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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.: 05, 05/2019
Embedded Software as of vers. 1.5.1 (CU) and 1.5.1 (MU)

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Summary of Contents for Berthold castxpert LB 452

  • Page 1 Evaluation unit LB 452 Operating Manual 47344BA2 Rev. No.: 05, 05/2019 Embedded Software as of vers. 1.5.1 (CU) and 1.5.1 (MU)
  • Page 2 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 3: Table Of Contents

    LB 452 1 About this Manual Table of Contents About this Manual ....................5 Some Prior Remarks...................... 5 Storage Place ........................ 5 Target Group ........................ 5 Validity of the Operating Manual ................6 Structure of the Manual ....................6 Copyright ........................6 Target Group ........................
  • Page 4 1 About this Manual LB 452 6.4.2 Data Logger ........................ 53 6.4.3 Network Logger ......................55 Service Submenu......................59 6.5.1 Remote Control Software ..................60 6.5.2 Export Complete Service Data ................... 61 6.5.3 Software update ......................62 Access Level ......................... 68 Menu Channel Overview ..................

  • Page 5: About This Manual

    Some Prior Remarks The product is handed over to you by the manufacturer BERTHOLD TECHNOLOGIES GmbH & Co. KG (designated as Berthold in the following) in a complete and func- tionally reliable condition. This manual demonstrates to you how to: ·...

  • Page 6: Validity Of The Operating Manual

    LB 452 Validity of the Operating Manual The operating manual is valid from the delivery of the Berthold product to the user until its disposal. Version and release date of this operating manual can be found in the bottom of each page. Modification services are not performed by the man- ufacturer Berthold.

  • Page 7: Warning Notes

    LB 452 1 About this Manual Warning notes Warning notes are designed as follows: Signal Word Source and consequence Explanation, if required Prevention In case of emergency… Warning symbols: (warning triangle) draws attention to the hazard. Signal word: Indicates the severity of danger. Source: Specifies the type or source of danger.

  • Page 8: Symbols Used On The Device

    1 About this Manual LB 452 1.9.2 Symbols Used on the Device Read the operating manual Please observe the instructions in this operating manual. Electrostatic discharge Please note the handling instructions. Electrostatically endangered components. Please observe the instructions in this operating manual. Protective earth connection At this position, connect the protective earth conductor (PE).

  • Page 9: Conformity

    Berthold, complies with relevant EU directives stated in the original declaration of conformity. This statement shall become void in the case of changes not authorised by Berthold or improper use. For the original declaration of conformity, please refer to Declaration of Conform- ity in the appendix “Technical Information”.

  • Page 10: Safety

    2 Safety LB 452 Safety Dangers and safety measures · Read these instructions thoroughly and completely before working with the product. · Store the instructions where they are accessible for all users at all times. Proper use The LB 452 evaluation unit (EVU) measures the fill level along with compatible de- tectors, a compatible radiation source and a compatible radiation source and it may only be used for this purpose.

  • Page 11: 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 / guaran- tee the correspondence of the device to its publicised specifications.
  • Page 12 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 for par- ticular tasks. When dealing with radioactive materials, a radiation safety officer must also be consulted.

  • Page 13: Product Description

    LB 452 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 basic module (channel 1). The EVU can be distributed with up to 4 basic modules (channels). This makes the simultaneous monitoring of 4 mould levels possible.

  • Page 14: Overview

    3 Product Description LB 452 Overview Front View On the front view of the EVU there are LEDs for displaying each operation mode, a 7’’ touch display, and a USB port. Operation mode indicators 7'' Touch display USB port for the connection of external devices, covered with a protective cap Fig.1 Front view of the EVU Control Unit Indicators...

  • Page 15: Back View

    LB 452 3 Product Description This LED (Fig. 2) lights up if an error has occurred. The actual Error LED measurement is retained. Check the device settings. All possible error reports are described in chapt. 8 Troubleshooting. This LED (Fig. 2) lights up if calibration is being carried out or Warning LED if the device is in test mode or if any other warning message is present.
  • Page 16 3 Product Description LB 452 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 17: Radiometric Measurement System

    LB 452 3 Product Description Radiometric Measurement System 3.5.1 Functional Principle For the radiometric principle, the weakening of the 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 detector and continually measures the fill level of the mould of a casting plant.

  • Page 18: Measurement System Components/Measurement Setup

    3 Product Description LB 452 3.5.2 Measurement System Components/Measurement Setup The measurement system is made up of the following components: · castXpert LB 452 evaluation unit (EVU) · A compatible detector · Radiation Source/Mould Level Shielding Fill level Beam path...
  • Page 19 LB 452 3 Product Description NOTICE Further information on the functional principle of the detectors can be found in the manual for the corresponding detector type detectors. Each active measurement channel consists of at least one basic module. This is in- dispensable for operating the EVU.

  • Page 20: Start-Up

    In general, we would recommend that you have the start-up carried out by the service of the company Berthold. IMPORTANT When operating the EVU, you must adhere to the manual "Mould Level Shieldings". Berthold recommends building a separate power connection for each meas- urement channel (Fig. 3). 47344BA2 Rev.05, 05/2019...
  • Page 21 LB 452 4 Start-Up The advantages of a separate power connection for each measurement channel are: Each measurement channel is supplied by its own Functional reliability in voltage source. the event of surges or short circuits If there is a fault in the power supply for one Redundancy strand, the other measurements can still be carried out without interference.
  • Page 22 4 Start-Up LB 452 Fig. 7 External power supply of the measurement channel, measurement channel 1 as example. Connect the detector to a terminal box or directly to the EVU with the spe- cial cable (in accordance with the local conditions). Connect the EVU to the terminal box if needed.

  • Page 23: The Use Of A Terminal Box

    LB 452 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 detectors and the EVU are to be connected via the terminal box. This connec- tion is to be made with a standard 6–wire shielded cable (6 x 0.5 mm²) with a max- imum length of up to 1000 m.

  • Page 24: Configuring The Current Output

    4 Start-Up LB 452 Configuring the Current Output DANGER Danger to life from electric shock! The installation may only be carried out by a qualified electrician. Please adhere to the relevant safety regulations. Only carry out maintenance work when the device is free of voltage. In case of an electric shock, carry out first aid measures and immediately call an emergency service.

  • Page 25: Configuring The Current Output On The Basic Module

    LB 452 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 26 4 Start-Up LB 452 Approach the configuration of the current output as follows: DANGER Danger to life from electric shock! The installation may only be carried out by a qualified electrician. Only open the device when free of voltage. In case of an electric shock, carry out first aid measures and immediately call an emergency service.
  • Page 27 LB 452 4 Start-Up Set the desired position at the changeover switch (Sink Mode (Fig. 11, Pos.1) or Position Source Mode (Fig. 11, Pos. 2). Basic Module, changeover switch – Position Sink Mode Basic Module, changeover switch – Position Source Mode (factory setting) Fig.

  • Page 28: Configuring The Current Output On Extension Module

    4 Start-Up LB 452 4.3.2 Configuring the Current Output on Extension Module Disconnect the EVU voltage. Loosen the three screws on the front panel (Fig. 10, Pos. 2). Fold down the front panel. Release the modules (Fig. 9, Pos. 3) and pull out the measurement channel at the same time.

  • Page 29: Data Definition Profibus Dp

    LB 452 4 Start-Up Data Definition Profibus DP Cyclic Output Data Variable name Description Type Size Mould Level Current Mould Level unit: %/mm/inch (selectable) Float 32 Bit Detector Current Detector Raw Value unit: Float 32 Bit Raw Value GAMMAcast & CONGAUGE - Pulses per Second (CPS) ECcast –...
  • Page 30 4 Start-Up LB 452 Cyclical Input Data Variable name Description Type Size Calibration Currently used calibration [0 ... 7] (decimal) Byte 8 Bit Index (Calibration curve, alarm thresholds, time constant, etc.) Function By writing a number in this field functions on the EVU Unsigned 32 Bit Actuation...

  • Page 31: Installation/Removal Of An Sd Card

    LB 452 4 Start-Up Installation/Removal of an SD Card NOTICE Material damage to the device or the system! System crashes. Never install or remove an SD card while in running operation. The EVU is supplied with a pre-installed SD card with the possibility of saving data, error reports, and adopted settings.

  • Page 32: Operation Of The Software

    5 Operation of the Software LB 452 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 power supply is connected, the system and the EVU start up.

  • Page 33: Overview Of The Standard Display

    LB 452 5 Operation of the Software Overview of the Standard Display When the system is fully up and running, the start page of the measurement system is displayed (Fig. 15). The display varies depending on which measurement channels are installed. For example, two measurement channels are shown in Fig.
  • Page 34 (Fig. 15, Pos. 5), and the count rate (Fig. 15, Pos. 4). In case of failure, the error or warning number is displayed (Fig. 15, Pos. 6). All castXpert LB 452 error messages have the prefix "M" and all detector error mes- sages have the prefix "D".

  • Page 35: Operation Of The Evu

    LB 452 5 Operation of the Software Operation of the EVU The graphical user interface of the EVU can be operated in multiple ways: · Via the touch display. · With a mouse and a keypad which are connected on the front panel and on the back panel (Fig.1, Pos.
  • Page 36 5 Operation of the Software LB 452 Numeric keypad Keypad Deletes space before the Deletes space before the Cursor Cursor Deletes space after the cursor Deletes space after the cursor Enter - Confirm the input Enter - Confirm the input Input of negative values Shift - Switch between Enter comma...

  • Page 37: The System Menu

    LB 452 6 The System Menu The System Menu In the system menu you can make system settings which apply to all measurement channels. IMPORTANT The system settings do not affect the measurement! Chapt. 6.1 Chapt. 6.2 Chapt. 6.3 Chapt. 6.4 Chapt.
  • Page 38 6 The System Menu LB 452 To reach the system menu, click on the top blue bar on the standard display (Fig. 15, Pos. 1). The System Menu (Fig. 19) 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 39: Channel Setting

    LB 452 6 The System Menu Channel Setting In the channel setting submenu, you can set the channel assignment (Fig. 20, Pos. 4) and the measurement method (channel mode) for the different detectors. NOTICE Measurement not possible! There are three methods of measurement. Set the method according to the detectors you are using: Radiometric in conjunction with the GAMMAcast detectors, which is based on the radiometric method.

  • Page 40: Channel Names

    6 The System Menu LB 452 6.1.1 Channel Names A name can be assigned to each of the four measurement channels. These names are then used in the standard display and used for all service files when exported. In the System menu, click on <Settings | Channel Settings | Channel Names>...

  • Page 41: Calibration Rig

    LB 452 6 The System Menu Calibration Rig The use of a Calibration Rig can be enabled. Click in the System menu on <Calibra- tion Rig> in order to enable the use for a calibration rig. Checkbox “Enabled” Fig. 22 System Menu, Calibration Rig 47344BA2 Rev.05, 05/2019...

  • Page 42: Settings

    6 The System Menu LB 452 Settings In the System Menu, click on <Settings> (Fig. 19, 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 43: Setting The Date/Time

    LB 452 6 The System Menu 6.3.1 Setting the Date/Time IMPORTANT The date and time must always be set correctly so that all records (log files) get the correct time stamp. In the System Menu | Settings, click on <Date/Time>, to reach the Date/Time submenu (Fig.
  • Page 44 6 The System Menu LB 452 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 45 LB 452 6 The System Menu Arrow keys for changing the time Fig. 26 System menu, Settings - Setting the Time Click on <Apply>, to adopt the date and time settings. IMPORTANT All settings applied must be confirmed by clicking on <Apply>, for the settings to become effective.

  • Page 46: Applying Network Settings

    6 The System Menu LB 452 6.3.2 Applying Network Settings In the network settings submenu, you can make changes to the network settings. DHCP check box Apply button Display of MAC address Fig. 27 System Menu, Settings - TCP/IP IMPORTANT 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 47 LB 452 6 The System Menu In the System Menu | Settings click on <TCP/IP> (Fig. 27, Pos. 4), to change the network settings. DHCP inactive Apply button IP address Fig. 28 System Menu, Settings - TCP/IP You can set the network address either manually or using DHCP (automatic assign- ment).

  • Page 48: Display

    6 The System Menu LB 452 6.3.3 Display Cursor visible "inactive" Button for adoption of settings Button for touch display calibration menu Display of the start screen after set seconds Switching off of the display after set seconds Fig. 29 System Menu.
  • Page 49 LB 452 6 The System Menu NOTICE The calibration may only be carried out with direct skin contact. Take gloves or any other protective equipment off your hands. Click on <Calibrate touch pad> (Fig. 29, Pos. 3). The calibration screen opens (Fig. 30). Press the middle of the displayed cross with your finger.

  • Page 50: Setting Language

    6 The System Menu LB 452 6.3.4 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 51: Setting Dimensions And Temperature Unit

    LB 452 6 The System Menu 6.3.5 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 "Level" (Fig. 32, Pos. 1), to select the desired measurement unit.

  • Page 52: Data Log

    6 The System Menu LB 452 Data Log In the System Menu, click on <Data Log> (Fig. 19, Pos. 5). 6.4.1 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...

  • Page 53: Data Logger

    LB 452 6 The System Menu 6.4.2 Data Logger IMPORTANT The Data Logger submenu only appears if an SD card is installed in the control unit. To install or remove the SD card, see chapt. 4.5. In the Data Logger submenu, you have the option of setting the log and to export or delete the measurement values (log data).
  • Page 54 6 The System Menu LB 452 Click on <Apply> to initiate the data log saving (Fig. 34, Pos. 2). The data log is now activated and records the data on the SD card. IMPORTANT The data log is saved in the main directory of the SD card in the form of a .txt file.

  • Page 55: Network Logger

    LB 452 6 The System Menu In the "Data" 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 onwards Export of the current data log (Fig. 35, Pos.
  • Page 56 TCP/IP, please contact Berthold. Use of the Software "Data Log Viewer" With the separately delivered software "Data Log Viewer" from Berthold, the vis- ualisation and saving of the log data on a computer is possible. Display of the process values...
  • Page 57 LB 452 6 The System Menu 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...
  • Page 58 6 The System Menu LB 452 IMPORTANT The Data Log Viewer software is not suitable for parameterising the device. The use of this software is intended for quality assurance purposes. Process regulation is not possible with this signal. 47344BA2 Rev.05, 05/2019...

  • Page 59: Service Submenu

    LB 452 6 The System Menu Service Submenu In the submenu “Service” you can adjust the following settings and read infor- mation: · Downloading of the Remote Control Software (RC Software) · Carrying out Updates for: the control unit the channels the detectors ·...

  • Page 60: Remote Control Software

    6 The System Menu LB 452 6.5.1 Remote Control Software IMPORTANT The check mark must be set to "Enable" in order for the Remote Control to func- tion (Fig. 39, Pos. 1). The IP address of the EVU must be in the same sub-network as the network adapter of the computer (see previous chapter).

  • Page 61: Export Complete Service Data

    LB 452 6 The System Menu 6.5.2 Export Complete Service Data Click on "Complete Service Data Export" to save the service data on the USB flash drive (Fig. 39, Pos. 2). The service data of all installed measurement channels and connected detec- tors are downloaded from the EVU and saved in the main directory of the USB flash drive.

  • Page 62: Software Update

    6 The System Menu LB 452 6.5.3 Software update In the "Information" submenu, information about the installed modules and the software installed is given. All updates are carried out via this page. NOTICE Data loss during the measurement! The measurement is interrupted during a software update. Only carry out software updates when the measurement is not currently be- ing used for process control.
  • Page 63 LB 452 6 The System Menu Software Update Control Unit IMPORTANT Update files for the control unit begin with LB452CU and end with .btw. Connect the USB flash drive with files to be installed to the USB port of the front panel (Fig.1, Pos.
  • Page 64 6 The System Menu LB 452 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 65 LB 452 6 The System Menu Measurement Channels Software Update IMPORTANT Update files for the measurement channels start with LB452MU and end with .bta. 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 66 6 The System Menu LB 452 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>...
  • Page 67 LB 452 6 The System Menu Detector Software Update IMPORTANT Update files for the detectors start with LB67XX and end with .bta. Display the software version of the detector Update button Fig. 46 System Menu, Service - Information (detector update) Click on Service | Information.

  • Page 68: Access Level

    This user level is only intended for system administrators User Level Admin of the company BERTHOLD TECHNOLOGIES. The access level Standard is automatically reset to Basic Automatic log out if the system jumps back to the start screen or the display switches off (see times in the menu "System...
  • Page 69 LB 452 6 The System Menu Select Standard in the drop-down menu of the "User Level" field (Fig. 47, Pos. 5). Click on <Change Password> (Fig. 47, Pos. 2). Click in the "Password" input field to create a password or to change it. „...

  • Page 70: Menu Channel Overview

    7 Menu Channel Overview LB 452 Menu Channel Overview In the channel menu, you can set values relating to the measurement task. In Fig. 48, the menu structure of the Channel Overview menu is represented. see corresponding detector manual Chapt. 7.2 Chapt.
  • Page 71 LB 452 7 Menu Channel Overview Click on <Channel XY> in the standard display (Fig. 15, Pos. 1) to reach the "Chan- nel Overview" menu. Display of the detector value and fill level in time progression Display of the error code Display of the error message Full adjustment button Empty adjustment button...
  • Page 72 7 Menu Channel Overview LB 452 The measured count rate (detector value - CPS) and the fill level are represented in the graph. By pressing the arrow buttons (Fig. 49, Pos. 15), the detector tempera- ture is displayed. Display Field "Alarm Status" Start-up Indicates that the start-up time constant is used (see chapt.
  • Page 73 LB 452 7 Menu Channel Overview Troubleshooting The error number (or warning) is displayed on each channel menu under the status indicator (red/orange). If you click on the error number, a pop-up message appears. Here you can con- firm/acknowledge the error. Fig.

  • Page 74: Empty And Full Adjustment

    Full adjustment with cold block (recommended) NOTICE Berthold recommends that the adjustment mode be set to "dynamic" (Fig. 55, Pos. 5) if only an empty adjustment is carried out before casting. If both an empty and a full adjustment are carried out, the recommended mode is "fixed".
  • Page 75 LB 452 7 Menu Channel Overview Empty adjustment button Full adjustment button Fig. 52 Menu "Channel Overview", Adjust 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 76 7 Menu Channel Overview LB 452 Display field stop condition Display of the values which are read Cancel button Fig. 53 Menu "Channel Overview", Adjustment - Reading in the values Display field "Stop Condition" The device is in test mode FUL/ETY A calibration routine is running in the device: FUL: Full adjustment...

  • Page 77: Settings

    LB 452 7 Menu Channel Overview Settings The following information can be seen in the "Settings" submenu: Display of the selected calibration curve and settings Active Settings (Fig. 54, Pos. 9) Display of adjustment mode (Fig. 54, Pos. 1) Calibration Display of the latest change to the calibration settings (Fig.
  • Page 78 7 Menu Channel Overview LB 452 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 Display of the maximum fill level alarm Display of the minimum fill level alarm Display of the name of the active calibration curve...

  • Page 79: Calibration

    LB 452 7 Menu Channel Overview 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 80 Pos. 5): NOTICE BERTHOLD TECHNOLOGIES recommends that the calibration mode be set to "dy- namic" (Fig. 55, Pos. 5) if only an empty calibration is carried out before casting. If both an empty and a full calibration are performed, the recommended mode is "fixed".
  • Page 81 LB 452 7 Menu Channel Overview 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 steel block are usually used to determine the count rate at 0% or 100% fill level.
  • Page 82 7 Menu Channel Overview LB 452 Input field Add Point button Read button Fig. 56 System Menu, Settings - Calibration (Adapt Calibration Point) When you add a new point, click on the input field "Detector Value" (Fig. 56, Pos. 1) and enter the corresponding fill level (e.g. 50% or 100 mm). Click on <Read in>...
  • Page 83 LB 452 7 Menu Channel Overview 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 84 7 Menu Channel Overview LB 452 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 OK button Standard button Read in button Fig.
  • Page 85 LB 452 7 Menu Channel Overview Plausibility In the "Channel Overview" menu click on Calibration | Plausibility (Fig. 59, Pos. Fig. 59 "Channel Overview" Menu, Settings - Calibration (Plausibility) In the "Plausibility" menu, the applied settings can be seen. If the settings are not plausible, an error is triggered.
  • Page 86 7 Menu Channel Overview LB 452 Test In the "Channel Overview" menu click on Settings | Calibration | Test (Fig. 59, Pos. 1). In the "Test" submenu, you can enter a test count rate (Fig. 60, Pos. 3) which is used instead of the count rate of the detector to calculate the fill level.
  • Page 87 LB 452 7 Menu Channel Overview Click in the input field (Fig. 60, Pos. 3). „ The numeric keypad opens (Fig. 17). 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 88: Filter

    7 Menu Channel Overview LB 452 7.2.2 Filter In the "Channel Overview" menu, click on Settings | Filter (Fig. 54, Pos. 4). Fig. 61 "Channel Overview" Menu, Settings - Filter 47344BA2 Rev.05, 05/2019...
  • Page 89 LB 452 7 Menu Channel Overview 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 Different Time Constants The setting of the time constant helps to balance out statistical variations, mainly from the statistical nuclear decay of the radionuclide.

  • Page 90: Alarms

    7 Menu Channel Overview LB 452 7.2.3 Alarms IMPORTANT The submenu "Alarms" is only displayed if an extension module is installed. In the "Channel Overview" menu click on Settings | Alarms (Fig. 54). Fig. 62 "Channel Overview" Menu, Settings - Alarms In the "Alarms"...

  • Page 91: Option/Display

    LB 452 7 Menu Channel Overview 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"...

  • Page 92: In/Outputs

    7 Menu Channel Overview LB 452 In/Outputs In the "Channel Overview" menu click on <In/Outputs> (Fig. 49, Pos. 8). Click on <Analogue IO> <Digital IO>. Fig. 64 "Channel Overview" Menu, Settings - In/Outputs In the "In/Output" submenu, you can configure the analogue current outputs, the digital inputs, the alarm relays (only with the extension module) and the fieldbus module (if installed).

  • Page 93: Analog Io

    In order to calibrate the current outputs, you will need an ammeter (not included in the delivery contents), which is to be connected to the relevant current output. NOTICE Berthold recommends calibrating the current outputs whenever a module has been installed/replaced or if a software update has been carried out. 47344BA2 Rev.05, 05/2019...
  • Page 94 7 Menu Channel Overview LB 452 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). Lower value input field Upper value input field Time constant input field Error mode drop-down menu Current monitoring drop-down menu Assignment drop-down menu...
  • Page 95 LB 452 7 Menu Channel Overview Error Mode Here, settings can be made concerning the way the current output is to behave if the EVU or the detector reports an er- ror. In the event of an error, the error relay is de-energised (see there), a message appears in the channel menu and the red measurement channel LED lights up.
  • Page 96 7 Menu Channel Overview LB 452 NOTICE If the second current output is assigned to the detector temperature or the detec- tor value (CPS), it is particularly important to adhere to an appropriate setting of the current output values for 4 or 20 mA. Additional filter An additional filter time constant can be applied to the (only for current...
  • Page 97 LB 452 7 Menu Channel Overview 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 98 7 Menu Channel Overview LB 452 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 99: Digital Io

    LB 452 7 Menu Channel Overview 7.3.2 Digital IO In the Digital IO submenu, you can set the two different alarm signals for the alarm relays. Alarm Relay IMPORTANT The Alarm Relay submenu is only displayed if an extension module is installed. In the "Channel Overview"...
  • Page 100 7 Menu Channel Overview LB 452 NOTICE 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", 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 101 LB 452 7 Menu Channel Overview 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) IMPORTANT The digital inputs cannot be configured.
  • Page 102 7 Menu Channel Overview LB 452 Click on <End Test Mode> (Fig. 69, Pos. 2) if you would like to end the test mode. IMPORTANT The test function ends automatically after around 5 minutes. If the test should be re-enabled, the value must be re-entered. 47344BA2 Rev.05, 05/2019...
  • Page 103 LB 452 7 Menu Channel Overview 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. IMPORTANT To be able to use the Fieldbus module, you must install the provided GSD file in the process control system.

  • Page 104: Error

    7 Menu Channel Overview LB 452 Error In the "Channel Overview" menu, click on <Error> (Fig. 49, Pos. 8). 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 105: Overview

    LB 452 7 Menu Channel Overview 7.4.1 Overview In the "Channel Overview" menu, click on Error | Overview to reach the Overview submenu. Display of the error details of the error messages Fig. 72 "Channel Overview" Menu, Error Overview In the Overview submenu, you can find a detailed error list (Fig. 72, Pos. 1). 47344BA2 Rev.05, 05/2019...

  • Page 106: Service

    7 Menu Channel Overview LB 452 Service In the Service submenu you have the following options: · Exporting service data to a USB flash drive. · Resetting of the channel settings to (calibrating, time constants, alarms thresholds, etc.) · Restarting of the software (of the relevant measurement channel). Service data includes: ·...

  • Page 107: Exporting Service Data

    LB 452 7 Menu Channel Overview 7.5.1 Exporting Service Data IMPORTANT <Export Service Data> button becomes active if you connect a USB flash drive to the front panel. Click on <Export Service Data> (Fig. 73, Pos. 3). Fig. 74 "Channel Overview" Menu, Service - Backup/restore is running „...

  • Page 108: Change Log

    7 Menu Channel Overview LB 452 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 109: Backup

    LB 452 7 Menu Channel Overview 7.5.3 Backup The "Backup" submenu offers you the following options: · Backing up the settings to a USB flash drive. · Restoring of settings from a USB flash drive. IMPORTANT Backing up the settings is always recommended to ensure quality and so original settings can be restored in the event of an emergency.
  • Page 110 7 Menu Channel Overview LB 452 Fig. 77 "Channel Overview" Menu, Service - Backup/restore is running „ A confirmation message opens after a successful backup. After the backup/restore is finished, click on <OK>. IMPORTANT All data relevant to measurement is backed up: ·...

  • Page 111: Troubleshooting

    LB 452 8 Troubleshooting Troubleshooting Error Search Problem Cause Measure No signal EVU does not work † Check power supply and fuses; is LED 1 blinking on the display? No signal Detector does not work † Check the functioning of the detec- Count rate too low Shielding not opened or not †...

  • Page 112: 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 infor- mation on how to fix them. All castXpert LB 452 errors have the prefix "M", all detector errors the prefix "D".

  • Page 113: Main Board

    LB 452 8 Troubleshooting 8.2.2 Main board Code Text Description Correction Class Monitoring The monitoring ADC (Analogue † Contact service Error Digital Converter) has failed Hardware error Error while calibrating the ADC † Contact service Error Calibration Hardware error 24 V failure Faulty 24 V operating voltage †...

  • Page 114: Application

    8 Troubleshooting LB 452 8.2.3 Application Code Text Description Correction Class Calibration Calibration curve not mono- † Check calibration table Error not monotonic tonic Background Background count rate larger † Check calibration table Error too high than smallest occurring calibra- †...

  • Page 115: Gammacast Control

    LB 452 8 Troubleshooting 8.2.4 GAMMAcast Control Code Text Description Correction Class No detector No compatible detector found † Connect a compatible Error found detector † Ensure the correct ca- bling is in place † Carry out software up- date †...

  • Page 116: Process Connection

    8 Troubleshooting LB 452 8.2.5 Process Connection Code Text Description Correction Class Current out- Faulty current output on the † Calibrate current out- Warning basic module † Contact service Current out- Current output on the basic † Check cabling on cur- Warning put loop open module not closed...

  • Page 117: Maintenance

    LB 452 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 Danger to life from electric shock! Exposed live parts in the device interior. Installation may only be carried out by a qualified electrician.
  • Page 118 9 Maintenance LB 452 Card slot with extension module Card slot with basic module Card slot for fieldbus module System board (control unit) with SD card slot SD card slot Front panel folded out Extension module Flat ribbon cable Basic module Fieldbus module Fig.

  • Page 119: Installation Of The Basic Module/Extension Module

    LB 452 9 Maintenance 9.1.1 Installation of the Basic Module/Extension Module NOTICE Damage to the device! Short circuit Install the module in the correct card slot! Please always observe the prescribed sequence when installing modules! IMPORTANT If an extension module is to be installed, it must be connected with the basic module via the flat ribbon cable before the installation.

  • Page 120: Installation Of The Fieldbus Module

    9 Maintenance LB 452 9.1.2 Installation of the Fieldbus Module NOTICE Damage to the device! Short circuit Install the module in the correct card slot! Please always observe the prescribed sequence when installing modules! NOTICE Device is not recognized! Limited range of functions Carry out an EVU software update before installing the fieldbus module if the control unit software version is less than version 1.0.3! IMPORTANT...
  • Page 121 LB 452 9 Maintenance Aperture on the main circuit board Fig. 79 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. Connect the module with the flat ribbon cable again (included in delivery contents) (Fig.

  • Page 122: Replacing Of Fuses

    9 Maintenance LB 452 Replacing of Fuses NOTICE Damage to the device! Short circuit! The modules can be damaged if the wrong fuses are used. 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.

  • Page 123: Replacing Of Basic Module Fuse

    LB 452 9 Maintenance 9.2.1 Replacing of Basic Module Fuse Disconnect the EVU voltage. Loosen the three screws on the front panel (Fig. 10, Pos. 2). Fold the front panel down. Pull out the basic module and if need be the extension module and/or fieldbus module (Fig.

  • Page 124: Replacing Of Extension Module Fuse

    9 Maintenance LB 452 9.2.2 Replacing of Extension Module Fuse Disconnect the EVU voltage. Loosen the three screws on the front panel (Fig. 10, Pos. 2). Fold the front panel down. Pull the extension module and the basic module out (Fig. 9, Pos. 3) carefully. Remove the flat ribbon cable (Fig.

  • Page 125: Cleaning

    LB 452 9 Maintenance Cleaning The display is designed for maintenance-free operation. Make sure you keep the touch screen clean. Use a cleaning cloth to clean the equipment. NOTE Unintentional response! When cleaning the touch screen, an unintentional response in the controller can be triggered by touching keys.

  • Page 126: Decommissioning

    10 Decommissioning LB 452 Decommissioning DANGER Danger to life from electric shock! All relevant safety regulations have to be observed. Decommissioning may only be carried out by qualified electricans. Only open the device when free of voltage. In case of an electric shock, carry out first aid measures and immediately call an emergency service.
  • Page 127 Modifications due to technical advancement reserved. © BERTHOLD TECHNOLOGIES GmbH & Co. KG Language: English Printed in Germany 05/2019 Rev.-No.: 05 BERTHOLD TECHNOLOGIES GmbH & Co. KG Calmbacher Str. 22 75323 Bad Wildbad Germany www.berthold.com Id.-No. 47344BA2...
  • Page 128 LB 452 Evaluation Unit Technical Information 47344TI2 Rev. No.: 04, 05/2019...
  • Page 129 Technical Information – LB 452 Evaluation Unit Mold Level Measurement System The castXpert LB 452 is the mold level measuring system that has been setting standards for years. It provides accurate and reliable measurements, and ensures optimal control of the continuous casting process due to the short cycle time of 5ms.
  • Page 130 Technical Information – LB 452 Evaluation Unit Technical Data Mechanical Data 19" Rack, 3 HE Frame 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 protection IP 20 Connections...
  • Page 131 Technical Information – LB 452 Evaluation Unit Can be configured for: Fill level (additional time constant, freely adjustable) § Detector temperature § § Detector count 2 digital inputs: potential-free, for ext. Choice of up to 4 calibration curves § 2 relay outputs for alarm signalling: §...
  • Page 132 Technical Information – LB 452 Evaluation Unit 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: §...
  • Page 133 53799-S (Card slot for) bus module 53772-S System board (control Unit) with SD Card slot 53779-S Front panel with display Replacement parts castXpert LB 452 53779-S Front panel with display for castXpert LB 452 53772-S System-control unit for castXpert LB 452 47344TI2 Rev. 04, 05/2019...
  • Page 134 Technical Information – LB 452 Evaluation Unit LB 452 Connections: Back View 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...
  • Page 135 Technical Information – LB 452 Evaluation Unit LB 452 Connections: Measuring channel base module 47344TI2 Rev. 04, 05/2019...
  • Page 136 Technical Information – LB 452 Evaluation Unit LB 452 Connections: Measurement Channel Extension Module When using CONGAUGE, 23 and 24 is current output for Powder level. 47344TI2 Rev. 04, 05/2019...
  • Page 137 Technical Information – LB 452 Evaluation Unit Terminal Box Terminal box for open ends (Id. no. 07005). Terminal box with plug-in connector (Id. no. 34787) 47344TI2 Rev. 04, 05/2019...
  • Page 138 Technical Information – LB 452 Evaluation Unit Data Definition Profibus DP Cyclic Output Data (as of MU Software Version 1.6.0) Name of Variable Description Type Size Level Actual mould level Float 32 Bit Unit: % / mm / inch (selectable) Steel Level Actual mould level without powder influence Float...
  • Page 139 Technical Information – LB 452 Evaluation Unit Cyclic Input Data (as of MU Software Version 1.6.0) Name of Variable Description Type Size Calibration Index Selection of calibration settings [0..7] (real number) Byte 8 Bit (Calibration curve, alarm levels and time constants.) Function By writing a number in this field functions on the LB452 can Unsigned...
  • Page 140 Technical Information – LB 452 Evaluation Unit Declaration of Conformity 47344TI2 Rev. 04, 05/2019...

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