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Berthold castxpert LB 452 Operating Manual

Evaluation unit
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Evaluation unit
LB 452
Operating Manual
47344BA2
Rev. No.: 04, 03/2015
Embedded Software as of vers. 1.3.0 (CU) and 1.3.0 (MU)

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  • Page 1 Evaluation unit LB 452 Operating Manual 47344BA2 Rev. No.: 04, 03/2015 Embedded Software as of vers. 1.3.0 (CU) and 1.3.0 (MU)
  • Page 3 BERTHOLD TECHNOLOGIES GmbH & Co. KG Calmbacher Str. 22 75323 Bad Wildbad, Germany www.Berthold.com Telephone +49 7081 177-0 Fax +49 7081 177-100 industry@Berthold.com...

  • Page 5: Table Of Contents

    Table of Contents Table of Contents About this Manual....................7 Some Prior Remarks...................... 7 Structure of the Manual ....................7 Validity of the Manual ....................7 Copyright ........................8 Target Group ........................ 8 Notation ........................8 Symbols Used ........................ 9 Safety ........................
  • Page 6 Table of Contents 6.4.3 Software update......................68 Access Level......................... 74 "Channel Overview" Menu ................77 Empty and full adjustment ..................81 Settings........................85 7.2.1 Calibration ........................87 7.2.2 Filter ..........................95 7.2.3 Alarms ......................... 97 7.2.4 Option/Display ......................98 In/Outputs ........................99 7.3.1 Analog IO ........................

  • Page 7: About This Manual

    Some Prior Remarks The LB 452 Evaluation Unit (from now on referred to as EVU) is delivered to you by the manufacturer BERTHOLD TECHNOLOGIES GmbH & Co. KG in a complete and functionally reliable condition. This manual demonstrates to you how to: ...

  • Page 8: Copyright

    1 About this Manual Copyright This manual contains copyright-protected information. None of the chapters may be copied or reproduced in any other form without prior authorisation from the manufacturer. Target Group This manual is directed at qualified specialist personnel who are familiar with han- dling electrical and electronic assemblies as well as with communication and meas- uring techniques.

  • Page 9: Symbols Used

    1 About this Manual Symbols Used The safety instructions point out possible dangers to you and instruct you on the operation. They apply to the whole document. Possible consequences: Death or serious injury! Points out a direct threat of danger. If the danger is not avoided, death or serious bodily injury are the consequences.

  • Page 11: Safety

    2 Safety Safety Proper use The LB 452 evaluation unit (EVU) measures the fill level along with the GAMMAcast detectors and a compatible radiation source and it may only be used for this pur- pose. The following constitutes proper use: ...

  • Page 12: Qualification Of The Personnel

    If the product is used in a way which is not described in the present manual, the device's protection is compromised and the warranty claim becomes invalid. BERTHOLD TECHNOLOGIES GmbH & Co. KG shall only accept liability for / guarantee the correspondence of the device to its publicised specifications. Qualification of the Personnel...
  • Page 13 Authorised Persons Authorised persons are those who are either designated for the corresponding task due to legal regulations or those who have been authorised by BERTHOLD TECH- NOLOGIES for particular tasks. When dealing with radioactive materials, a radia- tion safety officer must also be consulted.
  • Page 14 2 Safety Rev. 04, 03/2015...

  • Page 15: Product Description

    3 Product Description Product Description Description of the System The evaluation unit (EVU) consists of a system board (CU Control Unit) with an ex- works pre-installed measurement module (channel 1). The EVU can be distributed with up to 4 measurement modules (channels). This makes the simultaneous monitoring of 4 mould levels possible.

  • Page 16: Overview

    3 Product Description Overview 3.4.1 Front View On the front view of the EVU there are LEDs for displaying each operation mode, a 7’’ touch display and a USB connection. Operation mode indicators 7'' Touch display USB connection for the connection of external devices, covered with a protec- tive cap Fig.1 Back view of the EVU...

  • Page 17: Back View

    3 Product Description Control Unit Indicators (Continued) LED Error This LED (Fig. 2, Pos. 1) lights up if an error has occurred. The current measurement is retained. Check the device settings. All possible error reports are described in chapt. 8 Troubleshooting Warning LED This LED (Fig.
  • Page 18 3 Product Description Slots for channel 1 Slots for channel 2 Slots for channel 3 Slots for channel 4 External power supply of the device (in) and power supply of the channels 1-4 (out) Type plates Serial ports (unused) Ethernet and USB ports Fig.

  • Page 19: Radiometric Measurement System

    3 Product Description Radiometric Measurement System 3.5.1 Functional Principle The measurement system functions on the principle of the radiometric measuring method. Here, the weakening of gamma rays by fluid metal in the mould is used in order to (Fig. 4, No. 1) measure the fill level in the mould. The EVU evaluates the electrical signal generated by the GAMMAcast detector and continually measures the fill level of the mould of a casting plant.

  • Page 20: Measurement System Components/Measurement Setup

    3 Product Description 3.5.2 Measurement System Components/Measurement Setup The measurement system is made up of the following components:  LB 452 castXpert evaluation unit (EVU)  Detector from the GAMMAcast series  Radiation Source/Mould Level Shielding Fill level Beam path Measurement line for channel 1 Evaluation unit, back view Detector...
  • Page 21 3 Product Description Measurement System Components/Measurement Set-up (Contin- ued) Further information on the functional principle of the detectors can be found in the manual on the GAMMAcast detectors. Note Each active measurement channel consists of at least one basic module. This is in- dispensable for operating the EVU.

  • Page 23: Start-Up

     Losses of production.  Damage in the system.  In general, we would recommend that you have the start-up car- ried out by the service of the company BERTHOLD TECHNOLOGIES. When operating the EVU, you must adhere to the manual "Mould Level Shieldings".
  • Page 24 4 Start-Up Installation of the Evaluation Unit (EVU) (Continued) The advantages of a separate power connection for each measurement channel are: Functional reliability Each measurement channel is supplied by its own volt- in the event of surges age source. or short circuits Redundancy If there is a fault in the power supply for one strand, the other measurements can still be carried out without in-...
  • Page 25 4 Start-Up Installation of the Evaluation Unit (EVU) (Continued) Fig. 7 External Power Supply of the Measurement Channel, Measurement Channel 1 as Example Connect the GAMMAcast detector to a terminal box or directly to the EVU with the special cable (in accordance with the local conditions). Connect the EVU to the terminal box if needed.

  • Page 26: The Use Of A Terminal Box

    4 Start-Up The Use of a Terminal Box Install the terminal box in close proximity to the mould in a protected but easily accessible place. The GAMMAcast detectors and the EVU are to be connected via the terminal box. This connection is to be made with a standard 6–wire shielded cable (6 x 0.5 mm²) with a maximum length of up to 1000 m.

  • Page 27: Configuring The Current Output

    4 Start-Up Configuring the Current Output Danger to life from electric shock! The installation may only be carried out by a qualified electrician. D a n g e r  Electric shock.  Please adhere to the relevant safety regulations. ...

  • Page 28: Configuring The Current Output On The Basic Module

    4 Start-Up 4.3.1 Configuring the Current Output on the Basic Module Before you start to configure the current outputs, get an overview of the installed modules. Extension module Flat ribbon cable Basic module Bus module System board (control unit) with SD card slot Fig.
  • Page 29 4 Start-Up Configuring the Current Output on the Basic Module (Continued) Approach the configuration of the current output as follows: Danger to life from electric shock! The installation may only be carried out by qualified electricians. D a n g e r ...
  • Page 30 4 Start-Up Configuring the Current Output on the Basic Module (Continued) Set the desired position at the changeover switch (Sink Mode (Fig. 12, Pos.1) or Position Source Mode (Fig. 12, Pos. 2). Basic Module, changeover switch – Position Sink Mode Basic Module, changeover switch –...

  • Page 31: Configuring The Current Output On Extension Module

    4 Start-Up 4.3.2 Configuring the Current Output on Extension Module Disconnect the EVU voltage. Loosen the three screws on the front panel (Fig. 11, Pos. 2). Fold down the front panel. Pull all modules (Fig. 10, Pos. 3) of the measurement channel out at the same time and remove the flat ribbon cable(s) if need be (Fig.

  • Page 32: Data Definition Profibus Dp

    4 Start-Up Data Definition Profibus DP Cyclic Output Data Variable Description Type Size name Mould Level Current Mould Level unit: %/mm/inch (selectable) Float 32 Bit Detector Current Detector Raw Value unit: GAMMAcast - Float 32 Bit Raw Value Pulses per Second (CPS) ECcast –...

  • Page 33: Mounting An Sd Card

    4 Start-Up Variable Description Type Size Name Calibration Currently used calibration [0 ... 7] (decimal) Byte 8 Bit Index (Calibration curve, alarm thresholds, time constant, etc.) Function Unsigned 32 Bit By writing a number in this field functions on the EVU Actuation Integer can be actuated:...
  • Page 34 4 Start-Up For the saving of data, see chapt. 6.3.2 and 6.4. Approach the installation of the SD card as follows: Disconnect the EVU voltage. Loosen the screws on the front panel (Fig. 11, Pos. 2) and fold down the front panel.

  • Page 35: Operation Of The Software

    5 Operation of the Software Operation of the Software In this chapter, the operation of the software and the different setting options of the EVU are explained. The EVU does not have a separate on and off switch. As soon as the energy supply is connected, the system and the EVU start up.

  • Page 36: Overview Of The Standard Display

    5 Operation of the Software Overview of the Standard Display If the system is fully loaded and running, the start page of the measurement system is displayed (Fig. 16). The display varies depending on which measurement channels are installed. For example, two measurement channels are shown in Fig.
  • Page 37 5 Operation of the Software Click on the top blue bar (Fig. 16, Pos. 1) to reach the system menu (chap. 6 „The System Menu“). Under the display for the measurement channels, there is a button that leads to its respective "Channel Overview"...

  • Page 38: Operation Of The Evu

    5 Operation of the Software Operation of the EVU The following figures display the structural framework of the EVU (Fig. 17) and the input options (Fig. 18). Operation Options:  Via the touch display.  With a mouse and a keypad which are connected at the USB port on the front panel (Fig.1, Pos.
  • Page 39 5 Operation of the Software Operation of the EVU (Continued) As soon as you click on an input field , the numeric keypad or the keypad is auto- matically displayed on the touch display. Numeric keypad Keypad Deletes space before the Deletes space before the cursor cursor...

  • Page 41: The System Menu

    6 The System Menu The System Menu In the system menu you can make system settings which apply to all measurement channels. The system settings do not affect the measurement! Chapt. 6.1 Chapt. 6.2 Chapt. 6.3 Chapt. 6.4 Chapt. 6.5 Fig.
  • Page 42 6 The System Menu System Menu (Continued) To reach the system menu, click on the top blue bar on the standard display (Fig. 16, Pos. 1).  The System Menu (Fig. 20) is opened. Heading of the main menu Start screen of the system menu Display of the current submenu Button for reaching the respective higher level in the menu Buttons for the submenus...

  • Page 43: Channel Setting

    6 The System Menu Channel Setting In the channel setting submenu, you can set the channel assignment (Fig. 21, Pos. 4) and the measurement method (channel mode) for the different GAMMAcast de- tectors. Measurement not possible!  There are two methods of measurement. Set the method accord- Attention ing to the detectors you are using: ...

  • Page 44: Channel Names

    6 The System Menu 6.1.1 Channel Names A name can be assigned to each of the four measurement channels. This name is imported into the standard display and is used for all service files when they are exported. Click in the System menu on <Settings | Channel Settings | Channel Names>...

  • Page 45: Settings

    6 The System Menu Settings In the System Menu, click on <Settings> (Fig. 20, Pos. 5), in order to reach the Settings submenu.  The submenu Settings is opened (Fig. 23). Button submenus Fig. 23 System menu, Settings In the <Settings>...

  • Page 46: Setting The Date/Time

    6 The System Menu 6.2.1 Setting the Date/Time The date and time must always be set correctly so that all records (log files) have the right metadata. Note In the System Menu | Settings, click on <Date/Time>, to reach the Date/Time submenu (Fig.
  • Page 47 6 The System Menu Setting the Date Arrow keys for changing the month Selection of the day Selection of the current day Fig. 25 System menu, Settings - Set Date Set the month (Fig. 25, Pos. 1) by clicking on the arrow keys. Set the day (Fig.
  • Page 48 6 The System Menu Setting the Time In the "Time" display field, click on (Fig. 26, Pos. 1) the time unit (hours, minutes, seconds), which you want to change. Change the time by clicking on the arrow keys (Fig. 26, Pos. 1). Arrow keys for changing the time Fig.

  • Page 49: Applying Network Settings

    6 The System Menu 6.2.2 Applying Network Settings In the network settings submenu, you can make changes to the network settings. DHCP check box active Apply button Display of MAC address TCP/IP submenu button Fig. 27 System Menu, Settings - TCP/IP In the event of an automatic assignment of the IP address by a DHCP server, you can only look at the given IP address.
  • Page 50 6 The System Menu Applying Network Settings (Continued) No communication via the remote control software! The EVU cannot be accessed via the RC software. Note  If have tick next <DHCP active> (Fig. 27, Pos. 1), then check your applied network settings! In the System Menu | Settings click on...

  • Page 51: Display

    6 The System Menu 6.2.3 Display Cursor visible "inactive" Button for adoption of settings Button for touch display calibration menu Display of the start screen after X s Switching off of the display after X s Display submenu button Fig. 29 System Menu.
  • Page 52 6 The System Menu The following settings described "Switch off display", "Leave menu" and "Cursor visible" can all be applied at the same time. This way, it is only necessary to restart the EVU once. Note 6.2.3.1 Calibrate Touch Display The calibration may only be carried out with direct skin contact.

  • Page 53: Setting Language

    6 The System Menu 6.2.4 Setting Language In the System Menu | Settings click on <Language>, to change the menu language. (Fig. 23, Pos. 1). Click on the drop-down menu "Language" (Fig. 31, Pos. 2), to select the de- sired language. ...
  • Page 54 6 The System Menu Setting Language (Continued) The standard languages Bulgarian, German, English, French, Italian, Portuguese, Romanian, Russian, Spanish, Czech and Hungarian are al- ways installed. Note These can be supplemented by the following languages: Korean or Chinese The installation of these language packages is carried out using the control unit software update.

  • Page 55: Setting Dimensions And Temperature Unit

    6 The System Menu 6.2.5 Setting Dimensions and Temperature Unit In the System Menu | Settings click on <Units>, to change the measurement unit. (Fig. 32, Pos 3). Click on the drop-down menu "Fill Level" (Fig. 32, Pos. 1), to select the de- sired measurement unit.

  • Page 56: Data Log

    6 The System Menu Data Log In the System Menu, click on <Data Log> (Fig. 20, Pos. 5). 6.3.1 Graph In the Graph submenu, the interval used for visualising the log data in the channel overview is set. In the System Menu | Data Log , click on Graph...

  • Page 57: Data Logger

    6 The System Menu Graph (Continued) In the "log interval" input field, set the interval in which the log data is to be saved (Fig. 33, Pos. 2). The smallest log interval which can be set is 0.5 s. Note Click on the input field to set the log interval (Fig.
  • Page 58 6 The System Menu Data Logger (Continued) In the System Menu, click on Data Log | Data Logger (Fig. 33, Pos. 3) to reach the Data Logger submenu. Data log check box active Apply button Display of the storage space available on the SD card Display of data log recording time Log interval input field Data logger submenu...
  • Page 59 6 The System Menu Data Logger (Continued) Log Interval Shows the log data saving interval (Fig. 34, Pos. 5) Maximum Log Time Shows the maximum log data saving interval de- pending on the set log interval and the SD card storage capacity (Fig.

  • Page 60: Network Logger

    6 The System Menu Exporting Measurements (Continued) In the "Measurements" submenu you can adjust the following settings: Last export Displays the date and time of the last export (Fig. 35, Pos. 1). Export from last time on- Export of the current data log (Fig. 35, Pos. 5). wards Export all Exports the entire data log...
  • Page 61 6 The System Menu Network Logger (Continued) In the "Network Logger" submenu, you can transmit log data to a computer. The fill level signal transmitted via the Ethernet is intended only for quality assurance purposes. Process regulation is not possible with this signal.
  • Page 62 6 The System Menu 6.3.3.1 Use of the Software "Data Log Viewer" With the separately delivered software "Data Log Viewer" from BERTHOLD TECH- NOLOGIES, the visualisation and saving of the log data on a computer is possible. Display of the calibration curve...
  • Page 63 6 The System Menu 6.3.3.2 Establishing Connection and Saving Data Log Button for starting data log recording Button for stopping data log recording Display of log data storage location Button for selecting storage location Display of the log interval Display of the time of the last save Display of the storage space available on the hard drive Display of the data log file name Fig.
  • Page 64 6 The System Menu Establishing Connection and Saving Data Log (Continued) Enter the EVU IP address in the input field (Fig. 37, Pos. 6). Click on <Connect>to establish a connection (Fig. 37, Pos. 7). Click on the <Select Saving Location> (Fig.

  • Page 65: Service Submenu

    6 The System Menu Service Submenu In the Service Submenu you can adjust the following settings and read information:  Downloading of the Remote Control Software (RC Software)  Carrying out of Updates for: the control unit the measurement of channels the detectors ...

  • Page 66: Remote Control Software

    6 The System Menu Service Submenu (Continued) Stick the USB stick into the USB port of the front panel (Fig.1, Pos. 1).  The two buttons appear with black lettering and are active. 6.4.1 Remote Control Software The check mark must be set to "Active" in order for the Remote Con- trol to function (Fig.

  • Page 67: Export Complete Service Data

    6 The System Menu Remote Control Software (Continued) Click on the <File> tab then on <Connect…>to establish a connection to the EVU.  A new window "Connect" opens (Fig. 40). Enter the EVU IP address into the input field. You can find out where you can read the IP address in chapt.

  • Page 68: Software Update

    6 The System Menu 6.4.3 Software update In the "Information" submenu, information about the installed modules and the software installed on them is given. All updates are carried out via this page. Data loss during the measurement! The measurement is interrupted during a software update. Note ...
  • Page 69 6 The System Menu 6.4.3.1 Software Update Control Unit Update files for the control unit begin with LB452CU and end with .btw. Note Connect the USB flash drive with files to be installed to the USB port of the front panel (Fig.1, Pos. 3). In the System menu click on...
  • Page 70 6 The System Menu Software Update Control Unit (Continued) Button for control unit update Display update file Fig. 43 System Menu, Service - Information (Control unit update) Select the appropriate update file (Fig. 43, Pos. 2). Click on <Update> (Fig. 43, Pos. 1). ...
  • Page 71 6 The System Menu 6.4.3.2 Measurement Channels Software Update Update files for the measurement channels start with LB452MU and end with .bta. Note Display the measurement channels' software version Update button Display update file Fig. 44 System Menu, Service - Information (Measurement channels update) In the System menu click on...
  • Page 72 6 The System Menu Software Update Measurement Channels (Continued) Fig. 45 System Menu, Service - Information (Measurement channels update)  The software update is carried out.  After a successful update, the message "Programming finished" appears. Click on <OK>to finish the update process. ...
  • Page 73 6 The System Menu 6.4.3.3 GAMMAcast Detectors Software Update Update files for the GAMMAcast detectors start with LB67XX and end with .bta. Note Display the software version of the detector Update button Update file Fig. 46 System Menu, Service - Information (GAMMAcast detector update) Click on Service | Information (Fig.

  • Page 74: Access Level

    You can change all data necessary for operation (e.g. filter, calibration). User Level Admin This user level is only intended for system adminis- trators of the company BERTHOLD TECHNOLO- GIES. Automatic log out The access level Standard is automatically reset to...
  • Page 75 6 The System Menu Access Level (Continued) Damage to the device! Damage due to incorrect operation! Attention Incorrect measurement and calibration parameters can be set through unauthorised inputs. These can possibly lead to production losses and damage in the system. ...
  • Page 76 6 The System Menu Access Level (Continued) Click in the "Password" input field to create a password or to change it.  The keypad opens. Enter a password and confirm your entry with ENTER. (Fig. 18, Pos. 4). Click on <OK>to finish the password entry. Rev.

  • Page 77: Channel Overview" Menu

    7 "Channel Overview" Menu "Channel Overview" Menu In the channel overview, you can set values relating to the measurement task. In Fig. 48, the menu structure of the "Channel Overview" menu is represented. see the detector or the LB-452 EC manual Chapt.
  • Page 78 7 "Channel Overview" Menu "Channel Overview" Menu (Continued) Click on <Channel XY> in the standard display (Fig. 16, Pos. 1) to reach the "Chan- nel Overview" menu. Display of the detector value and the calibration curve in time progression Display of the error code Display of the error message Full adjustment button Empty adjustment button...
  • Page 79 7 "Channel Overview" Menu "Channel Overview" Menu (Continued) "System Status" Display Field: The "System Status" display field shows you the current status of the EVU. All castX- pert LB 452 errors have the prefix "M", all GAMMAcast LB67xx errors the prefix "D".
  • Page 80 7 "Channel Overview" Menu "Channel Overview" Menu (Continued) Troubleshooting The error number (or warning) is displayed on each side of the channel menu above right under the status indicator (red/orange) is displayed. If you click on the error number, a pop-up message appears. Here you can con- firm/acknowledge the error.

  • Page 81: Empty And Full Adjustment

     Empty adjustment (always necessary)  Full adjustment with cold block (recommended) BERTHOLD TECHNOLOGIES recommends that the adjustment mode be set to "dynamic" (Fig. 55, Pos. 5) if only an empty adjustment is carried out before casting. Note If both an empty and a full adjustment are carried out, the recom- mended mode is "fixed".
  • Page 82 7 "Channel Overview" Menu Button for "Channel Overview" menu Fig. 51 Start page with a channel Empty adjustment button Full adjustment button Fig. 52 Menu "Channel Overview", Adjust Rev. 04, 03/2015...
  • Page 83 7 "Channel Overview" Menu Empty and Full Adjustment (Continued) Click on <Empty Adjustment> to carry out an empty adjustment (reading in the 0% value) (Fig. 52, Pos. 1). Alternatively, you can close digital input 1. In this case, no confirmation message opens and the empty adjustment can be started directly from the casting platform.
  • Page 84 7 "Channel Overview" Menu Empty and Full Adjustment (Continued) Display field "Stop Condition" The device is in test mode FUL/ETY A calibration routine is running in the device: FUL: Full adjustment ETY: Empty adjustment The evaluation unit is in the "empty adjustment" mode as long as the abbreviation "ETY"...

  • Page 85: Settings

    7 "Channel Overview" Menu Settings The following information can be seen in the "Settings" submenu: Active Settings Display of the selected calibration curve and settings (Fig. 54, Pos. 9) Calibration Display of adjustment mode (Fig. 54, Pos. 1) Display of the latest change to the calibration settings (Fig.
  • Page 86 7 "Channel Overview" Menu Settings (Continued) In the "Channel Overview" menu, click on <Settings> (Fig. 49, Pos. 8), in order to reach the "Settings" submenu. Display of the adjustment mode Display of the latest changes to the calibration Display of the calibration curve Display of the time constant Display of the start-up time constant Display of the start threshold...

  • Page 87: Calibration

    7 "Channel Overview" Menu 7.2.1 Calibration In the "Channel Overview" menu, click on Settings | Calibration (Fig. in order to reach the "Calibration" submenu. Display of the background level Button for changing the background level Button for deleting, adding or changing a calibration point Measurement range input field Entry and display of properties Display of the calibration point - Fill level 50%...
  • Page 88 Two different modes are available for calculat- ing the new calibration curve (Fig. 55, Pos. 5): BERTHOLD TECHNOLOGIES recommends that the calibration mode be set to "dynamic" (Fig. 55, Pos. 5) if only an empty calibration is carried out before casting.
  • Page 89 7 "Channel Overview" Menu 7.2.1.1 Adding and Changing Calibration Points For correct calibration, at least two points (usually 0% and 100%) are required. An empty mould and a mould with a cold block are usually used to determine the count rate at 0% or 100% fill level. In order to increase the accuracy of the measurements, the natural background radiation (background level) can be offset.
  • Page 90 7 "Channel Overview" Menu Adding and Changing Calibration Points (Continued) Input field OK button Read button Fig. 56 System Menu, Settings - Calibration (Adapt Calibration Point) When you add a new point, click on the input field "Fill Level" (Fig. 56, Pos. 1) and enter the corresponding fill level (e.g.
  • Page 91 7 "Channel Overview" Menu Adding and Changing Calibration Points (Continued) Display of calibration mode Read-in value input field Cancel read-in button Fig. 57 System Menu, Settings - Calibration (reading in calibration point)  The EVU is in "Calibration (CAL)" mode (Display in Fig. 57, Pos. 1), as long as calibration is being carried out.
  • Page 92 7 "Channel Overview" Menu 7.2.1.2 Setting of the Background Level Click in the "Channel Overview" menu | Settings | Calibration (Fig. 54, Pos. 2).  The "Background Level" menu opens (Fig. 58). Background radiation input field Apply button Standard button Read in button Fig.
  • Page 93 7 "Channel Overview" Menu 7.2.1.3 Plausibility In the "Channel Overview" menu click on Calibration | Plausibility (Fig. 59, Pos. Plausibility submenu button Fig. 59 "Channel Overview" Menu, Settings - Calibration (Plausibility) In the "Plausibility" menu, the applied settings can be examined. If the settings are not plausible, an error is triggered.
  • Page 94 7 "Channel Overview" Menu Plausibility (Continued) Maximum Read-in time Maximum time waited when reading in a count rate during calibration or an adjustment. A minor average value error results if the time is longer. Read-in Statistic Thresh- The reading in of a count rate during calibration or an adjustment is cancelled as soon as this statis- tical variation limit of the count rate is fallen short 7.2.1.4...

  • Page 95: Filter

    7 "Channel Overview" Menu Test (Continued) Click in the input field (Fig. 60, Pos. 3).  The numeric keypad opens (Fig. 18). Enter a test count rate. Confirm your entry by clicking on "Enter".  The test mode is started (Fig. 60, Pos. 1). Click on <End test mode>to end the test.
  • Page 96 7 "Channel Overview" Menu Filter (Continued) In the "Filter" submenu, you can set the time constants for filtering the gross count rate and settings for the start mode. The Setting of Two Differ- The setting of the time constant helps to balance ent Time Constants: out statistical variations, mainly from the statistical nuclear decay of the radionuclide.

  • Page 97: Alarms

    7 "Channel Overview" Menu 7.2.3 Alarms The submenu "Alarms" is only displayed if an extension module is installed. Note In the "Channel Overview" menu click on Settings | Alarms (Fig. 54). Fig. 62 "Channel Overview" Menu, Settings - Alarms In the "Alarms" submenu, you can change the values for the fill level alarms (max. and min.) and the hysteresis of these.

  • Page 98: Option/Display

    7 "Channel Overview" Menu 7.2.4 Option/Display In the "Channel Overview" menu click on Settings | Select/Display (Fig. 54). Use setting button "Use digital input" check box "Use fieldbus" check box Drop-down menu for selecting a calibration curve Fig. 63 "Channel Overview" Menu, Settings- Select/Display In the "Select/Display"...

  • Page 99: In/Outputs

    7 "Channel Overview" Menu Select/Display (Continued) The selection works through the digital inputs as is described in the following: Select Digital Input 3 Digital Input 4 Calibration curve open open closed open open closed closed closed In/Outputs In the "Channel Overview" menuclick on <In/Outputs>...

  • Page 100: Analog Io

    (not included in the delivery contents), which is to be connected to the relevant current output. Note BERTHOLD TECHNOLOGIES recommends calibrating the current out- puts whenever a module has been installed/replaced or if a software update has been carried out.
  • Page 101 7 "Channel Overview" Menu 7.3.1.1 Setting of the Current Outputs In the "Channel Overview" menu, click on e.g. In/Outputs | Analogue IO | Current Output 2 (Fig. 65, Pos. 8). 0% fill level input field 100% fill level input field Time constant input field Error mode drop-down menu Monitoring drop-down menu...
  • Page 102 7 "Channel Overview" Menu Setting of the Current Outputs (Continued) You have the following options for configuring the current outputs: Range The current output signal is between 4 mA and 20 mA. The cor- responding values (e.g. fill level) can be freely assigned. Lower value: The lower value is the value at a current output signal of 4 mA.
  • Page 103 7 "Channel Overview" Menu Setting of the Current Outputs (Continued) Do not activate the "monitoring" (Fig. 65, Pos. 5) until the measure- ment has been fully wired. By doing so you will avoid the error alarm. Note Monitoring If the "monitoring" is activated, the current output will be monitored.
  • Page 104 7 "Channel Overview" Menu 7.3.1.2 Calibration of the Current Outputs Before calibrating the current outputs, connect an ammeter (not included in the delivery contents) to the relevant current output. Click on <Calibration> (Fig. 65, Pos. 7).  A confirmation message opens. Click on <Next>in the confirmation message.
  • Page 105 7 "Channel Overview" Menu 7.3.1.3 Test In the "Test" submenu, you can enter your own current value for the sake of the test (Fig. 66, Pos. 4). As long as this test current is in effect, the background of the input field will be shown in red.

  • Page 106: Digital Io

    7 "Channel Overview" Menu Test (Continued) If the entered value is accepted, the background of the input field will be shown in red. In the "Actual" field, the read-back current which is also used for the current output monitoring is displayed. If the conductor loop is not closed, no real meas- ured value will be displayed.
  • Page 107 7 "Channel Overview" Menu Alarm Relay (Continued) In the "Channel Overview" menu click on In/Outputs | Digital IO | Alarm Relay (Fig. 67, Pos. 2), to reach the Alarm Relay submenu. Assignment of alarm relay 1 drop-down menu Assignment of alarm relay 2 drop-down menu Fig.
  • Page 108 7 "Channel Overview" Menu Alarm Relay (Continued) The alarm relay 1 is a contact (SPDT). The behaviour of alarm relay 1 can be freely configured ("CLOSED", i.e. switching to the normally-open contact or "OPEN", Note i.e. the normally-closed contact, in the case of an alarm). Behavior for software versions earlier than 1.2.0: The relay always closes in the event of an alarm, i.e.
  • Page 109 7 "Channel Overview" Menu 7.3.2.2 Test In the "Test" submenu, you can change the states of the relay outputs for the sake of the test. Green background area = current state Red background area = manually switched state (test mode) The digital inputs cannot be configured.
  • Page 110 7 "Channel Overview" Menu Test (Continued) Digital Outputs CLOSED= Relay energised OPEN= Relay de-energised Digital inputs CLOSED= Terminals connected OPEN = Terminals not connected Click on the "Error Relay" drop-down menu, to switch the error relay man- ually (Fig. 69, Pos. 1). Click on the "Alarm Relay 1"...
  • Page 111 7 "Channel Overview" Menu 7.3.2.3 Fieldbus The "Fieldbus" submenu only appears if a Fieldbus module has been installed. For the installation of a Fieldbus module, see chapt. 9.1.2. To be able to use the Fieldbus module, you must install the provided GSD file in the process control system.

  • Page 112: Error

    7 "Channel Overview" Menu Error In the "Channel Overview" menu, click on <Error> (Fig. 49, Pos. 8). Display the error history Fig. 71 "Channel Overview" Menu, Error In the "Error" submenu, you can view the following information: Current Displays the current error message and the error code. History Displays the error history with the error message and the error codes.

  • Page 113: Overview

    7 "Channel Overview" Menu 7.4.1 Overview In the "Channel Overview" menu, click on Error | Overview to reach the Overview submenu (Fig. 72, Pos. 2). Display of the error details of the error messages Overview submenu button Fig. 72 "Channel Overview" Menu, Error Overview In the Overview submenu, you can find a detailed error list (Fig.

  • Page 114: Service

    7 "Channel Overview" Menu Service In the Service submenu you have the following options:  Exporting service data onto a USB flash drive. Service data includes:  The change log  The error log  The production data  Resetting of the channel settings to factory setting (calibrating, time constants, alarms thresholds, etc.) ...

  • Page 115: Exporting Service Data

    7 "Channel Overview" Menu 7.5.1 Exporting Service Data <Export Service Data> button becomes active if you connect a USB flash drive to the front panel. Note Click on <Export Service Data> (Fig. 73, Pos. 3).  The warning window opens automatically. Confirm the warning by clicking on <OK>.

  • Page 116: Change Log

    7 "Channel Overview" Menu 7.5.2 Change log In the Change Log submenu you can view all the applied settings. In the "Channel Overview" menu click on Service | Change log to reach the Change Log submenu (Fig. 75, Pos. 2) ...

  • Page 117: Backup

    7 "Channel Overview" Menu 7.5.3 Backup The "Backup" submenu offers you the following options:  Backing up the settings on a USB flash drive.  Restoring of settings on a USB flash drive. Backing up the settings is always recommended to ensure quality and so original settings can be restored in the event of an emergency.
  • Page 118 7 "Channel Overview" Menu Backup (Continued) Connect a USB flash drive to the USB port of the EVU front panel (Fig.1, Pos. 3). Click on <Backup Settings> Fig. 76, Pos. 1).  A confirmation message with the command to wait opens. Fig.
  • Page 119 7 "Channel Overview" Menu Restore Connect a USB flash drive to the USB port of the EVU front panel (Fig.1, Pos. 3). 10. Click on <Restore Settings> (Fig. 76, Pos. 2).  A window for selecting files opens. 11. Select a file and begin the restoration. ...

  • Page 121: Troubleshooting

    8 Troubleshooting Troubleshooting Error Search Problem Cause Measure  Check power supply and fuses; is No signal EVU does not work LED 1 blinking on the display?  Check the functioning of the detec- No signal Detector does not work ...

  • Page 122: Error Codes Of The Evaluation Unit

    Error Codes of the Evaluation Unit In the following tables you can find the EVU error codes which give you exact in- formation on how to fix them. All castXpert LB 452 errors have the prefix "M", all GAMMAcast LB67xx errors the prefix "D".

  • Page 123: Main Board

    8 Troubleshooting 8.2.2 Main board Code Text Description Correction Class  Contact service Monitoring The monitoring ADC (Analogue Error Digital Converter) has failed Hardware error  Contact service Error while calibrating the ADC Error Calibration  Contact service 24 V failure Faulty 24 V operating voltage Error Hardware error...

  • Page 124: Application

    8 Troubleshooting 8.2.3 Application Code Text Description Correction Class  Check calibration table Calibration Calibration curve not mono- Error not monotonic tonic  Check calibration table Background Background count rate larger Error too high than smallest occurring calibra-  Check background tion point count rate ...

  • Page 125: Gammacast Control

    8 Troubleshooting 8.2.4 GAMMAcast Control Code Text Description Correction Class  Connect a GAMMAcast No detector No compatible GAMMAcast de- Error found tector found detector  Ensure the correct ca- bling is in place  Carry out software up- date ...

  • Page 126: Process Connection

    8 Troubleshooting 8.2.5 Process Connection Code Text Description Correction Class  Calibrate current out- Current out- Faulty current output on the Warning basic module  Contact service  Check cabling on cur- Current out- Current output on the basic Warning put loop open module not closed rent output side...

  • Page 127: Maintenance

    9 Maintenance Maintenance In the maintenance chapter, the installation of modules, the replacing of fuses and the cleaning of the EVU are described. Installation of Modules Danger to life from electric shock! The installation may only be carried out by a qualified electrician. D a n g e r Exposed live parts in the device interior.
  • Page 128 9 Maintenance Installation of Modules (Continued) Card slot with extension module Card slot with basic module Card slot for fieldbus module Control unit with SD card slot SD card slot Front panel folded out Fig. 78 Front view in the open device Rev.
  • Page 129 9 Maintenance Installation of Modules (Continued) Extension module Flat ribbon cable Basic module Bus module System board (control unit) with SD card slot Fig. 79 Overview of the Modules Rev. 04, 03/2015...

  • Page 130: Installation Of The Basic Module/Extension Module

    9 Maintenance 9.1.1 Installation of the Basic Module/Extension Module Damage to the device! Short circuit Attention  Install the module in the correct card slot!  Please always observe the prescribed sequence when installing modules! If an extension module is to be installed, it must be connected with the basic card via the flat ribbon cable before the installation.

  • Page 131: Installation Of The Fieldbus Module

    9 Maintenance 9.1.2 Installation of the Fieldbus Module Damage to the device! Short circuit Attention  Install the module in the correct card slot!  Please always observe the prescribed sequence when installing modules! Device is not recognized! Limited range of functions Note ...
  • Page 132 9 Maintenance Fieldbus Module Installation (Continued) Aperture on the main circuit board Fig. 80 EVU LB 452, main circuit board Separate and remove the four hold points of the aperture on the pre-punched, green main circuit board with a wirer cutter (Fig. 55, Pos. 1). Connect the module with the flat ribbon cable again (included in delivery con- tents) (Fig.

  • Page 133: Replacing Of Fuses

    9 Maintenance Replacing of Fuses Damage to the device! Short circuit! The modules can be damaged if the wrong fuses are used. Attention  Only use fuses which correspond to the fuses on the modules. Two different types of fuses are used in the EVU. These fuse the individual modules and mains inlets: The two mains fuses Si1 and Si2 on the basic module fuse the cur-...

  • Page 134: Replacing Of Basic Module Fuse

    9 Maintenance Replacing of Fuses (Continued) The two mains fuses Si1 and Si2 on the system board fuse the power supply unit. If there is a defect in the fuses, no power is supplied to the EVU. System Board 9.2.1 Replacing of Basic Module Fuse Disconnect the EVU voltage.

  • Page 135: Replacing Of Extension Module Fuse

    9 Maintenance Replacing of Basic Module Fuse (Continued) Fuse Fuse with plastic covering Fig. 81 Basic module fuses Fit the new fuses into the basic module with the contacts and the cavities provided. 10. Connect the basic module if need be to the extension or fieldbus module with flat ribbon cables.
  • Page 136 9 Maintenance Replacing of Extension Module Fuse (Continued) Fuses Fig. 1 Extension Module Fuses Fit the new fuses into the extension module with the contacts and the cavi- ties provided. Connect the extension module to the basic module again with the flat rib- bon cable.

  • Page 137: Cleaning

    9 Maintenance Cleaning Damage to the touch display! Solvents and abrasive agents can damage the touch display. Attention  Only clean the touch display with a wet cloth.  Only clean the EVU with a dry cloth or a dusting brush. ...

  • Page 139: Decommissioning

    10 Decommissioning Decommissioning Danger of death by electric shock Decommissioning may only be carried out by qualified electricans.. D a n g e r  All relevant safety regulations have to be observed.  Decomissioning may only be carried out if the device has been de-energised.
  • Page 140 10 Decommissioning Rev. 04, 03/2015...

  • Page 141: Technical Information

    11 Technical Information Technical Information c LB 452: Technical Data 11.1 Mechanical Design Frame 19" Rack, 3 HE Operating unit with 7 inch colour display and touch screen Max. Assembly 4 measurement channels Weight approx. 4-6 kg depending on assembly Degree of IP 20 protection...
  • Page 142 11 Technical Information Extension- 4-20 mA current output with option of activating current output signal Module monitoring: (Option) potential-free Adjustable fault current in the event of an error: 2 mA, 22 mA or freezing of last value Can be configured for: Fill level (additional time constant, freely adjustable) Detector temperature Detector count...
  • Page 143 11 Technical Information Entire System Software Data entry via touch screen Operating languages: Bulgarian, Chinese (option), German, English, French, Italian, Korean (option), Portuguese, Romanian, Russian, Spanish, Czech, Hungarian Cycle time: 0.005 s (5 ms) Two time constants for filtering the raw signal: Lower measurement range: Fast reaction Upper measurement range: Calm signal Change-over point freely definable...

  • Page 144: Lb 452: Inside Overview

    11 Technical Information c LB 452: Inside Overview 11.2 50502-01-S Extension Module 50498-01-S Basic Module 53799-S (Card slot for) bus module 53772-S System board (control Unit) with SD Card slot 53779-S Front panel with display Rev. 04, 03/2015...

  • Page 145: Lb 452: Replacement Parts List

    11 Technical Information c LB 452: Replacement Parts List 11.3 Replacement parts castXpert LB 452 53779-S Front panel with display for castXpert LB 452 53772-S System-control unit for castXpert LB 452 Rev. 04, 03/2015...

  • Page 146: Lb 452 Connections: Rear Overview

    11 Technical Information c LB 452 Connections: Rear Overview 11.4 Rev. 04, 03/2015...

  • Page 147: Lb 452 Connections: Measuring Channel Base Module

    11 Technical Information c LB 452 Connections: Measuring channel base 11.5 module Rev. 04, 03/2015...

  • Page 148: Lb 452 Connections: Measurement Channel Extension Module

    11 Technical Information c LB 452 Connections: Measurement ChannelEx- 11.6 tension Module Rev. 04, 03/2015...

  • Page 149: Data Definition Profibus Dp

    11 Technical Information 11.7 Data Definition Profibus DP Cyclic Output Data Variable Description Type Size name Mould Level Current Mould Level unit: %/mm/inch (selectable) Float 32 Bit Detector Current Detector Raw Value unit: GAMMAcast - Float 32 Bit Raw Value Pulses per Second (CPS) ECcast –...
  • Page 150 11 Technical Information Cyclical Input Data Variable Description Type Size Name Calibration Currently used calibration [0 ... 7] (decimal) Byte 8 Bit Index (Calibration curve, alarm thresholds, time constant, etc.) Function Unsigned 32 Bit By writing a number in this field, functions on the EVU Actuation Integer can be actuated:...

  • Page 151: Declaration Of Conformity

    12 Declaration of Conformity Declaration of Conformity Rev. 04, 03/2015...
  • Page 152 12 Declaration of Conformity Rev. 04, 03/2015...

  • Page 153: Index

    13 Index Index Access Level ..........74, 75, 76 Test Count Rate ..........94 Basic ..............74 Display Change Password ..........76 Calibrating the Touch Display ......51 Standard ............74 Cursor visible ........... 51 Alarm Relay ............107 Leaving the menu ........... 51 Alarms Switch Off Display ...........
  • Page 154 13 Index Measurement System Export Service Data ........115 Components ............ 20 Factory setting..........114 Measurement Set-up........20 Restore Settings..........119 Measuring Channel Service Backup of Settings........ 117 Software Update ..........71 Setting background level........92 Menu Channel Overview Settings System Status..........
  • Page 155 13 Index Rev. 04, 03/2015...
  • Page 156 Modifications due to technical advancement reserved. © BERTHOLD TECHNOLOGIES GmbH & Co. KG Language: English Printed in Germany 04.2015 Rev.-No.: 04 BERTHOLD TECHNOLOGIES GmbH & Co. KG Calmbacher Str. 22 75323 Bad Wildbad Germany www.Berthold.com Id.-No. 47344BA2...

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