Technical Manual

Congrav® S

Subject:
Congrav® S

Category:

Single-controller

Title:

Technical Manual

Document: [Link]
Revision: 5.5
Date: 02-06-27

- Copyright as per DIN 34 -

 Technical Manual S-E

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©Brabender Technologie, 2002 Page 2/21

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Table of contents
1 Introduction 4
1.1 Index of revisions 4
1.2 Designations used in the technical manual 5
1.3 Abbreviations 5
1.4 Signs and warnings used in the technical manual 6
1.5 Signs on the Congrav® S 6

2 Congrav S: types 7

3 The electrical connections 8

3.1 Mains connection 8
3.2 The connection of IO 8
3.3 The IO module for Congrav® S 9
3.4 The IO module 2 for Congrav® S 9
3.5 Plan of terminal connections: IO-module 10
3.6 Plan of terminal connections: IO-module-2 11
3.6.1 Functions of the terminals 12
3.7 Wiring scheme Congrav® S and IO-module 13
3.7.1 Standard IO and extension card B 13
3.7.2 Standard IO and extension cards C + D 14

4 The circuitry 15
4.1 General specifications 15
4.1.1 The power supply of the IO-module 15
4.1.2 The internal 24VDC-supply of the IO-module 15
4.1.3 The external 24VDC-supply 16
4.1.4 Wiring of the digital inputs/outputs (DI / DO) 16
4.1.5 Digital inputs and digital outputs of extension cards C and D 16
4.1.6 Wiring of the analogue inputs and outputs (AI/AO) 18
4.1.7 Wiring of the analogue mV-input 18
4.1.8 List of the assisted load cell types 18
4.1.9 Wiring of the serial interfaces 19

5 Technical data 20
5.1 Electromagnetic compatibility 20
5.2 Data 20
5.3 Dimensions 21

©Brabender Technologie, 2002 Page 3/21

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1 Introduction

The present technical manual generally uses the designation Con-

grav® S. This designation means the actual hardware version Con- General
grav® S-E. Congrav® S-E substitutes the earlier hardware versions note
A – D, they are no longer available.

Congrav® S is a so-called single-controller; its function is the control

and monitoring of a weigh-feeder.
Congrav® S is described by

" the description of the software functions, the operating instruc-

tions and
" the description of the hardware components in this technical
manual.

The technical manual describes the hardware of Congrav® S as far

as the technical data and the necessary cabling work for the connec-
tion of the hardware is concerned. The functions of the individual
hardware components are defined by the software, they may vary
depending on the type of software employed. For this reason, make
sure to observe the operating instructions of the software employed.

This technical manual has been conceived for qualified electrical

staff, know-ledge of the valid national and international standards
and the state of the art is taken for granted.
Each chapter of the technical manual deals with a subject of its own,
so that points that are still unclear can be looked up in the chapter
concerned. However, this goes only for experienced qualified techni-
cal staff that is familiar with the Congrav® S.

1.1 Index of revisions

Rev.5.0 Revision of the technical manual.

- Integration of IO-module 2
- Index of revisions
- Criteria for the external 24VDC-supply
Rev.5.1 Page 13: connection of host computer interface = XS3
connection of Centronics interface = XS5
Page 10: plan of terminal connections IO/module , rev.1.2
Rev.5.2 Page 16: Examples for wiring DO, DI
Rev.5.3 Order of terminals PE,N,N1,L, PE (page 10)
Rev.5.4 Artikel-No. UBE-D/25F = E0000417 (page 14)
Rev.5.41 corretion of german text on page 11
Rev.5.5 plan of terminal connection: Relay customer side 230 VAC

©Brabender Technologie, 2002 Page 4/21

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1.2 Designations used in the technical manual

An analogue EMS load cell is connected to an AED-module, the

load cell has to comply with the technical specifications of the AED-
module. The AED-module delivers the necessary supply voltage for
the load cell and converts the mV-weight signal into a serial weight AED-module
signal. The processing of the weight signal of the load cell is made
by means of a digital filter that can be configured by means of the
software of the ISC-CM.
EMS is the abbreviation for Elongation Measuring Strip. The EMS
change their ohmic resistance as a function of their change in EMS
length.
This designation generally stands for a feeding system. Please note
that the software of the Congrav® S depends on the type of the Weigh-feeder
loss-in-weight feeder.
Digital one-wire-load cell with integrated filter technology that
IDL/F, IDL/F2
sends a TTL- weight signal or a serial weight signal.
Control signal of the Congrav® S for the drive controller of the feed
drive. The manipulated variable sets the drive controller to the
Manipulated vari-
speed or vibration amplitude of the drive motor. The manipulated able
variable is transmitted by means of a serial interface. The manipu-
lated variable is transmitted by means of an analogue output.
The software determines the functions of the individual hardware
components. The software is installed in the Congrav® S. It is im-
Software
portant that the hardware functions may vary with different soft-
ware types.
Within a weigh-feeder the load cell is the subassembly that permits
to measure the weight loading of the weigh feeder, i.e. the belt load
Load cell
or the hopper contents. The weight signal of the load cell is proc-
essed by the Congrav® S as a function of the software.

1.3 Abbreviations

DI1 = 1st digital input

The digital inputs are numbered continuously. This leads to the DI
complete designation, e.g. DI1, DI2 etc.
DO1 = 1st digital output
The digital outputs are numbered continuously. This leads to the DO
complete designation, e.g. DO1, DO2 etc.
AI1 = 1st analogue input
The analogue inputs are numbered continuously. This leads to the AI
complete designation, e.g. AI1, AI2 etc.
AO1 = 1st analogue output
The analogue outputs are numbered continuously. This leads to the AO
complete designation, e.g. AO1, AO2 etc.

©Brabender Technologie, 2002 Page 5/21

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1.4 Signs and warnings used in the technical manual

The following signs are used in the technical manual to point out
important notes:

These notes are important and have to be absolutely observed.

Generally, this warning sign marks dangers for the operating staff
or possible damage to the feeding system. Attention!

Important information on the operation, for understanding etc…

Be sure to observe this note as it permits to prevent possible
sources of danger and to avoid the dangers in advance. Important!

Instruction to be followed. If this instruction is not observed, this

may lead to functional failures or damage to the individual subas-
semblies of Congrav® S. <Instruction>

This sign marks additional information or references to other

sources of information.

1.5 Signs on the Congrav® S

A 230VAC supply voltage is connected to Congrav® S via a coupler

plug. Attention to live voltage, before any work on Congrav® S, i.e.
exchange of fuses, removing the plug-in cards etc., the plug con-
nector must be disconnected.

©Brabender Technologie, 2002 Page 6/21

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2 Congrav S: types

The Congrav S is a micro-controller that permits to control and to

evaluate, according to the software employed, continuous and dis-
continuous feeding operations. Optional hardware extensions adjust
the standard hardware equipment of Congrav S to the specific appli-
cation. The type designation shows the hardware execution of Con-
grav® S.

S-E 1 2 = S-E standard I/O + hardware option1 + hardware option 2

In its standard execution the basic device is equipped with the fol-
lowing inputs and outputs:

Digital inputs 8 Basic device

Digital outputs 8
Pulse output 1 x throughput pulse
Digital speed 1 x max. 6kHz, 24VDC
EMS-load cell 1 x 0 – 25mV
Analogue speed 1 x 0 – 10VDC
Analogue manipulated variable 1 x 0 – 10VDC
Actual value output 1 x 0(4) – 20mA (!)
Interface: serial load cell 1 x RS422
Interface: host computer 1 x RS422 (!)
Interface: master/slave 1 x RS422 (!)
(!) == the hardware functions can only be guaranteed by the cor-
responding software option

1st Hardware option: Extension card B

EMS-load cell 1 x 0 – 10VDC Extension card B

Analogue control 1 x 0 – 10VDC
2nd actual value output 1 x 0(4) – 20mA (!)
(!) == see above

2nd hardware option: Centronics printer interface Printer

3rd hardware option: Extension card C

Digital outputs 16 Extension card C

4th hardware option: Extension card D

Digital outputs 16 Extension card D

Extension card D only in combination with extension card C.

At present, the additional analogue output on extension cards C + D

is not assisted by the software.

©Brabender Technologie, 2002 Page 7/21

 Technical Manual S-E

3 The electrical connections

3.1 Mains connection

The mains connection of Congrav S is realized on the rear panel of

the controller via the coupler plug that is also supplied. Voltages
between 85VAC and 250VAC are permissible. The mains frequency
may be 47Hz to 63Hz. The connector box is equipped with two
time-lag fine-wire fuses (2A).
The mains hum filter in the connector meets the safety regulations
as per UL 1283, CSA C 22.2 no.8 and VDE 565.3. Mains interrup-
tions that exceed the limits of the electromagnetic compatibility
85 - 250 VAC; 47-63Hz
(EMC) - see chapter "Technical data" - have to be avoided. 2A, time-lag

The earthing screw (M5) on the rear panel of Congrav

S has to be laid on PE by means of a suitable lead
(earthing strap 10x1,5mm). Congrav® S has to be earthed!

3.2 The connection of IO

In its standard execution the IO-module serves for the electrical con-
nection of Congrav S-E. The IO-module is a clamping unit suitable
for fixing rails, it has been specially designed for Congrav S-E. For
the connection to Congrav S-E you have to employ the corresponding
connection cables. The connection cables are available with a length
of 1,2m or 3m.

A direct connection to the D-sub-plug or the D-sub-socket on the

rear panel of Congrav S is not recommended. The small dimensions
that are due to the design cause considerable problems as far as
Important!
the electromagnetic compatibility is concerned.

Please observe that two IO-modules are available for Congrav® S.

IO-module-Congrav S: old design with transformer

IO-module-2-Congrav S: new design (without transformer)

The two IO-modules are not compatible, i.e. the terminal functions dif-
fer from each other.
Important!
If you substitute the IO-module by the IO-module-2:

" You need an external supply voltage 24VDC

" You employ the confectioned cables for both module types for
the connection between Congrav® S and the IO-module(-2).

©Brabender Technologie, 2002 Page 8/21

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3.3 The IO module for Congrav® S

The IO-module

" voltage supply: 230VAC or 115VAC.

" is equipped with an internal
24VDC/250mA-supply for the standard-
digital-IO.
" can be supplied by an external 24VDC-
voltage (jumper 1)
" for the connection of load cell types
IDL/F, IDL/F-1, AED-module, platform
scales series B (ED60 with integrated
Jumper 1 on the left side of the relay
BR201) an external voltage supply is re-
quired.
= external = internal

3.4 The IO module 2 for Congrav® S

A new IO-module has been developed for

Congrav® S, namely the IO-module 2.

The IO-module 2

" is not downwards compatible, as its

terminal functions differ from the first
IO-module.
" is not equipped with an own 24 VDC-
power supply unit, thus it always has to
be supplied externally by 24 VDC.
" permits the connection and the supply
of the load cell types IDL/F, IDL/F-1,
AED-module, platform scales series B
(ED60 with integrated BR201).

For a conversion from the IO-module to IO-module-2, please ob-

serve that retrofitting of an external 24VDC-voltage supply is re-
quired. Important!

How can I distinguish the versions of the IO-module?

1. Type designation on the identification plate. IO-module or IO-module 2

2. Structure of the IO-module. The new IO-module 2 for instance is
not equipped with a transformer. Instead, a DC/DC-converter is
mounted (see figure).
3. Different number of terminals. The IO-module 2 is equipped with
99 instead of 96 terminals.

©Brabender Technologie, 2002 Page 9/21

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3.5 Plan of terminal connections: IO-module

Terminal 1 Power supply

PE N N1 L PE
Insert Buffer amplifier or bridge Relais K1, K2, K3
for the internal use
+ - + - + - + - + - + - 1A, 48VDC
N L PE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
230VAC

K1 K2 K3 PE N N1 L PE
analogue control actual value 1

Speed manipul. var. output Operation Alarm Refill N1 L PE

115VAC

Terminal 2
single screening (no earth!)

Use bridge or
strain gauche 0-25mV
Screening
Measure signal -

Measuresignal +

Relais K1’, K2’, K3’ für die

24 VDC
supply +
supply -

for use on customer site

Sens +

GND
Sens -

+ - 2A, 230VAC RB RA TB TA RB RA TB TA

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

K1’ K2’ K3’

analogue Operation RS422 RS422

strain gauche 0-25mV
control
Alarm Refill + -
Load cell Master/Slave
external 24VDC-
Spower supply

Jumper 1

Terminal 3
Impulse
24 VDC

24 VDC
GND

GND

+ - + - + -
65 66 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96

DI DO

Actual
value 1 DO9: Load cell Actual
0(4)-20mA switch GND! 0-10 V value 2 + -
0(4)-20mA external 24VDC-
power supply

Jumper 1
+ -
out

Speed
reading
max. 6kHz

Interface cable type max. length Rev.: 1.4 power supply

24 VDC
RS422 Belden 9843 300 m Date : 02 - 06 - 27

analogue signal Liy(c)y 2x0.5mm² 300m by: Schell 0e114522

I/O module Congrav S

©Brabender Technologie, 2002 Page 10/21

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3.6 Plan of terminal connections: IO-module-2

Terminal1 Power supply

Insert Buffer amplifier or bridge Relais K1, K2, K3 Input

for the internal use 24 VDC
+ - + - + - + - + - + - 1A, 48VDC
+ + - -
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

K1 K2 K3
analogue control actual value 1

Speed manipul. var. output Operation Alarm Refill

Terminal 2
single screening (no earth!)

Use bridge or
strain gauche 0-25mV
Screening
Measure signal -

Measuresignal +

Relais K1’, K2’, K3’ für die

supply +
supply -

for use on customer site

Sens +
Sens -

+ - 2A, 230VAC RB RA TB TA RB RA TB TA 10V 15V GNDP

GND
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66

K1’ K2’ K3’

strain gauche 0-25mV analogue Operation Alarm Refill RS422 RS422

control Master/Slave Load cell

+10V supply for IDL load cell, max. 120 mA

+15V supply for IDL/2 load cell, for AED module, max. 200mA
GND for 10V and 15V supply

GND für ED60 im CP-FlowMeter

Terminal 3

24V supply for ED60 within CP-FlowMeter, max. 250mA

Impulse
24 VDC

GND

+ - + - + -
67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99

DI DO

Speed DO9:
reading actual value 1 throughput Load cell
max. 6kHz impulse 0-10 V
0(4)-20mA
Actual value2
0(4)-20mA

+ -
out

Interface cable type max. length Rev.: 1.2 power supply

24 VDC
RS422 Belden 9843 300 m Date : 02 - 06 - 27

analogue signal Liy(c)y 2x0.5mm² 300m by: Schell 0e112518

I/O module 2 Congrav S

©Brabender Technologie, 2002 Page 11/21

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3.6.1 Functions of the terminals

Description Type
Controller value for the control unit of the feed drive (e.g. AO Manipulated vari-
frequency converter). The software employed determines able
the course of the manipulated variable (e.g. PID-controller).
Analogue actual value signal (0(4)-20mA) for external AO 1st actual value
evaluation, if the corresponding software assistance is 2nd actual value
available.
0 -10VDC speed signal of the feed drive. Required by the AI Speed
software e.g. for monitoring purposes.
0 - 10VDC-signal for the setpoint control of the feeding op- AI Analogue control
eration, provided the corresponding software assistance is
available.
The start of the Congrav sets the operation output, i.e. the Relay Operation
corres-ponding relay contact is closed and could be em-
ployed for instance for the release of the connected control
unit of the feed drive.
The relay contact is closed or opened as a function of the Relay Alarm
software configuration after an alarm cut-out of the Con-
grav.
This function depends on the software of the Congrav®. Relay Refill
The refill contact for a loss-in-weight feeder will be set if the
hopper filling level of the loss-in-weight feeder reaches the
limit value filling level min. The refill contact will be reset, if
the hopper filling level reaches the limit value filling level or
max. This contact permits for instance to trigger the sole-
noid valve for the shut-off device of the refill device.
For a weigh-belt feeder the relay will be set, if the auto-tare Auto-tare
operation has been selected. The auto-tare operation of a
weigh-belt feeder is carried through on the weighing belt
but without product. The relay permits to trigger the shut-
off device for the product feed.
Serial interface for the coupling of several Congravs RS422 Master/slave
according to the master/slave-principle provided the corre-
sponding software assistance is available.

©Brabender Technologie, 2002 Page 12/21

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3.7 Wiring scheme Congrav® S and IO-module

3.7.1 Standard IO and extension card B

XS60

XS10
XS20
XS40
a
b
c
d

Connection cable 1,2 m reference 3m reference no. Basic device

no.
XS4 $ XS40 new: E000070 new: E000085 Load cell, Mas-
a
old: E0105769 old: E0105770 ter/slave
XS2 $ XS20 new: E000069 new: E000084
b Standard digital IO
old: E0105771 old: E0105772
XS1 $ XS10 new: E000068 new: E000083
c Standard analogue IO
old: E0105773 old: E0105774
XS6 $ XS60 new: E000101 new: E000082
d Extension card B
old: E0105825 old: E0106072

Further reference no.:

IO-module: new: E000067 (old: E0107900)

IO-module-2: new: E003394 (old: -)

Further connections:

XS3 = Host computer interface

XS5 = Centronics interface (2nd hardware option)

Designation of IO-plug-in cards:

Standard-IO: first slot and a red point

Extension card B: second slot and a green point

©Brabender Technologie, 2002 Page 13/21

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3.7.2 Standard IO and extension cards C + D

XS60

XS10
XS20
XS40
a
b
c

e
e

-XS90

UBE-D/25F UBE-D/25F
13 1 13 1

14 14

Connection cable 1,2 m reference no. 3m reference no. Basic device

XS4 $ XS40 new: E000070 new: E000085 Load cell, Mas-
a
old: E0105769 old: E0105770 ter/slave
XS2 $ XS20 new: E000069 new: E000084
b Standard digital IO
old: E0105771 old: E0105772
XS1 $ XS10 new: E000068 new: E000083
c Standard analogue IO
old: E0105773 old: E0105774
XS7 $ XS70 new: E000069 new: E000084 Extension card C
e
XS9 $ XS90 old: E0105771 old: E0105772 Extension card D

Further reference no.:

UBE-D/25F = new: E000417 (old: E0105994)

Designation of IO-plug-in cards:

Standard-IO: first slot and a red point

Extension card C: second slot and a yellow point
Extension card D: third slot and a blue point

©Brabender Technologie, 2002 Page 14/21

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4 The circuitry
4.1 General specifications

The following points have to be generally observed:

" The analogue inputs always have to be cabled by means of a

screened cable and the screening has to be connected to the cor-
responding terminals of the IO-module.
" The screening is connected to earth on both sides. The junction
boxes of the loss-in-weight feeders are equipped with special ca-
ble screwings that permit to connect the screening to earth.
" Unscreened tail pieces must not be longer than 4 cm.
" With an interruption of the control lines (terminals, relays, etc.)
the screenings have to be connected by the shortest way.
" The signals that lie on the analogue inputs and outputs have to
be at zero potential. Otherwise you have to employ suitable buffer
amplifiers for the galvanic separation.

4.1.1 The power supply of the IO-module

The IO-module can be supplied alternatively with 230VAC/47-63Hz

or 115VAC/47-63Hz.

The supply voltage must only be connected to the designated ter-

minals.
Important!

4.1.2 The internal 24VDC-supply of the IO-module

The IO-module is equipped with an internal 24VDC/250mA-supply

that is required for the supply of the standard-digital IO.
The internal 24VDC-supply only permits to connect external de-
Important!
vices with a maximum consumption of 75mA.

If the hardware options, i.e. the extension cards C and D, are em-
ployed, more power is required, thus a sufficiently dimensioned ex-
ternal 24VDC/2A supply has to be provided for the IO-module. The
external internal
jumper J1 permits to switch between internal or external supply.

Terminals Function
95(+) 96(-) external 24VDC-supply
63(+) 64(-) 24VDC-supply for the hardware options
73(+) 87(-) 24VDC- supply of the digital inputs/outputs

©Brabender Technologie, 2002 Page 15/21

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4.1.3 The external 24VDC-supply

The IO-module-2 always requires an external 24VDC-supply volt-

age. This is especially important if an existing controller is retrofit-
ted from an IO-module to an IO-module-2. In this case it may pos-
Important!
sibly be required to retrofit an external 24VDC-supply voltage.

The external 24VDC supply of the IO-module or the IO-module-2 has

to comply with the following points:

Voltage range 24 VDC +/- 15%, stabilised

Residual ripple < 200 mVss
Spikes < 300 mVss
Output depends on the applications
per digital input: 7mA
per digital output: max. 250mA
load cell as specified

4.1.4 Wiring of the digital inputs/outputs (DI / DO)

In its standard execution the Congrav S is equipped with 8 digital

inputs and 9 digital outputs. The integrated relays provide the Load Counter
first three digital outputs operation, alarm and refill (loss-in-weight
feeder) or auto-tare (weigh-belt feeder) as contacts free from poten-
tial. The digital outputs DO4 - 8 are transistor outputs.

24VDC
DO4

DO9
GND
Terminal functions as per
The digital output DO9 throughput-pulse output is terminal connection plan

an open collector and thus switches the 24VDC

GND potential. Important!

The digital inputs are set by connecting a voltage of 24VDC. The

digital inputs DI2, DI3 and DI4 are designed as pulse inputs for a
pulse length of 0.5s to 2s.
24VDC
DI1

DI2

DI3

DI4

Terminal functios as per

Voltages >28V risk to destroy the protective wir- terminal connection plan

ings of the digital inputs.

Important!

4.1.5 Digital inputs and digital outputs of extension cards C and D

The extension cards C and D provide another 16 digital outputs

each. These digital outputs can only be employed in combination
with the corresponding software. For the connection of the additional
digital outputs you need the interposition element XS70 (C) or the
interposition element XS90 (D). For the wiring of the additional digi-
tal outputs you have to observe the following points:

©Brabender Technologie, 2002 Page 16/21

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" The digital outputs 1 - 8 of the extension card are designed as

transistor outputs (positive logic).
" The digital outputs 9 - 16 are designed as open collector (neg.
logic).

This means a different wiring for the digital outputs.

Screening

14
11 10 9 8 7 6 5 4 3 DO 10, 26 +24VDC

Load
-XS 70, 90
-XS 70, 90

Load

21
DO 23, 39

24V GND 24V GND

Screening

25
Terminals Function XS70 XS90
1 Screening
2 not to be wired!
3 Digital output 10 26
4 Digital output 11 27
5 Digital output 12 28
6 Digital output 13 29
7 Digital output 14 30
8 Digital output 15 31
9 Digital output 16 32
10 Digital output 17 33
11 24GND 24GND
12 not to be wired!
13 not to be wired!
not to be wired!
14 Screening
15 24VDC 24VDC
16 Digital output 18 34
17 Digital output 19 35
18 Digital output 20 36
19 Digital output 21 37
20 Digital output 22 38
21 Digital output 23 39
22 Digital output 24 40
23 Digital output 25 41
24 24VGND 24VGND
25 Screening

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4.1.6 Wiring of the analogue inputs and outputs (AI/AO)

IO-Modul Congrav S
Screening and potential-free cabling is generally specified for the
-X1
analogue inputs and outputs. If required, special buffer amplifiers AE2: Drehzahl
AI2: Speed
that are suitable for potential-free cabling have to be employed. For 1 2 3

the analogue input analogue control and the 1st actual value output
corresponding terminals for the connection of a buffer amplifier are
available. Please observe that the corresponding terminals are U
Trennverstärker
bridged, if you do not employ buffer amplifiers (see plan of terminal buffer amplifier
U
connections). For the other analogue inputs and outputs it is pos-
sibly required to connect the necessary buffer amplifiers as per the
figure on the right. This goes especially for the analogue input U
Messstelle
speed and the analogue output manipulated variable, if you do not measuring point n
employ the Brabender standard components.

4.1.7 Wiring of the analogue mV-input

The analogue mV-input is employed for the direct connection of EMS

with 6/4-conductors (max. 25mV, bridge resistance ≥ 200Ω). For the
cabling we prescribe the cable type KAB9/00-2/2/2 (6 x 0.14mm²)
with a maximum length of 300m.
If the analogue mV-input is not used, the connections for the supply,
sense and the measuring signal have to be bridged.

33 34 35 36 37 38 39
Connect EMS or
bridge the inputs

An open mV-input (not wired) leads to functional disorders, for in-

stance with the analogue speed reading.

4.1.8 List of the assisted load cell types

EMS 0-25mV: Direct connection of 6/4-conductor EMS load cells

with a maximum voltage of 25mV and a bridge re-
sistance ≥ 200Ω.
EMS 0-10V: Only with the 1st hardware option
The load cell is connected by means of a corre-
sponding amplifier card, that supplies a 0-10VDC-
signal for reading data into Congrav ® S.
IDL/F: Digital load cell with serial communication record.

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 Technical Manual S-E

AED: The EMS-load cell is connected to the AED-module

for a serial data transmission.
Attention: requires separate power supply (not con-
nected to earth!)

4.1.9 Wiring of the serial interfaces

The IO-module provides the serial interfaces serial load cell and mas-
ter/slave, type RS422. For wiring the cable type BELDEN 9842 is
prescribed. This cable type is composed of two twisted leads with
nearly 100% screening. For the transmission and reception lead one
twisted pair of leads each is employed. As an alternative, the cable
type BELDEN 9843 can be employed. Three cable pairs are available,
so that it is possible to connect the necessary supply voltage for se-
rial load cells.

For the cabling of the serial interfaces be sure to provide correct ca-
bling of the screening.

Functional failures on a serial interface connection due to a

" wrong cable type or

" inexpert screening

cannot always be recognized as in most of the cases they only lead to

so-called sporadic faults. These faults are hard to find, because due
to the apparently functioning connection everything seems to be all
right. However, the safety of the operations is troubled by the distur-
bances on the serial interface.

On the IO-module-2 the terminals of the two serial interfaces load

cell and master/slave are interchanged compared to the IO-module!
Important!

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 Technical Manual S-E

5 Technical data

5.1 Electromagnetic compatibility

The device complies with the EC regulations 89/336/EWG and

73/23 EWG and the corresponding harmonized standards, especially
EN60204-1:1992, EN50081:1993 and EN50082-2:1994.

5.2 Data

Congrav® S Voltage range : 85 - 250 VAC

Frequency range : 47 - 63 Hz
Power consumption : 18 VA (basic device)
35 VA (max. equipment)
Climatic class : KWF as per DIN 40040
Ambient temperature : 0 to +45°C
Transport/storage : -25°C to +65°C
Humidity : up to 85% without condensa-
tion
Protection Front : IP65
Housing : IP30
Dimensions (HxWxD) : 144x144x244 mm
+ offset plug : app 265 mm
Weight : max. 3,4 kg

Digital inputs Logic : positive

Rated voltage : 24 VDC
Voltage range : max. 28 VDC
Input current : app. 3 mA
Switching threshold : app. 17 VDC
L/H

Digital outputs Output type : Transistor or pulse output

Logic : positive or negative
Rated voltage : 24 VDC
Voltage range : 21 - 28 VDC
Rated current/output : 0,25 A with 50% simultaneity
Switching threshold : app. 20 VDC
L/H

Frequency input Input voltage : 24 VDC

Input current : 10 mA
Frequency range : 0 - 6kHZ

Analogue inputs Input voltage : 0 - 10VDC

Resolution : 15 bit

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Input resistance : 200kΩ

mV-input Input voltage : 0 - 25 mVDC

EMS-supply : 10 VDC / max. 50 mA
Bridge resistance: : ≥ 200Ω
Resolution : 15 bit

Analogue Output voltage : 0 - 10VDC

voltage output Resolution : 12 bit
Output current : max. 5 mA

Analogue Output current : 0(4) - 20 mADC

current outputs max. burden : 500 Ω
Resolution : 12 bit

IO-module Mains supply : 230 VAC or 115 VAC

Frequency range : 47 - 63 Hz
Dimensions HxWxD : 110 x 190 x 78
internal 24 VDC 250mA

IO-module 2 Mains supply : 24 VDC +/- 15%

Dimensions HxWxD : 110 x 190 x 78
Internal 10 VDC : max. 120 mA Supply voltage IDL/F
Internal 15 VDC : max. 200 mA Supply voltage IDL/F2 or
AED
Internal 24 VDC : max. 250 mA Supply voltage ED60 (CP-
FlowMeter)

external 24VDC Voltage range 24 VDC +/- 15%, stabilised

Residual ripple < 200 mVss
Spikes < 300 mVss
Output Depending on the execution

5.3 Dimensions
9

144

panel cut-out
Congrav S Schalttafelausbruch

138
244
8 9
144 138
Xs 6 138
Step

144
244

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