Summary of Contents for Borger STE-RSM2
- Page 1 Operating Manual Börger Reversing Control Unit Types STE-RS www.boerger.de www.boerger.com...
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Page 2: Börger Worldwide
France Börger France S.A.R.L. Phone +33 (0) 3 / 88515468 9 rue des Prés +33 (0) 3 / 88515413 67670 Wittersheim info@borger.fr France www.borger.fr Great Britain/ Börger UK Ltd. Phone +44 (0) 1902 / 798977 Ireland East Wing - Old School +44 (0) 1902 / 798979 Watling St. -
Page 3: Product Specifications
Product Specifications Product Specifications Machine: Product group: Control unit, reversing control unit STE-RSM, STE-RSR, STE-RSU Type: 2, 3 Manufacturer's address: Company: Börger GmbH Address: Benningsweg 24 Town / city: 46325 Borken – Weseke, Germany Phone: +49 (0)2862 / 9103 – 0 Fax: +49 (0)2862 / 9103 –... -
Page 4: Table Of Contents
Contents Contents Börger Worldwide.......................... 2 Product Specifications ........................3 Contents ............................4 General Information ...................... 7 Introduction ........................7 Notes on copyrights and property rights ................7 Information for the operator ..................... 8 Instruction ........................9 Safety ........................... 10 General information ....................... 10 Notes on signs and symbols .................. - Page 5 Contents 3.3.4 System limits ......................... 39 Transportation, As-delivered Condition, Storage, Installation ......... 41 Transportation ....................... 41 As-delivered condition ....................42 Storage / interim storage ....................42 4.3.1 Storage .......................... 42 4.3.2 Interim storage ......................42 Installation ........................43 4.4.1 Positioning ........................43 4.4.2 Installing the control cabinet ..................
- Page 6 Contents Oil, oily waste and grease ....................69 Plastics .......................... 69 Metals ..........................70 Electrical and electronic waste ..................70 Final decommissioning ....................70 Accessories ......................... 71 Appendix ........................71 Circuit diagrams, complete parts list and data sheets ............ 71 Type code........................
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Page 7: General Information
General Information General Information Introduction This operating manual is an important aid for the correct and safe operation of the control unit. It contains important information for operating the control unit and the units connected to it in a safe, proper and economical manner. Adhering to these instructions will help avoid associated dangers, reduce repair costs and downtimes and increase the reliability and service life of the control unit and the units controlled by it. -
Page 8: Information For The Operator
General Information Information for the operator The operating manual is an integral part of the control unit. The operator (i.e. the responsible party) is responsible for making the operating personnel aware of this manual. Additionally, the operator is obligated to ensure the notice and observance of national regulations for accident prevention and environmental protection, plus the notice and observance of supervision and reporting duties taking special operational... -
Page 9: Instruction
General Information Instruction As the operator, you are obligated to inform and, if necessary, instruct your operating personnel in regard to the applicable legal and accident prevention regulations, as well as the safety equipment available on the control unit and the units controlled by it. -
Page 10: Safety
Safety Safety General information Only high-quality components have been used in the control unit that have been specifically selected and programmed for the units controlled by it. Nevertheless, the operation of the control unit and the units controlled by it may endanger the operating person and cause damage to the connected units, the control unit or other material assets in the following circumstances: —... -
Page 11: Proper Use
Safety Notice Indicates a possible hazardous situation or unsafe, dangerous work processes that may lead to damage to the machine or surrounding area. Note Offers useful information on safe and proper operation. ● Bullet points describe work and / or operational steps. These steps must be carried out from the top down. -
Page 12: Residual Risk
Safety Proper use includes compliance with the instructions on — safety, — operation, — repairs and maintenance, which are described in this operating manual as well as in the operating manuals of the connected components. Any other use or use over and above these specifications is deemed as improper use. - Page 13 Safety Danger! Danger of serious injury or death from electric shock! For protection against contact, secure the power supply with an AC/DC sensitive residual current device (RCD Type B) according to the circuit diagram. Switch off the STE-RS control unit using the main switch before performing any repair or maintenance work.
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Page 14: Description Of The Safety Equipment
Safety Description of the safety equipment The control unit is equipped with the required safety equipment according to the applicable legal guidelines in the country of manufacture, current state-of-the-art technology and recognized safety regulations. 2.5.1 Fuses The circuit breakers (automatic fuses) indicated on the electric circuit diagrams protect the electric circuits from being damaged by overcurrent. -
Page 15: Marking And Signs On The Ste-Rs Control Unit
Safety Marking and signs on the STE-RS control unit Meaning: The control unit manufacturer’s nameplate Location: In a clearly visible position on the control cabinet door inside the control cabinet (The data provided are for illustrative purposes only. Here, they refer to a Multichopper P150 control unit.) Different address possible, e.g. - Page 16 Safety Meaning: Warns of dangerous electrical voltage Location: On the control cabinet and on individual components Meaning: Protective ground connection Location: On all connecting points to the protective ground wire Meaning: Warning: The electrical connections must be checked before commissioning the STE-RS control unit and the components connected to it.
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Page 17: Safety Instructions For Operating Personnel
Safety Safety instructions for operating personnel The control unit and the components controlled by it may only be operated while they are fully assembled, in perfect working condition and only for their intended purpose, in a safe and risk- conscious manner having regard to this operating manual. All malfunctions must be rectified immediately and professionally, especially those affecting safety. -
Page 18: Safety Instructions For Maintenance And Rectifying Malfunctions On The Ste-Rs Control Unit
Safety This especially applies to safety-related alterations to the control unit or connected components. Observe the maintenance instructions in the relevant operating manuals when carrying out maintenance on the connected components. Work on the control unit may only be carried out by trained, reliable personnel. - Page 19 Safety Dispose of any replacement parts in a safe and environmentally- friendly manner. BA-STE-RS, 26.09.2014 www.boerger.de / www.boerger.com...
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Page 20: Product Description
Product Description Product Description Construction of the STE-RS reversing control unit 1 Control cabinet with lock (S) 2 Main switch 3 Emergency stop 4 Operating terminal 5 Red LED indicator lamp, is lit in the event of malfunctions 6 Yellow LED indicator lamp, is lit during automatic operation 7 Blue LED illuminated pushbutton for restoring readiness for operation after an... - Page 21 Product Description Inside of the control cabinet, version with reversing contactor combination and motor protection switch Control cabinet with lock 14 PLC / CPU Main switch 15 Power supply unit, power supply 24 V DC Emergency stop 16 Motor protection switch Operating terminal 17 Reversing contactor combination with current Red LED indicator lamp...
- Page 22 Product Description Inside of the control cabinet, version with frequency converter Control cabinet with lock 15 Power supply unit, power supply 24 V DC Main switch 18 Emergency stop relay (safety relay) Emergency stop 19 Coupling relay Operating terminal 20 Serial feed-through terminals for connecting the Red LED indicator lamp components of the system according to the circuit diagram Yellow LED indicator lamp...
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Page 23: Control Cabinet
Product Description 3.1.1 Control cabinet The standard version of the control cabinet (1) is made of painted sheet steel. The casing protection degree according to DIN EN 60529 is IP 55. Two locks with a removable key make it possible to prevent unauthorized access. -
Page 24: Control Unit
Product Description 3.1.1.3 LED elements Red LED indicator lamp (5) Fault is lit in the event of malfunctions Yellow LED indicator lamp (6) Autom. Start-up warns of a possible automatic start-up of the macerator (when in automatic operation) Emergency Stop Reset is lit after Blue LED illuminated pushbutton (7) an emergency stop until... -
Page 25: Motor Protection Switch
Product Description The reversing contactor combination (17) is not available in the version with frequency converter, see chapter 3.1.5. 3.1.4 Motor protection switch In order to prevent damage from overload, a thermomechanical motor protection switch (16, bimetal) triggers the shut down of the macerator motor based on a preset heating curve when the stored current consumption limit is exceeded. -
Page 26: Operating Terminal
Product Description 3.1.7 Operating terminal The operating terminal (4) offers optimized visualization and enables comfortable operation. Display 4" STN display, 4 gray scales, resolution of 320x240 dpi Touchscreen analog resistive, IP 65 external / IP 20 internal, single touch Memory 512 KB The software of the terminal is programmed entirely according to the order specifications for the macerator to be connected. -
Page 27: Menu Navigation
Product Description 3.1.8 Menu navigation Main menu 1.1 Current date and time display 1.2 Operating status display System ready / System not ready 1.3 Operating mode activation fields: Manual operation (without regulation) or automatic operation (regulation according to the pump control unit), highlighted in dark gray when selected 1.4 Current value display: —... - Page 28 Product Description 2 Manual operation: Operating mode, to be activated for unregulated operation as well as for inching operation (e.g. for manual reversing), highlighted in dark gray when activated 2.1 Backwards: activates the backward operation of the macerator for the duration of the touch, highlighted in dark gray when activated 2.2 Forwards: activates the forward operation of the macerator for the duration of the touch,...
- Page 29 Product Description 3 Automatic operation: Operating mode, to be activated for controlled operation according to the pump control unit, flashes alternatingly in light and dark gray when activated 3.2 Manual reversing / Start: After starting the drives via the pump control unit, the start field for manual reversing appears during ongoing operation.
- Page 30 Product Description 4.1 Submenu Settings for reversing A Macerator overcurrent: The limit for the maximum admissible current consumption of the macerator is defined in the Tgt value field. The reversing process is triggered when the limit is exceeded. Settings can also be made during operation. The actual current consumption of the motor is displayed below the Act.
- Page 31 Product Description 4.2 Second submenu Settings for reversing G Reversing sequence duration: During a reversing process, the macerator repeatedly runs forwards and backwards in short sequences. The duration of a reversing sequence in seconds (i.e. the duration for which the macerator runs in one direction) is defined here in the second settings menu under Tgt value.
- Page 32 Product Description 4.3 Additional submenu for version with frequency converter (not applicable for version without frequency converter) J Macerator frequency The frequency of the drive of the connected macerator is defined in the third settings menu under Tgt value. By changing the frequency, the rotational speed of the macerator can be adjusted to the properties of the medium.
- Page 33 Product Description 4.4 Submenu Date, Time, Contrast and Service Program settings K Operating hours: Touching leads to the operating hours counter and intermediate meter L Scaling: This submenu for general functions of the control unit can only be accessed by Börger GmbH.
- Page 34 Product Description 5 Faults: Touching the field leads to the submenu for current fault messages 5.1 Example of a fault message 5.2 Short descriptions of the fault messages can be retrieved by touching the help field marked by a "?". 5.3 Navigation bar for navigating within the messages 5.4 Archive: Touching the field displays the alert log...
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Page 35: Options And Accessories
Product Description 3.1.9 Options and accessories 3.1.9.1 Remote maintenance module Optionally, the control unit can be supplied with a remote maintenance module. The remote maintenance module enables remote maintenance via GSM/UMTS by Börger GmbH. This option makes it possible to obtain quick, targeted support should a fault arise. -
Page 36: Function Of The Ste-Rs Reversing Control Unit
Product Description Note If a pump with an integrated pump control unit is connected, there will usually be no connection for the external control unit. An extension for connection to an external control unit is optional. Function of the STE-RS reversing control unit The STE-RS reversing control unit serves the purpose of preventing and removing slight blockages of a connected macerator caused by fiber materials in order to avoid downtimes. - Page 37 Product Description Notice The reversing control unit was specifically pre-programmed for your macerator in line with the specifications provided in the order. Do not change the programming beyond the measures described in chapter 5 without obtaining written consent from Börger GmbH. Otherwise, you may cause severe damage to the macerator and the drive.
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Page 38: Technical Data
Product Description Technical data The detailed technical specifications, performance data and maximum loads for the components of the STE-RS control unit are contained in the attached documentation from the manufacturers. 3.3.1 Dimensions Dimensions of the control cabinet in mm / inches (approx.) Version Ø... -
Page 39: Electrotechnical Data
Product Description 3.3.2 Electrotechnical data Voltage input: 400 V AC Control voltage: 24 V Frequency: 50 Hz No. of phases: 3P/N/PE Nominal current: Corresponds to the nominal current of the motor of the connected macerator as stated on the nameplate (see also chapter 3.3.4);... - Page 40 Product Description Factory default Limits Unit Value setting Current consumption limit of the macerator Nominal current for current-dependent reversing of the motor: Motor output 1.5 kW Motor output 2.2 kW Motor output 3.0 kW Motor output 4.0 kW 1-10 Motor output 5.5 kW 1-13 Motor output 7.5 kW 1-18...
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Page 41: Transportation, As-Delivered Condition, Storage, Installation
Transportation, As-delivered Condition, Storage, Installation Transportation, As-delivered Condition, Storage, Installation Transportation Warning! Dangerous crush injuries are possible during the transportation of the control unit. The control unit may tilt over and fall due to improper lifting and transportation. ● Only use hoists, cranes, auxiliary tools and protective equipment that are suitable for the load. -
Page 42: As-Delivered Condition
Transportation, As-delivered Condition, Storage, Installation As-delivered condition The control unit is usually set up for each respective application and delivered in a programmed condition. ● Check that the delivery is complete when you receive it. ● Inspect the delivery immediately for any signs of transport damage. -
Page 43: Installation
Transportation, As-delivered Condition, Storage, Installation Installation ● Prior to commissioning, make sure that you are using the correctly preset control unit for your macerator. Notice Do not commission the macerator using a control unit without the appropriate settings. Otherwise, your macerator may not function and damage to the unit, e.g. -
Page 44: Installing The Control Cabinet
Transportation, As-delivered Condition, Storage, Installation 4.4.2 Installing the control cabinet When a complete macerating system on a base frame is delivered, and in the case of mobile macerating systems, the STE-RS control unit is usually supplied readily mounted on the mounting frame and ready for operation. -
Page 45: Electrical Connections
Transportation, As-delivered Condition, Storage, Installation 4.4.3 Electrical connections Danger! Risk of fatal injury due to electric shock! Electrical connections may only be installed by qualified electricians. Please observe — the instructions and safety regulations set out in the installation instructions and operating manuals of the manufacturer of electronic components, and —... - Page 46 Transportation, As-delivered Condition, Storage, Installation ● If the unit supplied is not completely pre-assembled, connect the macerator drive according to the enclosed circuit diagram taking into account the note above. ● Connect any additional components according to the enclosed circuit diagram when the STE-RS control unit has been designed for this purpose.
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Page 47: Control Cabinet Climatization
Transportation, As-delivered Condition, Storage, Installation 4.4.4 Control cabinet climatization ● If available, turn the temperature controller (25) for control cabinet climatization to 20°C (68°F). 4.4.5 Secure installation / checking fastening screws ● Check that all the terminal and fastening screws, which may have become loose during transportation and installation, are tight and retighten them if necessary. -
Page 48: Operation
Operation Operation 1 Control cabinet with lock (S) 2 Main switch 3 Emergency stop 4 Operating terminal 5 Red LED indicator lamp, is lit in the event of malfunctions 6 Yellow LED indicator lamp, is lit during automatic operation 7 Blue LED illuminated pushbutton for restoring readiness for operation after an emergency stop 8 Start button / stop button... -
Page 49: Commissioning
Operation Commissioning 5.1.1 Switching on the control unit and checking the functions ● Turn the main switch (2) to ON. The control unit starts up (approx. 20 seconds). ● When the main menu shows on the operating terminal, check the function of any optional monitoring devices. 5.1.2 Password customization, password input The functions and menus that permit an adjustment of the preset... - Page 50 Operation The Set-up user is also not granted unlimited access to the parameters of the control unit. They are entitled to: — set the date and time, lock the screen for cleaning, perform the lamp test in the Setting menu, —...
- Page 51 Operation Unless you had already logged in, a login window for logging in with the corresponding password opens. ● Touch the entry field Password. A window with a digital keyboard opens. ● Make your selection by touching the number block. ●...
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Page 52: Setting The Date And System Time
Operation 5.1.3 Setting the date and system time The system time shown on the display can be corrected in order to adapt it to the local time, daylight saving time, or after longer power cuts. For this work step, the set-up user password is required or you have to be logged in as set-up user already. -
Page 53: Adjusting The Control Parameters
Operation ● Activate Manual operation by touching the relevant field (2) until activation is signaled by the field being highlighted. ● Continuously touch the Forwards field (2.2). ● Check the direction of rotation of the motor as described in the operating manual of the macerator. - Page 54 Operation Unit-specific values, limits as well as variable parameters for reversing processes are preset by factory default as described in chapter 3.3.4 or according to the order specifications for the particular case. Optimum adjustment of the reversing behavior of the STE-RS control unit strongly depends on the dry solids content and structure of the medium being macerated inside the macerator.
- Page 55 Operation If the current consumption permanently remains just below the maximum value and frequent reversing processes are triggered, the limit for triggering reversing processes can be slightly increased within the scope of the limits defined in chapter 3.3.4 upon careful examination of alternative options (e.g. stirring the medium, reducing the DS content).
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Page 56: Normal Operation
Operation Normal operation ● Select whether you would like time-dependent reversing to be triggered in order to prevent blockages by touching the field Automatic reversing On (3.1) or Off, independent of the current consumption of the drive. ● This requires time settings for automatic reversing in the Setting menu, submenu 4.1. -
Page 57: Downtimes
Operation Downtimes 5.3.1 Downtimes in automatic operation If Automatic operation has been activated, the control unit remains switched on during regular operation (LED indicator lamp Autom. Start-up is lit). The motor of the connected macerator (and any further components) is switched on and off according to the signals of the pump control unit (networked, external control unit, if applicable). -
Page 58: Faults
Operation Faults 5.4.1 Reversing when the current consumption is exceeded If the current consumption of the motor of the connected macerator exceeds the preset limit, the reversing process is initiated. The motor alternatingly runs forwards and backwards for short sequences, according to the preset duration and number. The display shows Reversing active (1.5). -
Page 59: Fault Messages And Troubleshooting
Operation 5.4.2 Fault messages and troubleshooting Warning! In the event of a malfunction, leave the macerator switched off and immediately shut down any upstream and downstream components until the cause has been rectified. Otherwise, damage to the components cannot be ruled out. If required (e.g. - Page 60 Operation Fault message: Possible causes ● Remedial action • Correct duration of reversing "Fault, number of sequences, number of reversing reversing processes Parameter settings incorrect cycles and number of reversing reached" processes as described in chapters 5.1.5.2 and 3.3.4 • Repeat reversing process manually, if necessary Blockage inside the macerator cannot be removed...
- Page 61 Operation Fault message: ● Possible causes Remedial action • Eliminate cause of overcurrent, e.g. "Macerator motor blockage inside the macerator protection switch" in • Reactivate the motor protection switch version with motor Motor protection switch has protection switch been triggered, current consumption of macerator was exceeded beyond the permissible limit...
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Page 62: Resetting The Intermediate Meter
Operation Fault message: Possible causes ● Remedial action "Fuse, PLC outputs" • Rectify any causes for short circuit / Short circuit / overcurrent at overcurrent, if applicable the PLC, circuit breaker set to 0 • Reactivate the circuit breaker The following applies to versions with a •... -
Page 63: Maintenance And Repairs
Maintenance and Repairs Maintenance and Repairs Danger! Risk of fatal injury due to electric shock! Electrical connections may only be installed by qualified electricians. Pay particular attention to all instructions and safety regulations contained in the operating manuals for electronic components in the appendix. Danger! Danger of serious injury or death from electric shock! Switch off the STE-RS control unit using the main switch... -
Page 64: Machine Care
Maintenance and Repairs Warning! The following applies to versions with a frequency converter: The frequency converters may carry a dangerous contact voltage for up to 10 minutes after disconnection from the power supply. Only open the control cabinet 10 minutes after shut down. Notice Electrostatic discharges (ESD) can damage electronic components. -
Page 65: Cleaning The Outside Of The Control Cabinet
Maintenance and Repairs Notice Improper cleaning can result in malfunctions and damage! Do not use water jets. Do not use aggressive cleaning agents, solvents or sandpaper, as these can damage the metallic and plastic surfaces, paint and seals. Do not use metal objects such as scrapers and screwdrivers for cleaning. -
Page 66: Cleaning The Outside Of The Operating Terminal During Operation
Maintenance and Repairs 6.1.2 Cleaning the outside of the operating terminal during operation If the operating terminal is to be cleaned while the control unit is switched on, the program Cleaning screen must be activated to prevent touching the screen causing changes to the settings. For this work step, the set-up user password is required or you have to be logged in as set-up user already. -
Page 67: Lamp Test
Maintenance and Repairs The following intervals are guidelines. These intervals may be significantly reduced depending on the operating conditions, e.g. a dusty environment. Interval Inspection / maintenance Measures (approx.) Cleaning the outside See chapter 6.1 Machine care Cleaning the inside See chapter 6.1 Machine care Replace relays, if necessary, according Checking the relays... -
Page 68: Insulation Measurements
Maintenance and Repairs ● Touch the Lamp test field (M). The LED indicator lamps (see chapter 3.1.1.3) are lit when functioning properly. Failing this, no proper connection to the corresponding power supply may have been established or the respective LED element may be defective. -
Page 69: Disposal
Disposal Disposal Environmental protection Caution! Water-polluting materials Such materials can pollute the soil and groundwater and enter the sewage system. Comply with the legal obligations regarding waste avoidance and the proper recycling / disposal of waste during all work on and around the machine. -
Page 70: Metals
Disposal Metals ● Sort and separate different metal types. ● Dispose of these metals according to the legal requirements through authorized waste disposal companies / authorities. Electrical and electronic waste Electrical and electronic waste must be disposed of separately. Electrical and electronic waste must not be disposed of with domestic waste. -
Page 71: Accessories
Accessories Accessories If your STE-RS control unit has been equipped with special accessories, the corresponding data sheets and / or operating manuals can generally be found in the appendix or in the packaging of the units, if delivered as originally packed. Appendix Circuit diagrams, complete parts list and data sheets The appendix contains the circuit diagram, the complete parts list,... -
Page 72: Type Code
Appendix Type code Type code 1-3 Equipment group Control unit 4-5 Basic type Reversing control unit 6 Macerator the control unit is designed for Multichopper, P series Rotorrake, RR series Multicrusher, HAL, HPL, HCL, HFL, HLA series 7 Version and display Operation of the macerator with PLC, reversing contactor combination and motor protection switch, limit adjustment via 4"... - Page 73 Appendix Type code 10 Extension of the control unit with frequency converter for pump (identical or max. two output levels above the macerator output) Output 1.5 kW Output 2.2 kW Output 3.0 kW Output 4.0 kW Output 5.5 kW Output 7.5 kW Output 9.2 kW Output 11.0 kW Output 15.0 kW...
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Page 74: Checklist For Commissioning
Appendix Checklist for commissioning This checklist can be used as an additional aid when commissioning a macerator with a STE-RS control unit. It is not a substitute for careful reading of the operating manual before commissioning the unit. Customer: Börger order confirmation no.: Machine number: Type code: Your project:... -
Page 75: Ec Declaration Of Conformity
Appendix EC Declaration of Conformity BA-STE-RS, 26.09.2014 www.boerger.de / www.boerger.com... -
Page 76: Additional Documentation
Appendix Additional documentation Further, separate supplementary operating manuals for special versions are part of this operating manual. ● Observe these documents. Supplier documentation ● You must completely read the separate supplier documentation and consider it accordingly. We hope that we have clearly described all the relevant operating steps in this operating manual. However, the operating conditions are so multi-faceted that a general operating manual cannot answer all questions entirely.
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