F (ex works: 0) Offset curve (°C/°F)

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Autotune off autotune / self tuning out of action (ex works: off) (selftuning algorithm) on autotune / self tuning active ( one time) The tuning algorithm determines the characteristic values within the controlled process, and calculates the valid feedback parameters ( P,D,I ) and the cycle time ( = 0.3 x D ) of a PD/I-controller for a wide section of the range. Using the heat-cool controller, the temperature drop will be accelerated by switching on the cooling for a short duration. The autotune activates during start-up shortly before the setpoint is reached. The setpoint must amount to the least 5% of the total range. If activated after the setpoint has already been reached, the temperature will first drop by approx. 5% of the total range, in order to detect the exact amplification of the process. Autotune active: indication in display „Zone Information“: OPT The tuning algorithm can be activated at any time by selecting the Autotune=on . After having calculated the feedback parameters, the controller will lead the process value to the actual setpoint. Selecting Autotune=off will stop the autotune-function. X X Set Set OPT on t OPT on t Self tune Self tune, after the setpoint during start-up has already been reached End of this parameter level. Next Display: Setpoint 2

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8. Technical Data Input PT100 (RTD): 2 - or 3 - wire connection possible. Built-in protection against sensor breakage and short circuit. Max. permissible line resistance by 3-wire connection: 80 Ohms Sensor current: < 1 mA Calibration accuracy: < 0,2 % Linear error: < 0,2 % Influence of the ambient temperature: < 0,01 % / K Input Thermocouple: Built-in internal compensation point and protection against sensor breakage and incorrect polarity. Re-calibration not required for a line resistance of up to 50 Ohms. Calibration accuracy: < 0,25% Linear error: < 0,2 % Influence of the ambient temperature: < 0,01 % / K K1 … k5: Ext. potential-free contact, switching voltage approx. 24 V DC, max. 1 mA. Control outputs OUT 1H ... 8H: Bist. voltage signal, 0/18 V DC, max. 10 mA, short-circuit proof Control outputs OUT 1C ... 8C: Triac; max. 264VAC, max. 0,3A External fuse recommended. Type: Wickmann G, 5x20mm. No. 19194, 315mA, 250V (UR) Outputs A1 and A2: Relay, max. 250 VAC, max. 3 A (cos-phi = 1) Output A: Bist. voltage: 0/18VDC, max. 10mA, short-circuit proof LCD-Display: Blue STN-display with permanent, white LED-background lightening 128 x 64 pixel 8 lines with 21 characters each Ser. interface (option): CANopen, CiA Device Profile DS-404 Data protection: EAROM CE – mark: Tested according to 89 / 336 / EWG EN 61000-6-4, EN 61000-6-2 Electr. safety: EN 61010 Power supply: Standard: - 230 V AC (115VAC, 24VAC); ± 10 %, 48...62 Hz, appr. 10VA - 24 V DC, +25%, appr.10W Connections: Screw terminals, Protection mode IP 20 (DIN 40050), Insulation class C Permiss. operating conditions: Operating temperature: 0...50 °C / 32...122 °F Storage temperature: -30...70 °C / -22...158 ° F Climate class: KWF DIN 40040; equivalent to annual average max. 75 % rel. humidity, no condensation Casing: Format, case: ¼-DIN; 96 x 96 mm (DIN 43700), installation depth 122 mm Panel cutout: 92 +0,5 mm x 92 +0,5 mm Format, face plate: 98 x 98 mm Material: Noryl, self-extinguishing, non-drip, UL 94-V1 Protection mode: IP 20 (DIN 40050), IP 50 front side Weight: approx. 800 g Subject to technical improvements!

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9. Error Displays Display Cause Possible remedy LOC Parameter has been locked Unlock, if need be.

See: Device Configuration -> Adjustment lock LOC EXT Parameter has been locked by contact K2 Open contact K2 Er.H Top range end has been exceeded, Check sensor and cable sensor defect Er.L Bottom range end has been exceeded, Check sensor and cable sensor defect E.OP Self tuning error Extinguish error signal by pressing the

„E“ - key. Check the self tuning conditions and restart. E.SY System error Extinguish error signal by pressing the

„E“ - key. Check all parameters.

If the error signal continues please send the controller for examination.

E.O System error Please send the controller for examination. KONF Alarm configuration: off Set „Alarm configuration“ No alarm value adjustable. See: Device Configuration -> Alarm Configuration. E.SP2 Setpoint 2 active Setpoint 2 can not be adjusted in display „Zone Information“. Adjustment only in level „Control Parameter“ possible.

10. Installation Instructions Make certain that the devices described here are used only for the intended purpose. They are intended for installation in control panels. The controller must be installed so that it is protected against impermissible humidity and severe contamination. In addition, make sure that the permitted ambient temperature is not exceeded. The electrical connections must be made according t o the relevant locally applicable regulations and b y properly qualified personnel. If using a thermocouple sensor, the compensation cables must be laid directly to the controller terminals. Transducers must be connected only in compliance with the programmed range. Transducer cables and signal lines (e.g. logic or linear voltage outputs) must be laid physically separated from control lines and mains voltage supply cables (power cables). Spatial separation between controller and inductive loads is recommended. Interference from contactor coils must be suppressed by connecting adapted RC-combinations parallel to the coils. Control circuits (e.g. for contactors) should not be connected to the mains power supply terminals of the controller. Disclaimer of liability We have checked the contents of the document for conformity with the hardware and software described. Nevertheless, we are unable to preclude the possibility of deviations so that we are unable to assume warranty for full compliance. The information given in the publication is, however, reviewed regularly. Necessary amendments are incorporated in the following editions. We would be pleased to receive any improvement proposals which you may have. The information contained herein is subject to chan ge without notice.

ELOTECH Industrieelektronik GmbH Verbindungsstr. 27 D - 40723 HILDEN, Germany Tel.: 0049 2103 23055 Fax: 0049 2103 23057

www.elotech.de E-mail: [email protected]

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