K-TRON KSU-II/KCM Programming Instructions Manual
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K-TRON KSU-II/KCM Programming Instructions Manual

Kcm lwf programming
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Read this manual prior to operating
or servicing the equipment. This ma-
nual contains all safety labels and
warnings.
Original operating instructions
0590020601-EN Rev. 1.6.0
PROGRAMMING
INSTRUCTIONS
KCM LWF Programming
Software Version 2.0
text
text
M

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Summary of Contents for K-TRON KSU-II/KCM

  • Page 1 PROGRAMMING INSTRUCTIONS KCM LWF Programming Software Version 2.0 text text Read this manual prior to operating or servicing the equipment. This ma- nual contains all safety labels and warnings. Original operating instructions 0590020601-EN Rev. 1.6.0...
  • Page 2 If an error or ommission is found, please contact: documentation@ktron.com. Docu-No.: 0590020601-EN “K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part of operating personnel. Further, reference is made to the purchase order, acceptance or other document that contains Datum: 2011/Jan./03 the express K-Tron disclaimer of warranties for a statement of the provisions limiting or disclaiming certain warranties with respect to the Company's equipment.

  • Page 3: Table Of Contents

    Machine setup menu ......................34 1.7.1 General sub-menu ....................... 34 1.7.2 Changing feeder control application type ................35 1.7.3 KSU-II/KCM screen saver description ................. 36 1.7.4 Motor sub-menu ........................37 1.7.5 Motor sub-menu for DC motor .................... 37 1.7.6 Motor sub-menu for AC Interface drive ................39 1.7.7 Motor sub-menu for vibratory drive ..................
  • Page 4 1.10 HCU / LSR loader set-up ..................... 56 1.11 System setup (only KSU-II/KCM)..................58 1.11.1 Communication sub-menu ....................58 1.11.2 SW Version Submenu ......................59 1.11.3 Drive type by displayed MDU# ...................60 1.11.4 Parameter Backup sub-menu ....................61 1.11.5 Changing the K-PROM password..................61 1.12...
  • Page 5 5.4.6 Actiflow drive hex status codes ..................100 Loading language file ......................101 Service variables ....................... 102 LWF PSR Map ........................104 LWF ASR Map ........................106 Parameter listing-LWF ....................... 112 Docu-No.: 0590020601-EN Rev. 1.6.0 Page 5...
  • Page 6 Page 6 Docu-No.: 0590020601-EN Rev. 1.6.0...

  • Page 7: Programming Reference

    The following programming instructions covers LWF application programming for the displays KSU-II/KCM, KSL, K-Vision, KSC. This manual is only for skilled staff instructed by K-Tron. The menu architecture for the application is the same for all displays. The main differences between the displays are the navigation and the short variable name for the KSU-II/KCM.

  • Page 8: Manual Notation

    • Dialog box indication as <Dialog>. • Key or button as KEY The first parameter name (in CAPs) is for KSU-II/KCM display. The second parameter name below the first is for the KSL and KSC. The BOLD PARAMETERS are command functions for the KSU-II/ KCM.

  • Page 9: Abbreviations And Terminology

    • KCM-SD = KCM with status display only • kgr = host communication file residing in KCM • KSC = K-Tron Smart Commander, a PC based HMI system for use with up to 30 controllers • KSL = K-Tron line interface for up to 8 feeders •...

  • Page 10: Menu And Sub-Menu Listing

    Programming Reference 1.0.4 Menu and sub-menu listing • Product Change menu • Calibration menu – Calibration sub-menu – Feedfactor sub-menu • Alarm menu – Alarm limits sub-menu – Alarm setup sub-menu • Tuning menu • Refill menu • Scale menu –...

  • Page 11: Product Change Menu

    Programming Reference Product change menu 1.1 Product change menu This menu allows easy product changeover. See section • manuals to be used specifically when calibrating the feeder. 1.1.1 Product change parameters Parameter Definition REFILL ENABLED Setting for automatic refill. The net weight alarm limit is active.
  • Page 12 This command allows the current weight value to be entered into the TARE memory when the product hopper is empty. Switch of the automatic refill and then tare.  For KSU-II/KCM select parameter then press  For KSL press F5-MORE then  For KSC press TARE Weight of the feeder and hopper with no material.
  • Page 13 ▲ This command will start the feeder. Make sure that nobody is working on the machine.  For KSU-II/KCM select this parameter, press ENTER twice and then press RUN  For KSL press MORE-F5 then press then press RUN.
  • Page 14 <Empty Drive Cmd> may be changed by the Service Variables. ▲ This command will start the feeder. Make sure that nobody is working on the machine.  For KSU-II/KCM select EMPTY FDR, then press ENTER twice then RUN  For KSL press MORE-F5- then press then press RUN.
  • Page 15 Programming Reference Product change menu 1.1 Parameter Definition ACTIFLOW CALIB ActiFlow calibration function 1. Fill the feeder with material. 2. Set material characteristic “Easy, Medium, Hard or Manual“ in the KCM ActiFlow menu. 3. Run the ActiFlow calibration. Notes: • This calibration routine will run a frequency sweep on the ActiFlow to find the mechanical resonance point of the feeder.

  • Page 16: Calibration

    Programming Reference 1.2 Calibration Calibration Use the FF Calibration menu to perform feeder calibration. If the VOL RATE function is activated in the Service Variable Index, the volumetric rate will be calculated if a product bulk density is entered in the PRODUCT CHANGE menu. •...
  • Page 17 ▲ This command will start the feeder. Make sure that nobody is working on the machine.  For KSU-II/KCM select this parameter, press ENTER twice and then press RUN  For KSL press MORE-F5 then press then press RUN.
  • Page 18 Programming Reference 1.2 Calibration Parameter Definition SPAN This is the weight span and it is automatically calculated when an entry is made to the <ACT. PROD FED> variable. This is the value that corrects for massflow inaccuracy. For feeding, the span must be Weight Span nearly 1.000 or there is a problem with the weighing system.

  • Page 19: Feedfactors Sub-Menu For Motor Driven Feeders

    Programming Reference Calibration 1.2 1.2.2 Feedfactors sub-menu for motor driven feeders Parameter Definition REFILL ARRAY Refilling feedfactor storage array is on. The feeding factor values are stored in these registers when the gravimetric mode is active. During refilling, the stored Feedfactor Array or feeding factor values in conjunction with setpoint are Density Array...

  • Page 20: Feedfactors Sub-Menu For Vibratory Feeders

    Programming Reference 1.2 Calibration 1.2.3 Feedfactors sub-menu for vibratory feeders Parameter Definition MF @ 8% DC These individual values are calculated automatically by the function <AUTO FF CALIB>. When the setpoint change exceeds the <SEPT CHG LIM>, the Vibratory FF 8% controller switches to using the appropriate MF value at the Drive Command expected.

  • Page 21: Alarm Menu

    Programming Reference Alarm menu 1.3 Alarm menu This menu sets the alarm parameters and limits. Any alarm that is set in percent, is disabled when the entry is <0>. 1.3.1 Limits sub-menu Parameter Definition MASSFLOW ERR+[%] Massflow error limit is the permissible difference in percentage Massflow (+) Alarm Limit between the setpoint and mass flow without triggering an alarm.
  • Page 22 Programming Reference 1.3 Alarm menu Parameter Definition NW HI LIMIT Maximum product level, by weight, above which an alarm is immediately triggered. If this condition is triggered, the controller switches to volumetric control. Net Weight High Limit Input range: 0 to scale range Default: 0 kg = no alarm Table page 2 of 2 Page 22 Docu-No.: 0590020601-EN Rev.

  • Page 23: Alarm Setup Sub-Menu

    Programming Reference Alarm menu 1.3 1.3.2 Alarm setup sub-menu Parameter Definition ALARM DELAY [sec] Time between the alarm detection and activation of the alarm relay output when the alarm is of the type <Timed> or <Timed-Stop>. The alarm output will not be activated and the alarm will be cancelled if Alarm Delay the fault is corrected within this time period.
  • Page 24 The KSL will display this data on the Alarm Log screen. • Board reset: KCM CPU was shutdown • Local display: KSU-II/KCM STOP key pressed • External display: KSL or KSC STOP key pressed • ALS Input: Alarm shutdown input caused the stop •...

  • Page 25: Tuning Menu

    Programming Reference Tuning menu 1.4 Tuning menu This menu programs the tuning and control parameters for the application. Please review the section 5.1.3 and the two sections following for more information on control performance. 1.4.1 Tuning parameters Parameters marked ** are only displayed when <METHOD> = <Man- ual>.
  • Page 26 Note: Note: Not for vibratory feeders This parameter is displayed at the KSU-II/KCM only if the proper motor drive is installed and the proper gear reduction is entered. This parameter is not used for vibratory drives. Table page 2 of 3 Page 26 Docu-No.: 0590020601-EN Rev.

  • Page 27: Method Selection Versus Tuning Parameters Table

    Programming Reference Tuning menu 1.4 Parameter Definition SETPT CHG LIM Defines control behavior during setpoint changes when a vibratory feeder is used. If the setpoint change exceeds the input value, the behavior is executed on the basis of the calculated calibration curve. Vibratory SP See FF@%DC in the CALIBRATION menu, FEEDFACTOR sub- menu.

  • Page 28: Refill Menu

    Programming Reference 1.5 Refill Menu Refill Menu This menu allows easy refill set-up. Parameter Definition REFILL Enabled Setting for automatic refill. The net weight alarm limit is active. Disabled The feeder hopper can be emptied without refilling being Refill Enable triggered.
  • Page 29 Programming Reference Refill Menu 1.5 Parameter Definition VALVE DELAY This Entry is used to activate the refill complete target software. The exact time of closing the "Refill Window" output signal varies automatically based on the "as measured" refill rate and the parameter ValveDelayTime to avoid over filling the feeder.

  • Page 30: Scale Menu

    AUTO TARE This command allows the current weight value to be entered into the TARE memory when the product hopper is empty.  For KSU-II/KCM select parameter then press  For KSL press F5-MORE then  For KSC press SPAN Input of the span correction factor for fine compensation of mechanical scale weighing errors.

  • Page 31: Sft Sub-Menu

    REPOLL This command will cause the controller to execute a poll on the weight/internal channel to locate connected and operational SFTs by address.  For KSU-II/KCM select this parameter and press twice.  For KSL press  For KSC press AUTO READDRESS This parameter allows SFTs to be auto-readdressed automatically.
  • Page 32 Programming Reference 1.6 Scale menu Parameter Definition SFT SELECTED Selects the SFT to query parameters: SFT #, SFT SN#, SFT ADDRESSED, SFT WEIGHT, SFT TYPE, SFT STATUS. Node # Of Selected SFT Input range: 0 to 11 SFT ADDRESSED Switching <Off> will address the selected SFT to <0>. Switching <On>...

  • Page 33: Manual Addressing Of Sfts

    Programming Reference Scale menu 1.6 1.6.3 Manual addressing of SFTs To set the address of a newly installed SFT to a prescribed address, follow the next procedure. 1. Select SCALE menu, SFT sub-menu. 2. View SFTs variable to verify the SFT in question is at address <0>. 3.

  • Page 34: Machine Setup Menu

    Programming Reference 1.7 Machine setup menu Machine setup menu This menu programs the feeder specific information. The data is arranged in three separate screens or menus. 1.7.1 General sub-menu Parameter Definition SETPOINT MODE Setting Meaning LOCAL Feeder is operated as an individual unit. Setpoint Mode RATIO Percentage of an external analog setpoint input =...

  • Page 35: Changing Feeder Control Application Type

    Default: LWF for LWF LANGUAGE Selects the desired language for the Display. Choices are English, German, French, Spanish, Italian and Custom. Only in KSU-II/KCM SCREEN SAVER When set to <On> activates the KSU-II and KCM screen saver function. Only in KSU-II/KCM...

  • Page 36: Ksu-Ii/Kcm Screen Saver Description

    Programming Reference 1.7 Machine setup menu 1.7.3 KSU-II/KCM screen saver description The screen saver is used to protect the screen from burning out when always the same data is shown. The screen saver is based on the parameter <MACHINE SETUP> menu, <GENERAL> sub-menu, <SCREEN SAVER>...

  • Page 37: Motor Sub-Menu

    Programming Reference Machine setup menu 1.7 1.7.4 Motor sub-menu Some parameters will not be displayed for every drive case. T The motor sub-menu is shown for four types of drives. • DC drives for 450 and 1600 watts • AC interface drive •...
  • Page 38 Programming Reference 1.7 Machine setup menu Parameter Definition MAX MOT SPEED - [rpm] Input of the maximum motor rpm for 100% drive command. Input range: Drive specific. Default: drive specific Maximum Motor Speed (See nameplate on motor for value) MDU STATUS The MDU status codes reveal operational condition of the Drive.

  • Page 39: Motor Sub-Menu For Ac Interface Drive

    Programming Reference Machine setup menu 1.7 1.7.6 Motor sub-menu for AC Interface drive Parameter Definition GEAR REDUC This parameter is used if the Screw Modulation or the Auto Gear Reduction functions are used. This entry must be the total reduction value between the drive motor and the feed screw.

  • Page 40: Motor Sub-Menu For Vibratory Drive

    Programming Reference 1.7 Machine setup menu 1.7.7 Motor sub-menu for vibratory drive Parameter Definition KV DEVICE Selection of the used Vibratory type. KV1=1, KV2=2, KV3=3. Vibratory Type Input range: 1,2,3 Default: KV2=2 VIB SPAN Span adjustment for vibratory tray displacement. The displacement must be measured at the vibratory and the SPAN calculated according following formula: Vibratory Displacement...

  • Page 41: Motor Sub-Menu For Universal Stepper Motor

    Programming Reference Machine setup menu 1.7 1.7.8 Motor sub-menu for universal stepper motor • Some parameters will not be displayed for every drive case. This section is used for stepper motor driven feeders. A chart of stepper motor sizes will be provided to aid in proper programming. •...

  • Page 42: Motor Sub-Menu For Hipo, Lopo Stepper Motor

    Programming Reference 1.7 Machine setup menu 1.7.9 Motor sub-menu for HiPo, LoPo Stepper motor This chart is used to program the HiPo and LoPo stepper drives, part numbers 0000004568 and 0000001430 respectively. Parameter Definition GEAR REDUC This parameter if entered as the gear reduction value between the stepper motor and the disk/screw, results in the disk/screw speed being displayed in the parameter <SCREW SPEED>.

  • Page 43: Stepper Motor Programming Table

    Programming Reference Machine setup menu 1.7 1.7.10 Stepper motor programming table • Stepper motor mounted optical encoder provides 400 pulses per revolution-quadrature. • For BSP150-S, use a gear reduction of 2.00. • This list may change. Review stepper motor label before selecting stepper drive and programming.

  • Page 44: Service Sub-Menu

    Programming Reference 1.7 Machine setup menu 1.7.11 Service sub-menu Parameter Definition S.VAR Display of the service variable name. See list in the appendix see section 5.6. Service Variable Function S.VAR VALUE Display and change of the service program value as selected with S. VAR.

  • Page 45: Performance Sub-Menu

    Programming Reference Machine setup menu 1.7 1.7.12 Performance sub-menu Depending upon drive type, certain parameters will not be displayed. Parameter Definition CONTROL-% This parameter is a quality indicator of loss-in-weight feeding performance. This value uses the same technique like the pert value calculation in relation to the setpoint where 100% means no noise, Control-% 0% means too much noise.
  • Page 46 Programming Reference 1.7 Machine setup menu Parameter Definition BRUSH REMAIN-% The DC motor brush life is estimated according to the following formula: Estimated_Life = Expected_Life * Nominal_Power / Current_Power Brush Remain-% To indicate the remaining life, the following formula is calculated once per second: Brush_Remain = Brush_Remain - [(100/(3600*5000))*(MotorPower / Nominal_Power)]...

  • Page 47: Actiflow Sub-Menu

    Programming Reference Machine setup menu 1.7 1.7.13 Actiflow sub-menu This menu is only displayed, if a actiflow is connected. Parameter Definition DISPLACE.[%] Displacement of the actiflow. Input range: Display only MATERIAL Setting of the vibration from the Actiflow according to the material properties.

  • Page 48: I/O Menu

    Programming Reference 1.8 I/O Menu I/O Menu These menus program the digital and analog I-O functions. The KSL shows these variables over four pages; Digital Output, Digital Input, Analog Input, Analog Output. The KSC uses 3 screens. See KCM Electronics manual for wiring details I/O Definitions: •...

  • Page 49: Digital Input Sub-Menu

    Programming Reference I/O Menu 1.8 1.8.1 Digital input sub-menu Parameter Definition DIG IN Selection of the desired bit input of the KCM for programming. Select any of the following inputs: CPU1-CPU4, MDU_IN1, MDU_IN2, Spare 1, Spare 2, Ext _In1 - Ext _In8. Digital Input Note: For Ext In function to work, Modbus I-O must be configured first and...

  • Page 50: Digital Output Sub-Menu

    Programming Reference 1.8 I/O Menu 1.8.2 Digital output sub-menu It is not allowed to change Digital output function, polarity and map if the feeder is running. Parameter Definition DIG OUT Selection of the desired bit output of the KCM for programming. Select CPU_Out1 to CPU_Out4, MDU Relay 1, MDU Relay 2, MDU Relay 3, Spare, Ext_Out1 to Ext_Out8.

  • Page 51: Setpoint Input Sub-Menu

    Programming Reference I/O Menu 1.8 1.8.3 Setpoint input sub-menu Refer to manual KCM Electronics for more information. For calibration, see section 3.2. Parameter Definition SOURCE Selection of the desired remote setpoint input for the KCM. Select CPU_0-10kHz, CPU_Analog, Extern Notes: Analog Input Source •...

  • Page 52: Analog Output Sub-Menu

    Programming Reference 1.8 I/O Menu 1.8.4 Analog output sub-menu • The KCM CPU only outputs a 0-20 mA current value. Use appropriate resistors to convert to the desired voltage. • Maximum source voltage is 12 Vdc for the current output. •...

  • Page 53: Modbus I-O Sub-Menu

    Programming Reference I/O Menu 1.8 1.8.5 Modbus I-O sub-menu Note: • This menu is not available on the KSL, K-Vision or KSC. Parameter Definition ADDR 80 - 83 These are the read only I-O addresses for any external Modbus I-O that has been connected to K-Port 2.

  • Page 54: Adding External Modbus I-O, An Example

    Programming Reference 1.8 I/O Menu 1.8.6 Adding External Modbus I-O, an example Follow this procedure to configure remote I-O.  Preset the Modbus I-O module to an address of 80, 81, 82 or 83.  Program the Modbus I-O module to follow the K-Port 2 communication specifications –...

  • Page 55: Loader Menu

    Programming Reference Loader menu 1.9 Loader menu This menu programs the vacuum loader function. No HCU is required. See section for more information on loader applications. Notes: • In later KCM S/W versions 1.3 and later, this menu will be hidden if an HCU is connected to the KCM.

  • Page 56: Hcu / Lsr Loader Set-Up

    Programming Reference 1.10HCU / LSR loader set-up 1.10 HCU / LSR loader set-up This menu programs the Hurricane loader function. This menu is used in place of the HSU. • This menu is only displayed, if a HCU / LSR is connected. •...
  • Page 57 Input range: Display only PARAM NUM Input of the parameter number. The name and value represented by the parameter number will be displayed under the variables PARAM Only in KSU-II/KCM DESC and PARAM VALUE respectively. Input range: see section and manual 0290023601.

  • Page 58: System Setup (Only Ksu-Ii/Kcm)

    Programming Reference 1.11System setup (only KSU-II/KCM). 1.11 System setup (only KSU-II/KCM). This menu is only used with the KSU-II/KCM display and not available for KSL, K-Vision or KSC. This menu programs the key communication functions for the KCM. Note: • Siemens 3694R protocol is not supported.

  • Page 59: Sw Version Submenu

    Selection of the Hardware The application software part number and revision. The hardware number and revision. SER# The serial number. Note: • Before calling K-Tron service, have the SW version numbers available for your system. Docu-No.: 0590020601-EN Rev. 1.6.0 Page 59...

  • Page 60: Drive Type By Displayed Mdu

    Programming Reference 1.11System setup (only KSU-II/KCM). 1.11.3 Drive type by displayed MDU# MDU # Software from Display MDU Drive Type PCB Part Number 04900-20211 1600 Watt DC motor drive 0000002610 02900-20200 450 Watt DC motor drive 0000007405 04900-20202 AC drive interface...

  • Page 61: Parameter Backup Sub-Menu

    Programming Reference System setup (only KSU-II/KCM). 1.11 1.11.4 Parameter Backup sub-menu This menu provides a method for parameter back-up in the KCM K- Prom. It is important to save your programming to the K-Prom using the steps below, once your programming is verified and complete.

  • Page 62: Security Menu (Only Ksu-Ii/Kcm)

    1.12Security menu (only KSU-II/KCM) 1.12 Security menu (only KSU-II/KCM) This menu sets access for all menus in the KSU-II/KCM. • The access to the parameter in the security menu can be de- activated by the data lockout input of the KSU-II/KCM display (see section 1.12.2).

  • Page 63: Function Data Lock Out

    Programming Reference Security menu (only KSU-II/KCM) 1.12 1.12.2 Function data lock out To activate the security function is it necessary to assign a digital input to <Data Lock> by KCM/KD or use the data lock input from KSU-II and to connect a key switch to that input. To enable the security menu to change the settings the key switch needs to be closed.

  • Page 64: Calibration

    Calibration 1.12Security menu (only KSU-II/KCM) Calibration Calibration should be done on a regular basis and the tare values and MF or WT Span values recorded for future use. Refer to the operating manuals for this activity. • For detailed operating instructions, use operating manual KCM.

  • Page 65: Other Programming

    Other Programming Setting refill parameters 3.1 Other Programming Setting refill parameters 3.1.1 Setting the Refill Max value 1. Select the REFILL menu. 2. Select <REFILL MAX> parameter. 3. Enter a suitable value. 4. Execute a refill to verify that the scale does not over-range or that material does not back-up into the hopper in-feed port.

  • Page 66: Setting The Refill Timer

    Other Programming 3.1 Setting refill parameters 3.1.4 Setting the Refill Timer Refill timer set-up equipment required: • Stop watch Refill timer set-up procedure: 1. Execute a refill 2. Start a stop watch when the refill begins 3. Stop the stop watch when the refill is compete and the discharge device stops discharging product.

  • Page 67: Calibrating Analog I-O

    Other Programming Calibrating analog I-O 3.2 Calibrating analog I-O The formula for an analog value output can be demonstrated by the following formula as an example. Setpoint will be used as the value and 20 mA is the full scale representation. ...

  • Page 68: Using An External Motor Drive

    Other Programming 3.3 Using an external motor drive Using an external motor drive To use an external motor drive rather than the internal KCM motor drive, do the following: 1. The AC Interface drive board is installed. 2. In the ANALOG OUTPUT sub-menu, set the following: –...

  • Page 69: Alarm Messages- Cause And Remedy

    • The HCU is the control unit for the Hurricane vacuum material loader for the feeder. It is programmed via the KSU-II/KCM and its alarms are reported there. • The first number is the KCM alarm, the second the HSU alarm.
  • Page 70 Alarm Messages- Cause and Remedy 4.1 System alarms Alarm Num- Alarm Cause Remedy  Locate which SFT has failed on the 06 WT PROC • SFT(s) failed. FAILURE <SFTs> line in the <SCALE> • Serial communication to the load cell Menu, <SFT>...
  • Page 71 Alarm Messages- Cause and Remedy System alarms 4.1 Alarm Num- Alarm Cause Remedy  Reduce motor load. • Motor current limit is exceeded. MOTOR  Check motor power limit in the Note: OVERLOAD <MECHANICAL> menu, The Safety switch is not designed to be <MOTOR>...
  • Page 72 Alarm Messages- Cause and Remedy 4.1 System alarms Alarm Num- Alarm Cause Remedy  Clear alarm. 23/01 • EEPROM failed. HCU EEPROM Change EEPROM or HCU. FAILED  Cycle power to the HCU.  Change HCU. 24/02 • The controller's digital output driver HCU DRIVER has detected a fault.
  • Page 73 Alarm Messages- Cause and Remedy System alarms 4.1 Alarm Num- Alarm Cause Remedy  Make corrections as necessary. • Protocol of KGR file does not match KLINK WRONG that required by the installed com- munication circuit card.  Load KGR file with SmartConfig or 31 KLINK NO KGR •...
  • Page 74 Alarm Messages- Cause and Remedy 4.1 System alarms Alarm Num- Alarm Cause Remedy  Check status line. 42 START • Start conditions not fulfilled. IGNORED  Check for setpoint and re-enter if necessary.  Check all KCM digital inputs for correct operation.
  • Page 75 Alarm Messages- Cause and Remedy System alarms 4.1 Alarm Num- Alarm Cause Remedy  Check for proper feeding of 46 DRIVE CMD • The drive command has exceed the HIGH value <DRV CMD HI> Limit in the material. <ALARM> menu. –...

  • Page 76: Lwf Alarms

    Alarm Messages- Cause and Remedy 4.2 LWF alarms LWF alarms Cause Remedy Process alarms  Enter new feedfactor. 52 FEEDFACT. BAD • Feedfactor is zero or feeding condition changed so that the  Check feedfactor limit in <ALARM> feedfactor exceed the set limit in the menu <FF DEV LIMIT>.

  • Page 77: Display Messages

    Alarm Messages- Cause and Remedy Display messages 4.3 Display messages Message Cause Remedy  Enter a value within the permitted Out of Range • Maximum permissible input value Tare Failed has been exceeded. limits of the parameter. See the specific programming manual for more information.

  • Page 78: Massflow Variances In Lwf Feeding

    Alarm Messages- Cause and Remedy 4.6 Massflow variances in LWF feeding Massflow variances in LWF feeding Alarms Cause Remedy  Improve the location of the scales. General massflow • Vibrations and drafts on feeder. fluctuations LWF – Reduce the <CTRL GAIN> in the <TUNING>...
  • Page 79 Alarm Messages- Cause and Remedy Massflow variances in LWF feeding 4.6 Alarms Cause Remedy  Increase lower refilling level in General massflow During Refill: fluctuations LWF program parameter <PRODUCT MASSFLOW HIGH. (continued) CHANGE> menu, <REFILL MIN>, • Increased degree of feeder-screw reduce the refilling speed or fit filling or even the material is flowing different feeder screws if...

  • Page 80: Appendix

    Notes: • See KCM Electronics manual for wiring information on reversing motor rotation. • Automatic gear switching is only possible on selected K-Tron feeders that utilize the dual speed gearbox. Refer to the feeder manual for specific details. To use the gear switching one must connect a reversing contactor to a digital output of the KCM.
  • Page 81 Appendix Special KCM LWF features 5.1 gear ratio. The screw speed modulation algorithm will automatically use the correct gear reduction. To operate the gear switch manually, the user can select High or Low to the GEARSWITCH parameter in the PRODUCT CHANGE menu. To operate the gear switch automatically, the user can select Auto Hi or Auto Lo to the GEARSWITCH parameter in the PRODUCT CHANGE menu.

  • Page 82: Sft Addressing

    Appendix 5.1 Special KCM LWF features 5.1.2 SFT Addressing SFT version 'S' and later version SFTs, have special means to allow readdressing of individual SFTs with the same address. These are: 1. A command to poll and identify SFT's with the same address based on their serial number.

  • Page 83: Lwf Tuning For The Kcm

    Appendix Special KCM LWF features 5.1 5.1.3 LWF tuning for the KCM The Pert Value shows us the noise condition of the netweight even if the self tuning is off and the feeder is stopped. This is called net weight quality.

  • Page 84: Tuning Parameter Descriptions

    Appendix 5.1 Special KCM LWF features 5.1.5 Tuning parameter descriptions Parameter Range Description Adaptive Gain If the adaptive gain feature of the KCM is <On>, this value shows the amount of adaptive gain set by the controller. Self Tuning: On The adaptive gain will automatically adjust to give the best gravimetric performance.

  • Page 85: Refill Algorithms For The Kcm

    Appendix Special KCM LWF features 5.1 5.1.6 Refill Algorithms for the KCM Refill modes selections include: – Manual – Automatic-Auto – Automatic_Terminate Refill Mode: Manual Manual refill mode is designed for those applications, particularly for low federate applications where bulk material will be randomly added to the feeder.
  • Page 86 Appendix 5.1 Special KCM LWF features Refill Mode: Auto Automatic refill mode-terminate is designed for those applications where material addition to the feeder is from an automated refill system. Hopper Weight Refill Max Refill Min Net Weight Low Empty Refill Window active high active high Refill Alarm...
  • Page 87 Appendix Special KCM LWF features 5.1 Refill Mode: Auto Terminate Automatic refill mode-terminate is designed for those applications where material addition to the feeder is from an automated refill system. Hopper Weight Refill Max Refill Min Net Weight Low Empty Refill Window active high active high...

  • Page 88: Refill Using The Integrated Loader Function

    Appendix 5.1 Special KCM LWF features 5.1.7 Refill using the integrated loader function If the <Loader> function parameter is set to <On> and <Refill> is <Enabled> and the loader enable bit input is activated, the internal KCM loader algorithm is enabled. Normal operation sequence: –...
  • Page 89 Appendix Special KCM LWF features 5.1 The next diagram shows the refill & load cycle when loading of the loader hopper fails. Hopper Weight Refill Max Refill Min Refill Window active high Loader Motor Hi=On Prox SW input Hi = no material Loader Alarm Time Fig.
  • Page 90 Appendix 5.1 Special KCM LWF features The next diagram shows refill with empty loader due to failed proximity switch Hopper Weight Refill Max Refill Min Refill Window active high Loader Motor Hi=On Prox SW input Low = material Loader Alarm Time Fig.
  • Page 91 Appendix Special KCM LWF features 5.1 The next diagram shows refill during loading of the loader hopper. Hopper Weight Refill Max Refill Min Refill Window active high Loader Motor Hi=On Prox SW input Hi = no material Loader Alarm Time Fig.
  • Page 92 Appendix 5.1 Special KCM LWF features The next diagram shows loading an empty hopper. Hopper Weight Refill Max Refill Min Refill Window active high Loader Motor Hi=On Prox SW input Hi = no material Time 2 sec Fig. 5.8 Loading an empty loader and refilling function diagram Notes: •...

  • Page 93: Programming The Loader Function

    Appendix Programming the loader function 5.2 Programming the loader function Use this procedure to program the KCM for the internal loader function. This is not for the LSR/HCU loader function. The Level Indicator must be placed so that it is covered when the loader is full.

  • Page 94: Programming Parameters For Hcu

    Appendix 5.3 Programming parameters for HCU Programming parameters for HCU This table shows parameter number and description, which can be entered in the section 1.10 for HCU loader control. 1.9.1For a detailed description of all parameters see manual 0290023601. Param Number/ Param description Step Default Actual...

  • Page 95: Status Tables

    Appendix Status tables 5.4 Status tables 5.4.1 DC Drive hex status codes-1600/450 W drives Notes: • Failure modes occur on bits 7 to 15, excluding 9 • These codes are displayed at the KCM interface Function Hex Code 1 = Motor Run. 0 = Stop. 0001 1 = safety switch closed.

  • Page 96: Vibratory Drive Hex Status Codes

    Appendix 5.4 Status tables 5.4.2 Vibratory drive hex status codes Notes: • Failure modes occur on bits 7 to 15, excluding 9 • These codes are displayed at the KCM interface Function Hex Code 1 = Motor Run. 0 = Stop. 0001 1 = safety switch closed.

  • Page 97: Stepper Drive Hex Status Codes For All Types

    Appendix Status tables 5.4 5.4.3 Stepper drive hex status codes for all types Notes: • Failure modes occur on bits 7 to 15, excluding 9 • These codes are displayed at the KCM interface Function Hex Code 1 = Motor Run. 0 = Stop. 0001 1 = safety switch closed.

  • Page 98: Ac Drive Interface Hex Status Codes

    Appendix 5.4 Status tables 5.4.4 AC drive interface hex status codes Notes: • Failure modes occur on bits 7 to 15., excluding 9 • These codes are displayed at the KCM interface Function Hex Code 1 = Motor Run. 0 = Stop. 0001 1 = safety switch closed.

  • Page 99: Sft Status Table

    Appendix Status tables 5.4 5.4.5 SFT status table This table shows the table of the possible Status displayed in the scale menu at the variable SFT Status 1.6.2. Function Code 1 = Group mode 0001 1 = Group leader 0002 Not used 0004 1 = Continuous mode...

  • Page 100: Actiflow Drive Hex Status Codes

    Appendix 5.4 Status tables 5.4.6 Actiflow drive hex status codes Notes: • Failure modes occur on bits 7 to 15, excluding 9 • These codes are displayed at the KCM interface Function Hex Code 1 = Activator Run. 0 = Stop. 0001 1 = safety switch closed.

  • Page 101: Loading Language File

    Appendix Loading language file 5.5 Loading language file It is important to erase any previous file before downloading a new one since it will not overwrite an existing file. Downloading a language file 1. To load the language file to the KCM, switch parameter SYSTEM - COMMUNICATION - CONFIG MODE to "Diag".

  • Page 102: Service Variables

    Appendix 5.6 Service variables Service variables This table shows the Service Index which can be entered for Service Variables on page A service technician can enter current values for reference. Variable Desc Current Value PreLoad MF=SP When set to <1> the MF value is preloaded with SP upon KCM starts or large SP changes.
  • Page 103 Appendix Service variables 5.6 Variable Desc Current Value PertValueMode 0 = PertValue is displayed in Grams 1 (default) = PertValue is displayed as a % of setpoint. With setpoint=0, pertvalue is shown in Grams. MFDispFilter2 For LWF Only: If <0>, the massflow display is filtered only by the variable <MF Display Filter>.

  • Page 104: Lwf Psr Map

    Appendix 5.7 LWF PSR Map LWF PSR Map PSR( Description Process number) 02 RUN • Motor/machine running 03 DISABLE • Run disabled by Interlock input or run enable input 04 ENABLE • Drive output enabled 05 ALS_IN • Alarm shutdown input active 06 ALS-OUT •...
  • Page 105 Appendix LWF PSR Map 5.7 PSR( Description Process number) 45 REFILL_BP_IN • Refill bypass input status 46 VOL_MODE_IN • Volumetric input status 47 EXTERN_IN • Extern (local) input status 48 DIRECT_IN • Direct (ratio) input status 49 EXT_AL_IN • External alarm input status 51 GEAR_SW_OUT •...

  • Page 106: Lwf Asr Map

    Appendix 5.8 LWF ASR Map LWF ASR Map See section for alarm specifics. ASR( Description Alarm number) 00 HARDWARE • KCM Hardware error. EEPROM ERROR data is corrupt. For example, this message will occur after updating or changing firmware on the KCM. 01 KPROM MEM •...
  • Page 107 Appendix LWF ASR Map 5.8 ASR( Description Alarm number) • Motor drive has lost communication MDU SERIAL with the KCM CPU and then turns off TIMEOUT all digital outputs and shuts of drive power. 12 MDU THERMAL • Drive temperature has been exceeded >...
  • Page 108 Appendix 5.8 LWF ASR Map ASR( Description Alarm number) 20 MDU POLARITY • Coil polarity is incorrect on the vibratory drive. (Vibratory feeder only) • Displacement frequency out of range. 21 HCU REMOVED • HCU was removed. 22 HCU ALARM •...
  • Page 109 Appendix LWF ASR Map 5.8 ASR( Description Alarm number) 29/07 • Receiver is still full after discharge. HCU REV.FULL AL. • Receiver proximity switch too sensitive adjusted or failed. • Protocol of KGR file does not match KLINK WRONG that required by the installed com- munication circuit card.
  • Page 110 Appendix 5.8 LWF ASR Map ASR( Description Alarm number) 45 DRIVE CMD • Drive command has reached the CEILING limit <DC CEILING> 46 DRIVE CMD • The drive command has exceed the HIGH value <DRV CMD HI> Limit in the <ALARM>...
  • Page 111 Appendix LWF ASR Map 5.8 ASR( Description Alarm number) 55 NETWT > LIMIT • The material weigh in the hopper is above the limit set in the <ALARM> menu. <NW HI LIMIT>. 56 NETWT < LIMIT • The material weigh in the hopper is below the limit set in the <ALARM>...

  • Page 112: Parameter Listing-Lwf

    Appendix 5.9 Parameter listing-LWF Parameter listing-LWF Value Menu Variable Home Drive Cmd-% Net Weight Motor RPM Not always visible Screw RPM Displacement(vib) Ave FF Total Product Change Menu Refill Refill Max Refill Min Gearswitch Tare Weight Net Weight Init Feedfactor Not always visible Bulk Density Page 112...
  • Page 113 Appendix Parameter listing-LWF 5.9 Menu Variable Value Calibration Menu Calibration sub Initial Feedfactor Average Feedfactor Cal Product Fed Act Product Fed Span Cal Correla Cal Corr Limit Cal DC-% Cal Time [sec] Calibration Menu Refill Array Feedfactor sub FeedFactor 1 Feedfactor 5 Feedfactor 9 For vibratory only...
  • Page 114 Appendix 5.9 Parameter listing-LWF Menu Variable Value Alarm Menu FF Dev Limit-% Limits sub Net Weight Low Limit Max Refill Time NW Hi Limit-% NW Lo Limit-% Alarm Menu Alarm Delay-sec. Set-up sub Startup Delay-sec. Stops Clrs Alarms ALR Number ALR Mode Stop By: Read only...
  • Page 115 Appendix Parameter listing-LWF 5.9 Menu Variable Value Refill Menu Refill Refill Max Refill Min Post Refill Delay Refill Mode Valve Delay Flt Clear Time Scale Menu General sub Tare Span Net Weight Gross Weight Scale Range SFT sub SFT Required SFTs SFT Selected SFT Addressed...
  • Page 116 Appendix 5.9 Parameter listing-LWF Menu Variable Value Machine Menu General sub Setpoint Mode Max Setpoint Units Run Time - hours Fdr Address Machine Menu Application General sub Language Screen Saver Machine Menu Gear Reduction Motor sub Gear Reduction L Pick-Up Teeth Actual Power Maximum Motor Power Maximum Motor Voltage...
  • Page 117 Appendix Parameter listing-LWF 5.9 Menu Variable Value Machine Menu Control Performance sub Grav Ratio Int Channel KCM Temperature Torque Brush Remain Machine Menu Displace. Actiflow sub Status Voltage Current Frequency I-O Menu CPU1 Digital Inputs CPU2 CPU3 CPU4 MDU1 MDU2 Ext1 Docu-No.: 0590020601-EN Rev.
  • Page 118 Appendix 5.9 Parameter listing-LWF Menu Variable Value Ext2 Ext3 Ext4 Ext5 Ext6 Ext7 Ext8 I-O Menu CPU1 Digital Outputs CPU2 CPU3 CPU4 MDURelay1 MDURelay2 MDURelay3 I-O Menu Ext1 Digital Outputs, con’t Ext2 Ext3 Ext4 Ext5 Ext6 Ext7 Ext8 Page 118 Docu-No.: 0590020601-EN Rev.
  • Page 119 Appendix Parameter listing-LWF 5.9 Menu Variable Value Ext Total Pulse DigiOut Map Setpoint sub Source AinValue-% Ain Min-% Ain Max-% Deadband-% Analog Out Menu Aout Num Function Aout Value AoutMin AoutMax Deadband I-O Menu Address 80 Modbus I-O Menu Address 81 Address 82 Address 83 Loader Menu...
  • Page 120 Appendix 5.9 Parameter listing-LWF Menu Variable Value Valve Close Time HCU Loader Refer to 0290023601 System Menu Host Prot Host File System Menu K-Port 1 Prot Baud Rate K-Port 2 Prot Config Mode MDU# Password Security Menu Product Change Calibration Alarm Tuning Refill...
  • Page 121 Appendix Parameter listing-LWF 5.9 Menu Variable Value HCU Loader System Fdr Being Viewed Tot Key SP Access Vol/Alarm Clear Docu-No.: 0590020601-EN Rev. 1.6.0 Page 121...

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