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K-TRON K-Commander Programming Manual

K-TRON K-Commander Programming Manual

Lwf programming
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805
K-Commander Loss-in-Weight Programming
LWF Programming
Using the
K-Commander
Produced by the K-Tron Institute
Rev: G

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  • Page 1 K-Commander Loss-in-Weight Programming LWF Programming Using the K-Commander Produced by the K-Tron Institute Rev: G...
  • Page 2 K-Commander Loss-in-Weight Programming Produced by the K-Tron Institute Rev: G...
  • Page 3 K-Tron Institute. All translation rights are reserved by the K-Tron Institute . The K-Tron Institute has made every effort to ensure the accuracy and validity of this document. However, errors and omissions may have occurred.

  • Page 4: Table Of Contents

    LWF Page 07: Program Priority (Security Level) LWF Page 08: Frequency I/O LWF Page 09: Control or Tuning Parameters LWF Page 10: Overview Screen LWF Page 11: SPC Set-up Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 5 K-Commander Loss-in-Weight Programming Overview, Continued LWF Page 12: SPC Chart LWF Page 13: Software Part Number Alarm Shutdown Masking INDEX Produced by the K-Tron Institute Rev: G...

  • Page 7: General Information

    K-Commander Loss-in-Weight Programming General Information Overview Introduction: The following pages describe the K-Commander (K-Cdr ) pages or K-Cdr screens for the loss-in-weight application. A listing of menu selections is provided for each screen. This document is suitable for rev. Z software.
  • Page 8 The weight of the feeder and hopper, less material. Volumetric control The control is manual. That is, the massflow is calculated if possible, but no comparison to Setpoint is made and the Drive Command remains fixed. Produced by the K-Tron Institute Rev: G...

  • Page 9: Standard Key Arrangements

    Unused Unused When pressed, highlights the first variable that can be changed. The Edit Mode switch then becomes "Change Value". Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 10 These Causes the active page in Quad screen to move clockwise. It moves the active screen once each time the key is pressed. Unused Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 11 CALIBRATE is shown, the machine is doing the FeedFactor calibration. REFILL can also be shown. Window above F6 Indicates if machine is in Local, Ratio, Direct or Line 1-4 Mode or Line 1-7. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 12 When F5 says "Change Value", this key , when pressed, gets you out of <Esc> the data changing activity and back to the normal display. Produced by the K-Tron Institute Rev: G...

  • Page 13: Editing Variables

    Change the engineering units to those of your operation. Program Full Scale Setpoint on page Mcn.07 Program other values as required. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 14 If power is left off the system for 3 weeks or more, it is possible that your entered programming data will be lost due to the battery being discharged. If this is a problem, see your maintenance department for resolution. Produced by the K-Tron Institute Rev: G...

  • Page 15: Common Messages And Meanings From K-Cdr

    Common Messages and Meanings from K-Cdr Introduction This section will present some common messages as displayed by the K-Commander (K-Cdr) and provide an explanation and resolution to them. Alarm specific messages are found in the Alarm page 03. Common The following table outlines common K-Cdr messages.

  • Page 16: Operator Level Programming

    This section deals with the pages that the operator will likely program. Please note that the page numbers beginning with 01 is merely to give reality to the display and this number could range from 01 to 15. Produced by the K-Tron Institute Rev: G...

  • Page 17: Lwf Page 00: Feeder Overview

    999.980 Kg/hr MATERIAL NET WEIGHT 130.670 Kg DRIVE COMMAND 57.770 % TOTALIZER VALUE 133456.500 Kg MOTOR SPEED 1039.860 RPM Grav Totalizer Edit Mode Mode Clear Mode Change <ESC> Value Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 18 Material Net Weight If the "Tare" is done correctly, this number represents the weight in Kg or Lb. of the material in the feeder hopper. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 19 Page 00 special The following is a listing of keys and their function. key list Key Name Description Number Totalizer Clear Will clear the totalizer value on page 00 to zero. Produced by the K-Tron Institute Rev: G...

  • Page 20: Lwf Page 01: Feed Factor Setup

    10 % CALIBRATE TIME 60 sec CALIB. CORRELATION LIMIT 84.2 LAST CALIB. CORRELATION 87.7 MATERIAL FED LAST CALIB. 2.8850 Grav Calibrate Edit Mode Mode Cycle Mode Change <ESC> Value Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 21 Min Ave FF = 900 If the average Feedfactor goes beyond the max or min limit, a feedfactor alarm results. Range of Values 0 to 100,000,000 Default value: 0.012 Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 22 If the Density or Feedfactor Array is "ON", then this variable shows the computed running average of feedfactors when the hopper is nearly at the Refill Complete/ Refill Maximum point. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 23 Note: If value is "0", the Feedfactor alarm is turned off. Range of Values 0 to 1000% Default value: 0% Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 24 Range of Values 30-300 Default Value: 60 Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 25 Compare this value to the actual material weight delivered during the calibrate cycle. If the actual weight agrees with the value displayed here, the feeder is also calibrated accurately by weight. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 26 This function is special to loss-in- weight control. By using the calibrate function, you can determine the capacity of your feeder. The procedure for Feedfactor Calibration follows this section. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 27 Mcn.05 and redo the calibration process. New Span = old span *(container weight/mt’f fed last calib) Put controller in Gravimetric control and run feeder. Produced by the K-Tron Institute Rev: G...

  • Page 28: Lwf Page 02: Refill Parameters

    REFILL COMPLETE WEIGHT 180.000 Kg REFILL REQUEST WEIGHT 40.000 Kg POST REFILL MODE DELAY 5 sec REFILL MODE Automatic PERT VALUE 0.00000000 Grav Edit Mode Mode Mode Change <ESC> Value Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 29 If the refill takes longer than this entered value, an alarm and an output from the Refill Timer Output will occur. Range of Values 5 to 240 seconds Default value: 30 seconds Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 30 See the next section to see how to set this value. Range of Values 0.01* Scale Range to 0.95 * (Scale Range -Tare) Default value: 0 Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 31 Default value: 5 seconds Refill Mode Manual Automatic < You select Automatic if the LWF is refill by machine, manual if you will manually refill it. The default value is "Automatic". Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 32 Basically this value should remain stable. If you note that the value is increasing or peaks, this may cause massflow errors. Refer to the Loss-in-Weight Control Theory manual #4002. There is a section that discusses PERT. Produced by the K-Tron Institute Rev: G...

  • Page 33: Refill Setup Procedures

    Run the system and use trial an error to optimize the Refill Complete point so that you do not overfill the hopper or overrange the scale system. Good luck. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 34 Average the values. Increase the average by 25% and enter that value into the refill timer. Test to see that the Refill Alarm does not actuate in normal operation. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 35 Refill, select the "No Refill" selection for Refill Mode prior to the refill feeder hopper system actuating. This will prevent a refill from occurring and permit emptying of the feeder hopper. Produced by the K-Tron Institute Rev: G...

  • Page 36: Lwf Page 03: Current Alarm Messages

    Alarm 2: Alarm 3: Alarm 4: Alarm 5: Alarm 6: Alarm 7: Alarm 8: Alarm 9: Alarm 10: FEEDER STOPPED BY Motor Drive Failure Grav Alarm Clear Mode Mode Alarm Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 37 Review leds on K10S Pc board. Fdr Internal Channel Internal channel of Check physical Failure Alarm K10S Pc board has connections and slave failed. device that is connected to this data channel. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 38 If used, it indicates (invoked only after controller digital that the motor drive alarm timer expires) input #42 is taken is in alarm and the low. drive must be corrected. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 39 Massflow + Alarm changing. Make sure Limit, see K-Cdr page limit setting is not Mcn.04. tighter than the feed system can deliver. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 40 SFTs to An SFT failure, a which it is connected. Scale Interface Pc failure, a power failure to the SFT or scale Interface Pc board. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 41 Study why vibration Gain set by the or other influence is Kalman Filter has resulting in low dropped below the Motor Control Gains. Motor Control Gain Reduce Limit. Limit Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 42 With serial connected motor controllers, this message will occur if the drive is powered down while running or if the drive's safety interlock is opened while running. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 43 Alarm corrective action. Alarm indicator Acknowledge will turn yellow. Will clear an alarm if the condition that caused the alarm is no longer Alarm Clear present. Alarm status indicator will return to white. Produced by the K-Tron Institute Rev: G...

  • Page 44: Lwf Page 04: Alarm Limits

    ALARM DELAY SETTING 30 sec START-UP DELAY SETTING 60 sec CLEAR ALARMS ON STOPS Enabled NET WEIGHT LOW LIMIT 2.000 % Grav Edit Mode Mode Mode Change <ESC> Value Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 45 1100 Kg/hr which = 1000 + 100. If the flow goes above 1100 Lb/hr an alarm will occur. Range of Values 0 to 100% Default value: 10% Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 46 This entry is 10%, If drive command goes below this value, an alarm will occur. Range of Values 0 to 95%. Must be 5% or more below Drive Command High Limit Default value: 0% Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 47 Range of Values 0 to 240 seconds Default value: 60 seconds Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 48 On Rev. Z software, this value will also set the under limit for Scale Under-range using this value a -% value so that scale under-range occurs at this percentage below 0 gross weight. Produced by the K-Tron Institute Rev: G...

  • Page 49: Maintenance Level Programming

    This chapter will provide information on the following program activities. Please note that the page numbers beginning with 01 is merely to give reality to the display and this number could range from 01 to 15. Produced by the K-Tron Institute Rev: G...

  • Page 50: Lwf Page 05: Scale Programming And Weight Span

    SCALE GROSS WEIGHT RANGE 300.000 Kg MEASURED GROSS WEIGHT 281.789 Kg MATERIAL NET WEIGHT 130.670 Kg FEEDER TARE WEIGHT 151.119 Kg WEIGHT SPAN 1.000 Grav Edit Mode Mode Mode Change <ESC> Value Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 51 SFTs in a system. Material Net Weight This value represents the amount of material in the hopper. Material Net Weight = Measured Gross Weight -Tare Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 52 NWS = CWS *( applied weight/displayed weight) where NWS = New Weight Span CWS = current weight span. Range of Values 0.1 to 10 Default value: 1.000 Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 53 Read the SFT range from the SFTs side of the SFT and multiply by 3 to get the scale range. Enter the calculated value. If you are unsure Call K-Tron Service for help. Page 05 key list Key Name Description Number...

  • Page 54: Tare And Span Calibration Procedures

    Check the material net weight change again after entering the new span value to make sure that the weight increase you see agrees with the value of the weight you applied to the scale. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 55 Repeat steps 5 to 8 to check that the span is OK. If not, redo the calculations, enter new span as in step 9, and redo steps 5-8 again. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 56 New span = 1.004 * ( 99/100) = 0.994 Enter the new span. Redo steps 3-9 to check the accuracy of the new span value. You have calibrated the feeder. You can now run the feeder in production. Produced by the K-Tron Institute Rev: G...

  • Page 57: Lwf Page 06: Sft Programming

    SFT TYPE CODE SFT CONFIGURATION - - - - - - - - - - - - - - - Edit Grav Poll Mode Mode Mode SFTs Change <ESC> Value Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 58 (2 bytes) that describe various problems with the SFT being interrogated. There should be some number, zero is a failure condition. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 59 "t" = Timeout. The SFT is not communicating with the controller. The reasons are many. "?" = Incorrect response from SFT. " - ' = No SFT at the location indicated. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 60 Feeder # Single SFT 3 SFT's 1-2-3 4-5-6 7-8-9 10-11-12 Note: If you are using multiple Quad controller boards, this addressing scheme is repeated for each Quad Controller board Produced by the K-Tron Institute Rev: G...

  • Page 61: Lwf Page 07: Feeder Setup Data

    FULL SCALE DRIVE COMMAND 10000 Hz PROGRAMMING PRIORITY LCD Locked Out SERVICE VARIABLE INDEX Full Scale Drive Command SERVICE VARIABLE VALUE 10000.0000 Grav Edit Mode Mode Mode Change <ESC> Value Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 62 Select the units of choice for your operation. The units of operation for each feeder must be the same if you are going to work in the Line mode of control. Default value is "Kg/hr". Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 63 Feed Factor Array being cleared. The default value is " Screw Fdr" where the array is not cleared upon setpoint changes.(Rev. Z- LWF) Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 64 Default value is 120 Total Gear Reduction This is always 1. Anything else will cause the Motor RPM to be incorrect. Range of Values 0.2 to 100 Default valu e is 1.000 Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 65 Command reads 100%. The default for this entry is 10000 Hz and is normal for most applications. Range of Values 1,000 Hz to 40,000 Hz Default value is 10,000 Hz Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 66 The operator can also change the line setpoints. All as a selection means that every variable can be altered for every machine or situation in the system. Produced by the K-Tron Institute Rev: G...

  • Page 67: Lwf Page 07: Service Variable Index

    Variable Name Edit? Description Service Variable Index This permits selection of often hidden variables in the K10S. Used by K-Tron service personnel. SAB Input Usage Undefined < SAB Input Range Calibrate Drive Command SAB Input Current Value...
  • Page 68 See Alarm Shutdown Mask to select which alarms Mask procedure later will cause an alarm in this section shutdown Pre Load Totalizer Allows you to 0.0000 to 999999 preload the totalizer Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 69 12 = Ref Time Col 13 = Tare (WBF) 14 = Beltload Lo(WBF) 15 = Beltload Hi(WBF) Bit Output 2 Same as Bit Output 1 Bit Output 3 Same as Bit Output 1 Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 70 9 = Beltload 10 = Batch % 11 = Batch size 12 = Pre Fdr DC SAB Output Same as Assignment Assignment 2 SAB Output Same as Assignment Assignment 3 Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 71 3 SAB Output 1 Calib See document 6503 Value for calibration instructions SAB Output 2 Calib Same as above Value SAB Output 3 Calib Same as above Value Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 72 Nameplate Motor Entered value of Units are watts. Power Namplate motor speed for software programmable motor drive Actual Motor Power Actual motor power being drawn. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 73 The Kalman filter parameters remain unchanged. WBF Slip Idler Y/N For weigh belt feeder applications. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 74 Quad Old Style SAB For Quad SAB 0 is the correct value addr applications for current SAB apps MDU Status Indicates operational Hex value. See related status of software programmable motor programmable motor drives controller Produced by the K-Tron Institute Rev: G...

  • Page 75: Lwf Page 07: Program Priority (Security Level)

    Mass Flow Error - Drive Command High Limit Drive Command Low Limit Alarm Delay Start-Up Delay Initial FeedFactor FeedFactor Alarm Limit Locked Out None for selected No variables for the selected machine. machine can be changed. Produced by the K-Tron Institute Rev: G...

  • Page 76: Lwf Page 08: Frequency I/O

    FREQ INPUT #3 VALUE 0.000 Hz SCALED FREQ INPUT #3 0.000 Hz SCALE FACTOR INPUT #3 1.000 FREQ IN #3 DEADBAND 1 Hz Grav Edit Mode Mode Mode Change <ESC> Value Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 77 These variables show the incoming Value frequency at these inputs. Scaled Frequency Input This is the frequency value of Input #3 after it has been scaled by the Scale Factor for Input #3. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 78 10 Hz, any frequency input to Input #3 that varies less than 10 Hz will be recognized as non- changing. Range of Values 0 to 1,000,000,000 Hz Default value is 1 Hz Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 79 Screw Speed Fo = Motor speed frequency/(# of Gear Teeth*Total Reduction) ex: Fo = 3200/(120*1) = 26 Hz Density Factor Fo = (5Khz/Initial Feedfactor)* Ave. Feedfactor ex: Fo = (5000/1000)*343 = 1715 Hz. Produced by the K-Tron Institute Rev: G...

  • Page 80: Lwf Page 09: Control Or Tuning Parameters

    DESIRED STD DEVIATION 0.560 MOTOR CONTROL GAIN MASSFLOW FILTER LENGTH 5 sec ADAPTIVE TUNING ENABLED FEEDER RUN TIME 0.0000 DRIVE COMMAND CEILING 125.00% Grav Edit Mode Mode Mode Change <ESC> Value Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 81 Numbers in the range of 20-50 are good. Numbers larger than 100 require work to be done to the installation to reduce the vibration to the feeder. Range of Values 1 to 999 Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 82 The larger this value is, the more stable the massflow display will be. This value has no affect on control. Range of Values 1 to 300 seconds Default value is 5 seconds Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 83 Enter the value of "0" to clear the variable. Drive Command Ceiling Sets the maximum motor drive command. The range is: 0 to 125%. The default is 125%. Produced by the K-Tron Institute Rev: G...

  • Page 84: Lwf Page 10: Overview Screen

    S ET POINT MAS S FL OW 1 00 0.0 0 9 9 9 .9 8 DRIVE COMMAND 57 .77 Grav Alarm Edit Clear Mode Mode Mode Alarm Change Value Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 85 100%, the active 57.77 portion will extend to the right beyond the bar outline. The alarm points are in red. The actual value of drive command is shown above the bar. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 86 Description Number Alarm When pressed will acknowledge Acknowledge the alarm present. Alarm Clear When pressed will clear the alarm that is present if the conditions that caused the alarm are no longer present. Produced by the K-Tron Institute Rev: G...

  • Page 87: Lwf Page 11: Spc Set-Up

    Edit key is pressed and a variable is highlighted. POWDER LWF : SPC Set-Up M01.11 SPC VARIABLE TO LOG SPC X-BAR SAMPLE WIDTH CHART SCALING FACTOR 1.0000 # of SAMPLES IN SIGMA Change <ESC> Value Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 88 # of Points in Sigma ONLY POINTS ON CRT < ALL RECORDED POINTS Variance value on Mcn.12 is computed based upon either all the recorded samples taken or only those immediately displayed on the video screen. Produced by the K-Tron Institute Rev: G...
  • Page 89 Amplitude = 2000*(chart scaling factor)* Deviation from target where chart scaling factor is set on page Mcn.11. The height of the chart between zero deviation and either dashed line is 100 pixels. Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 90 SPC Values - Current value of At the right hand side Standard Deviation computed standard of the graph near the deviation from all "x" axis. previous data points Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 91 Note: If the display is zoomed, only 52 points are shown rather than the normal 104. SPC note for A K-Tron PC program titled SPC.EXE will permit extraction of all SPC data retrieval data stored in the ram card. Access is via the Config. port on the K-Cdr.
  • Page 92 There can be up to 10 of these recalled. The snapshot shows the display with data in which any feeder alarm occurred. The condition is triggered by setting of bit 14, 15 of the PSR word. Produced by the K-Tron Institute Rev: G...
  • Page 93 This diagram shows the data layout. The second row of keys pop up when the Edit key is pressed and a variable is highlighted. POWDER LWF : SW Part Numbers M01.13 CONTROLLER SW PART # C9700-20000-V Continued on next page Produced by the K-Tron Institute Rev: G...
  • Page 94 M01.13 is machine 1 M05.13 is machine 5 The number displayed is the software part number and revision letter that you should know for this controller if you call our service department for help. Produced by the K-Tron Institute Rev: G...
  • Page 95 This is done using the K10S ASR word and calculating the decimal value and then entering that value in the Service Variable Value on the K-Commander. Below is a list of alarms for LWF with an example.
  • Page 96 16,777,151 (default) - 524,288 (decimal value of Int. Channel Range Error -------------- New Value 16,252,927 Note: The default value is 16,777,151 because the Low Battery should not shutdown the feeders. Produced by the K-Tron Institute Rev: G...
  • Page 97 Display action line above the function keys, 5 Display Board Failure, 35 Drive Comm Greater than DHS Alarm, 31 Drive Comm less that DLS Alarm, 31 Hard Alarm, 37 Drive Command, 1, 13 Produced by the K-Tron Institute Rev: G...
  • Page 98 Page 04 variable list, 39 Service Variable Index, 61 Page 05 key list, 47, 54 Service variable index and value listing, 62 Page 05 layout, 44 Service Variable Value, 61 Page 05 variable list, 45 Produced by the K-Tron Institute Rev: G...
  • Page 99 Speed Pick-up Gear Teeth, 58 Standard keys and their functions, 3 Zero Setpoint Message, 36 Standard keys and their functions con't, 4 Start-up Delay Setting, 41 Stop Bit Message, 36 Stop Clrs Alarms, 62 STP, 2 Produced by the K-Tron Institute Rev: G...

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