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K-TRON K-Commander Programming Manual Download Page 78

805.

72

K-Commander Loss-in-Weight Programming

Rev: G

            

Produced by the K-Tron Institute

LWF Page 08: Frequency I/O, 

Continued

Page 08
variable list
con't

Variable Name

Edit?

Description

Scale Factor Input #3

`

This value scales the incoming
frequency as presented to Input #3.
The frequency will be used to
provide the  ratio or direct control
signal as set on page 07. The
procedure on how to set this value
is described in DCS#322.

   Range of Values
   0 to 999
Default value is 1.000

Frequency In #3
Deadband

`

This value sets the variation level at
which the frequency signal will be
ignored. For example, if the entry is
set to 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

Summary of Contents for K-Commander

Page 1: ...805 K Commander Loss in Weight Programming Rev G Produced by the K Tron Institute LWF Programming Using the K Commander ...

Page 2: ...805 K Commander Loss in Weight Programming Rev G Produced by the K Tron Institute ...

Page 3: ...ron 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 If an error or omission is found please contact the K Tron Institute at 856 256 3267 Information in this manual is correct as of the date of publication K Tron assumes no responsibili...

Page 4: ...ill Parameters 22 Refill Setup Procedures 27 LWF Page 03 Current Alarm Messages 30 LWF Page 04 Alarm Limits 38 MAINTENANCE LEVEL PROGRAMMING 43 Overview 43 LWF Page 05 Scale Programming and Weight Span 44 Tare and Span Calibration Procedures 48 LWF Page 06 SFT Programming 51 LWF Page 07 Feeder Setup Data 55 LWF Page 07 Service Variable Index 61 LWF Page 07 Program Priority Security Level 69 LWF Pa...

Page 5: ...805 K Commander Loss in Weight Programming Rev G Produced by the K Tron Institute Overview Continued LWF Page 12 SPC Chart 83 LWF Page 13 Software Part Number 87 Alarm Shutdown Masking 89 INDEX 91 ...

Page 6: ......

Page 7: ...e is a listing of common terms used in loss in weight feeding Term Definition Adaptive Tuning This is a control concept that when implemented the controller continues to optimize its operation zeroing in if you will on the best point of control Density Array A group of FeedFactors that are placed in an array from Refill Complete to Refill Request The values in the array are used to operate the fee...

Page 8: ...mpared to the setpoint and if different a change in drive command will occur Massflow Standard Deviation This is the variance of the massflow value as calculated by the controller Measured Standard Deviation This is the variance of the weight values captured from the weighing system Refill Complete Weight The point by weight at which the refilling will stop Refill Request Weight The point by weigh...

Page 9: ... F8 Change Value ESC Standard keys and their functions Key Number Key Name Description F1 Grav Mode Places the control in Gravimetric or Mass control The LWF Controller measures the massflow compares this value to the setpoint and causes the Drive Command to change so that the massflow will equal the setpoint F2 Vol Mode When operating in Volumetric control the Drive Command is fixed There is no a...

Page 10: ...their functions con t Key Number Key Name Description F6 Causes the active page in Quad screen to move counterclockwise It moves the active screen once each time the key is pressed These F7 Causes the active page in Quad screen to move clockwise It moves the active screen once each time the key is pressed F8 Unused Continued on next page ...

Page 11: ...umetric control Window above F2 key Indicates whether machine is running or is stopped Window above F4 key If the word DISA is indicated an external Run Enable interlock is preventing the machine from operating If the word ALSHUT is indicated an external Alarm Shutdown interlock is preventing the machine from operating Window above F5 key If PERT Is displayed the weighing system is disturbed and t...

Page 12: ...ption F5 Change Value When this key is indicating Change Value pressing this key will result in a pop up menu being displayed from which you can select a value for entry by scrolling with the F6 and F7 key F6 Permits selection of a parameter from a pop up menu As you press this key you scroll down through the selections F7 Permits selection of a parameter from a pop up menu As you press this key y...

Page 13: ...desired entry 5 Press the Enter Key to load your desired selection 6 Press F8 to return to normal operation Order of data entry an important point The order of data entry is very defined and is all based from the scale range setting Please follow the next procedure to program the controller from default conditions Use this procedure if data is lost in a power or battery back up failure If SFTs are...

Page 14: ...age Mcn 07 It will be 0 if data has been lost To re enter data go to the prior procedure entitled Order of Data Entry It is recommended that you retain a hard copy printout of the programming data for each machine and its pages plus the Line and System pages You can use the K Cdr print function to help you If power is left off the system for 3 weeks or more it is possible that your entered program...

Page 15: ...cific messages are found in the Alarm page 03 Common message listing with resolution The following table outlines common K Cdr messages Message Meaning Resolution Feeder Range Error The entry is outside the limits of the variable selected Re check the entry Check the range limits of the variable Hint see the Serial Protocol for those limits NAK Due to Feeder Running Some variables like scale range...

Page 16: ... Tron Institute Operator Level Programming Overview Introduction 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 ...

Page 17: ... to move from page to page Page 00 layout This diagram shows the data layout The second row of keys pop up when the Edit key is pressed and a variable is highlighted F5 F6 F7 F8 Edit Mode F1 F2 F3 F4 Grav Mode Vol Mode Totalizer Clear F5 F8 Change Value ESC POWDER LWF Feeder Overview M01 00 MASS FLOW SETPOINT 1000 000 Kg hr ACTUAL CURRENT MASS FLOW 999 980 Kg hr MATERIAL NET WEIGHT 130 670 Kg DRIV...

Page 18: ...value entered in that is greater than the Full Scale Setpoint will result in a Range Error message The entry is in units of rate e g 1000 Kg hr You must press the enter key after entry of the value to load that value into the Massflow Setpoint location Range of Values 0 to Full Scale Setpoint pg 07 Default value 0 Actual Current Massflow This is the result of what the feeder is delivering into the...

Page 19: ...e 0 100 Desired Range 10 100 Totalizer Value This value is the quantity of product that has been delivered in either Kgs or Lbs since the last time the Totalizer was reset or cleared Range of Operation Maximum Range 999 999 999 Motor Speed If the Total Gear Reduction is set to 1 0 and the Gear Teeth Setpoint is correct then this value represents the motor rpm of the feeder Page 00 special key list...

Page 20: ...e 01 layout This diagram shows the data layout The second row of keys pop up when the Edit key is pressed and a variable is highlighted Edit Mode F5 F6 F7 F8 F1 F2 F3 F4 POWDER LWF Feed Factors M01 01 INITIAL FEEDFACTOR 1878 000 AVERAGE FEEDFACTOR 1731 002 FF HOPPER EMPTY 1656 607 FF HOPPER MID 1698 667 FF HOPPER FULL 1735 998 DENSITY ARRAY On FEEDFACTOR ALARM LIMIT 0 000 CALIBRATE DRIVE COMMAND 1...

Page 21: ...eedfactor This value of feedfactor is used for two purposes 1 To set Drive Command when in Vol control by the formula DC SP IFF 100 where SP setpoint and DC Drive Command 2 The Initial Feedfactor multiplied by the Feedfactor Alarm Limit value is how much the Average Feedfactor can wander without a feedfactor alarm ex Initial Feedfactor IFF 1000 Feedfactor alarm 10 Max Ave FF 1100 Min Ave FF 900 If...

Page 22: ... system is in Pert or the setpoint deviation is greater than 25 FF Hopper Empty 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 Request Refill Minimum point FF Hopper Mid If the Density or Feedfactor Array is ON then this variable shows the computed running average of feedfactors halfway between R...

Page 23: ...op up window looks like Off On The symbol indicates the choice selected Default value is Off Feedfactor Alarm Limit This is a percentage value that is used to provide an alarm if the average feedfactor goes outside the bounds as set by the product of this value and the Initial Feed Factor ex Initial Feedfactor IFF 1000 Feedfactor alarm 10 Max Ave FF 1100 Min Ave FF 900 If the average Feedfactor go...

Page 24: ... AFF 100 where SP setpoint and AFF average feedfactor This factor is not used for vibratory feeders Range of Values 0 to 100 Default Value 10 Calibrate Time Permits selection of feedfactor calibrate time from 30 seconds to 300 seconds Pick a larger number as the setpoint becomes lower For most cases 60 seconds is a good average choice You may select a time interval however that is relevant to your...

Page 25: ...The correlation value captured during the last feedfactor calibration Look for consistency A value of 100 is perfect 90 is good indicating consistent material flow 80 is indicating the flow is less consistent The smaller the number the less consistent the flow possibly suggesting changing the feeder type or feed screw if used Material Fed Last Calibration The physical amount of product delivered d...

Page 26: ...or Setup Continued Page 01 special key list Key Number Key Name Description F3 Calibrate Cycle 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 ...

Page 27: ... Calibrate Time in seconds The default is 60 seconds We suggest a time of 120 to 300 seconds 7 Put an empty tared container under the discharge 8 Press F3 Calibrate Cycle Feeder runs for the Calib Time 9 When stopped note the new Average and Initial Feedfactor This tells you what the capacity of the unit is with that material It also insures that when you begin operation the feeder will start clos...

Page 28: ...ation Use the Scroll keys to move from page to page Page 02 layout This diagram shows the data layout The second row of keys pop up when the Edit key is pressed and a variable is highlighted Edit Mode F5 F6 F7 F8 F1 F2 F3 F4 POWDER LWF Refill Parameters M01 02 REFILL ENABLE Refill ALLOWED REFILL TIME 30 sec REFILL TIMER OPTION Enable REFILL COMPLETE WEIGHT 180 000 Kg REFILL REQUEST WEIGHT 40 000 K...

Page 29: ...o Refill Refill You select Refill to have the Automatic function if selected continue to activate the refilling process If you select No Refill no refill will occur and this will allow you to clean out the feeder hopper with no problems The default value is Refill Allowed Refill Time This entry sets the time period for a normal refill in Automatic Refill mode to occur If the refill takes longer th...

Page 30: ...arm system You get no Alarm from a refill failure Enable Connects the refill timer to the alarm system You get an alarm with a refill failure if set properly Terminate Terminates any alarm from the refill timer The default value is Enable Refill Complete Weight This is the point at which an automatic refilling system will stop adding material to the feeder hopper See the next section to see how to...

Page 31: ... the weight in the feed hopper reaches this point Range of Values 0 to Refill Comp 2 of weight units ex 100 2 kgs 98 kgs Default value 0 Post Refill Mode Delay This entry determines how long the control will remain in Vol control after the refill is terminated This delay improves mass flow stability after a refill See a later section on how to set this value Range of Values 0 to 240 seconds Defaul...

Page 32: ... more noise in the weight signal The minimal value is 0 When the feeder is stopped this value should be less than 5 When the feeder is running this value should be from 2 10 As enviormental noise increases this value may increase to 20 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 Theor...

Page 33: ...et available weight capacity NAWC by NAWC Scale Gross Weight Range Tare You will find these values on page Mcn 05 ex Scale Range 264 Lbs Tare 122 Lbs 120 Kgs 55 35 Kgs NAWC 264 122 142 Lbs or 64 4 Kgs 5 Use the smaller of the two calculated values In this example the hopper can hold more weight than the scale can support Use the scale capacity number NAWC NAWC 142lbs or 64 4 Kgs MHSC 200 lbs or 89...

Page 34: ...he bulk density of the material being fed From the above example we measured 0 64 Kg L or 40 Lb ft3 3 The Refill Request Weight is 0 64 Kg L 30L 19 3 Kgs or 40 lb ft 3 1 ft 3 or 40 Lbs This is the minimum recommended value to be used for Refill Request The Refill Request value could be as large as 0 5 times the Refill Complete Weight value and still work well Setting Refill Timer Use this procedur...

Page 35: ...ccurately record those values 2 With the default setting in the Post Refill Mode Delay operate the feeder through a refill Note the deviation of motor speed or drive command during the time beginning immediately prior to refill and ending a minute or so after the unit has switched to Mass control If you not an unacceptable deviation increase the time by a couple of seconds and repeat the process C...

Page 36: ...sages will be presented here Also please refer to the troubleshooting section of your manual for more information Use the Scroll keys to move from page to page Page 03 layout This diagram shows the data layout F5 F6 F7 F8 F1 F2 F3 F4 POWDER LWF Current Alarms M01 03 Alarm 1 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 Mode Vol ...

Page 37: ...oint called Drive Command High Limit see K Cdr page Mcn 04 The setpoint is too high for the given conditions of feeder and material Material blockage possible Important if Mass Flow Low alarm is present Drive Comm less that DLS Alarm Actual Drive command is lower than the Alarm setpoint called Drive Command Low Limit see K Cdr page Mcn 04 Setpoint is too low for a given material and or feeder Re s...

Page 38: ...d Check agitation and for proper hopper level You may have a hopper bridge or arch or you are out of product Also check that a refill did not occur during feedfactor calibration Feeder Invalid Command Alarm The K10S Pc does not recognize the commands sent by the K Cdr Check that K10S Pc software is compatible with current level of K Cdr software Feeder Range Error Alarm The entry value is greater ...

Page 39: ...h speed feedback Refill Timer Expired Alarm Actual refill time in automatic refill has taken longer than the refill timer setpoint allows See K Cdr page Mcn 02 Check refill valve for operation and refill hopper for adequate material Recheck actuation time I O Board Failure Alarm Failure between K Cdr Controller and I O Pc boards Check hardware in K Cdr for correct operation Refer to led chart and ...

Page 40: ...m The scale or individual SFT as identified by the xx is in underrange condition The gross weight reading is below zero by more than the Net Weight Low value Generally a failure condition in the transducer or scale system In a B scale the counterweight has shifted Binding or forced unloading of the SFT may also result in this problem Weight Processor Failure Alarm Controller is not receiving a wei...

Page 41: ...y Many causes are possible Refill failure Too low a Refill Request Point Refill Bypass entered are but a few of the possibilities Controller Board Failure Alarm The K10S controller pc board has failed Replace the offending K10S controller pc board Locate by address Reprogram Display Board Failure The K10S DU or display pc board has failed Replace the offending K10S DU pc board and reprogram Lo Mot...

Page 42: ... was stopped by the stop bit input Alarm Shutdown Message The feeder was stopped by the alarm shutdown input Local Display Message The feeder was stopped by stop button on the local display External Display Message The feeder was stopped by stop button on the remote display Zero Setpoint Message No setpoint is present Drive Command Low Message Drive command is below 1 Motor Drive Failure Message M...

Page 43: ... actuating the alarm system The alarm indicator is red Acknowledged Alarm The alarm condition is still present but the alarm system has been silenced Page 03 special key list Key Number Key Name Description F3 Alarm Acknowledge Will silence the alarm system but retain the alarm message for corrective action Alarm indicator will turn yellow F4 Alarm Clear Will clear an alarm if the condition that c...

Page 44: ...layout This diagram shows the data layout The second row of keys pop up when the Edit key is pressed and a variable is highlighted Edit Mode F5 F6 F7 F8 F1 F2 F3 F4 POWDER LWF Alarm Limits M01 04 MASSFLOW ALARM LIMIT 10 MASSFLOW ALARM LIMIT 10 DRIVE COMMAND HIGH LIMIT 100 DRIVE COMMAND LOW LIMIT 0 ALARM DELAY SETTING 30 sec START UP DELAY SETTING 60 sec CLEAR ALARMS ON STOPS Enabled NET WEIGHT LOW...

Page 45: ... Low Mass Flow Alarm will occur ex Setpoint 1000 Kg hr Your entry is 10 Minimum deviation without alarm 1000 0 1 100 Kg hr or a flowrate of 900 Kg hr which 1000 100 If the flow drops below 900 Kg hr an alarm will occur Range of Values 0 to 100 Default value 10 Massflow Alarm Limit If the massflow goes above this entry multiplied times the setpoint a High Mass Flow Alarm will occur ex Setpoint 1000...

Page 46: ...n an alarm called High Drive Command ex This entry is 80 If drive command exceeds this value an alarm will occur Range of Values 5 to 100 Default value 100 Drive Command Low Alarm Limit Sets the point below which if drive command goes will result in an alarm called Low Drive Command ex 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 ...

Page 47: ...t be pending before a hard alarm can exist actuate the alarm system Other alarms will bypass this delay and immediately actuate the alarm system Range of Values 5 to 240 seconds Default value 30 seconds Start up Delay Setting Sets the time when the Run button for a feeder is pressed where the massflow and drive command alarms will not be permitted to cause an alarm to occur Range of Values 0 to 24...

Page 48: ... alarms will be cleared by the user through the keyboard or by the Alarm Shutdown Input The menu is below Disabled Enabled Net Weight Low Limit This entry sets the level where the low weight limit alarm is detected The value of weight at which this alarm is presented is Weight Scale Range Tare ex SR 120 kg Tare 50 Kg 4 Weight 4 120 50 2 8 kg Range of Values 0 10 Default value 2 On Rev Z software t...

Page 49: ...n deals with the K Cdr pages that are likely to be used by maintenance personnel for calibration and servicing the equipment In this chapter 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 ...

Page 50: ...s for it Use the Scroll keys to move from page to page Page 05 layout This diagram shows the data layout The second row of keys pop up when the Edit key is pressed and a variable is highlighted F5 F6 F7 F8 Edit Mode F1 F2 F3 F4 Grav Mode Vol Mode POWDER LWF Scale Programming M01 05 SCALE GROSS WEIGHT RANGE 300 000 Kg MEASURED GROSS WEIGHT 281 789 Kg MATERIAL NET WEIGHT 130 670 Kg FEEDER TARE WEIGH...

Page 51: ...ry for your scale gross capacity which you will find on the scale tag The units of entry are in Kg Failure to have the units in Kg hr will result in an entry error Range of Values 0 001 Kg to 1 000 000 000 Kg Default value 0 001 Kg Note You must have the units in Kg before trying to enter the value here Measured Gross Weight This is the gross weight value as seen by the scale system and in multipl...

Page 52: ...aterial This number can be entered when this data value is highlighted or the same result can come from pressing the Tare push button Please record this value for future use Range of Values 0 0 Kg to 1 000 000 000 Kg or less than Scale Range Default value 0 000 Kg Weight Span This value will correct an error in weight measurement NWS CWS applied weight displayed weight where NWS New Weight Span CW...

Page 53: ...ale range from label on scale Enter this value for scale range If you have a Modular feeder with 3 SFTs Read the SFT range from the 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 Number Key Name Description F3 Tare Pressing this button when the feeder hopper is empty will tare the scale system ...

Page 54: ...e scale calibration uses weights Step Action 1 Note the current material net weight reading 2 Add an accurate known weight to the machine Use a weight that is at least 10 of the scale range for this activity The material net weight reading should increase by that amount 3 New weight Span Current Weight Span Applied weight Displayed weight ex If current weight span is 0 9 the weight applied to the ...

Page 55: ...e stable 5 Take 5 1 minute catch samples in a row ex 3 66 kg 3 56 lkg 3 58 kg 3 60 kg and 3 59 kg 6 Add up the samples and divide by the number of samples taken to get the average sample value Total 17 99 kg and divide by 5 samples 3 598 kg sample 7 Recalculate the setpoint into the same time units ex Setpoint 220 kg hr 3 666 kg minute 8 Calculate the new span using the current span in the followi...

Page 56: ...table Stop the feeder 3 Clear the totalizer Be sure that you have a large container to catch the flow of material during this run 4 Start the feeder 5 When the container becomes full stop the feeder 6 Note the totalizer reading 7 Weigh the contents of the container 8 Compare the container weight to the totalizer They should match 9 Calculate the new span setting from the following equation New Spa...

Page 57: ...m page to page Page 06 layout This diagram shows the data layout The second row of keys pop up when the Edit key is pressed and a variable is highlighted Edit Mode F5 F6 F7 F8 F1 F2 F3 F4 POWDER LWF SFT Programming M01 06 NODE OF SELECTED SFT 1 SFT CONNECT DISCONNECT Dscnct NUMBER OF SFTS REQUIRED 3 SFT RAW WEIGHT 0 000 KG SELECTED SFT STATUS 00000000 SFT TYPE CODE 0 SFT CONFIGURATION Grav Mode Vo...

Page 58: ...tem by picking Connect or to remove the selected SFT from the system by selecting disconnect The default value is Dscnct Number of SFTs Required Set this to the number of SFTs used in the particular feeder system Normally either a value of 1 or 3 is entered here SFT Raw Weight This represents the weight applied to the SFT that is selected by address above If the SFT weight exceeds the SFT range an...

Page 59: ...6 Kg to 1500 Kg SFT Configuration By pressing the F3 key you will cause a Poll to result and thus identify the connected SFTs To connect an SFT its address must be preset to 0 SFT Failure Codes f SFT failure of its internal parts A vibrating wire or other malfunction has occurred The SFT is still communicating with the controller t Timeout The SFT is not communicating with the controller The reaso...

Page 60: ... Controller If you select QLWF120 or QLWF240 as feeder type on Mxx 07 use the following information for SFT programming Special care must be taken in addressing SFT s when using the Quad Controller Software The Quad software will automatically assign an SFT to a particular feeder depending on the SFT s address For QLWF selections use the table below for addressing assignments Feeder Single SFT 3 S...

Page 61: ... keys pop up when the Edit key is pressed and a variable is highlighted F5 F6 F7 F8 Edit Mode F1 F2 F3 F4 Grav Mode Vol Mode POWDER LWF Feeder Data M01 07 FULL SCALE SETPOINT 2000 000 Kg Hr UNITS SELECTION Kg Hr EXT TOTALIZER INCR 1 000 Kg FEEDER TYPE SELECTION LWF120 SPEED PICKUP GEAR TEETH 120 TOTAL GEAR REDUCTION 1 000 FEEDER MODE Local FULL SCALE DRIVE COMMAND 10000 Hz PROGRAMMING PRIORITY LCD...

Page 62: ...Scale Setpoint Maximum Setpoint This entry sets the maximum value of setpoint that you can enter on page 0 without getting and error message and this value also sets the scaling for the frequency I O that is used by the controller Range of Values 0 to 90 Scale Range Entry Default value 0 Units Selection Kg hr Kg m lb hr lb min ton hr E ton hr g hr g min Select the units of choice for your operatio...

Page 63: ...0 000 Default Value 0 Feeder Type Selection This selection sets the loss in weight software to work with the correct feeder type The Q prefix is used only with the Quad controller electronics VIB LWF120 LWF240 W300 W600 W1000 QLWF120 QLWF240 QWBF300 QWBF600 QWBF1000 QWBF HF PID NOT USED Caution Only select the Vibratory type if a vibratory feeder is used by this controller since any change is setp...

Page 64: ...liquid or screw feeder is used with a motor that has a speed pick up type of tachometer this entry scales the RPM display to read correctly Look to the feeder specification sheet to determine this entry Range of Values 0 to 500 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 Continu...

Page 65: ...eeder is to be operated by itself or a part of Lines 1 to 7 This entry determines where the controller s setpoint comes from Refer to the section on Control Modes to learn how each selection affects the function of the controller Default value is Local Full Scale Drive Command This value determines the frequency output for drive command when the Drive Command reads 100 The default for this entry i...

Page 66: ...he pop window that appears at the right middle side of the screen Locked Out SP only SP and Alarm All Locked Out as a selection means that the operator can view all variables but can make no changes to any variables SP Only as a selection means that the operator can only change the Setpoint for machines or lines SP and Alarm as a selection means that the user can only modify the machine setpoint a...

Page 67: ... Feedfactor Array 2 Feedfactor Array 3 Feedfactor Array 4 Feedfactor Array 5 Feedfactor Array 6 Feedfactor Array 7 Feedfactor Array 8 Feedfactor Array 9 Feedfactor Array 10 SAB Input Usage SAB Input Range SAB Input Current Value SAB Input Calib Value SAB Output Usage Chn 1 SAB Output Usage Chn 2 SAB Output Usage Chn 3 SAB Output Range Chl 1 SAB Output Range Chl 2 SAB Output Range Chl 3 SAB Output ...

Page 68: ...xt totalizer pulse output 0 0001 to 999999 Full Scale Drv Cmd Sets the Drive Cmd output freq range at 100 Drive Cmd 1 000 to 40 000Hz default 10 000Hz Gear Reduction 1 000 to 999999 default 11 00 Set at 1 000 for LWF Gear Teeth Enter the number of teeth on the speed pickup gear 1 to 999999 Use Refill Array LWF only Selects whether or not refill array is used 0 No 1 Yes Refill Only Run LWF only Set...

Page 69: ...4 Mass Ena 5 Cust Alrm 6 Motor Fail 7 Refill Bypass LWF 8 Refill Cmd LWF Bit Input 2 Same as Bit Input 1 Bit Input 3 Same as Bit Input 1 Bit Input 4 Same as Bit Input 1 Bit Output 1 This entry allows you to select the function of the bit output 0 Drv Ena 1 Ref Win LWF 2 Fdr Run 3 Alrm Relay 4 Alrm Shut 5 Alrm Shut Col 6 Alrm Relay Col 7 Tot Pulse 8 Mass Mode 9 Ref Comp LWF 10 Ref Req LWF 11 Ref Ti...

Page 70: ...y allows you to set the range of the incoming analog signal to the SAB Bd 0 0 to 1 V 1 0 to 5 V 2 1 to 5 V 3 0 to 10 V 4 0 to 20ma 5 4 to 20ma SAB Current Input Value This is the freq value of the current input 0 10 000Hz Read only SAB Input Calib Value Refer to DCS 564 for Calib instructions SAB Output Assignment 1 This entry allows you to select what the output will represent 0 Unassigned 1 Cali...

Page 71: ... 0 to 20ma 3 4 to 20ma SAB Output Range 2 Same as output 1 SAB Output Range 3 Same as output 1 SAB Output Value 1 This is the current value for output 1 Read only SAB Output Value 2 This is the current value for output 2 Read only SAB Output Value 3 This is the current value for output 3 Read only SAB Output 1 Calib Value See document 6503 for calibration instructions SAB Output 2 Calib Value Same...

Page 72: ...s above FTS FDR 3 Same as above Fr6 Hyster This entry sets the hysteresis for freq input 6 0 to 1000Hz Fr6 Offset This entry sets the offset for freq input 6 0 to 1000Hz Spurious Case For software analysis only Nameplate Motor Speed Entered value of Namplate motor speed for programmable motor drive Standard range is 1800 to 2500 rpm Nameplate Motor Power Entered value of Namplate motor speed for s...

Page 73: ...w Motor Gain Limit An entered limit that if the Motor Control Gain page Mcn 09 drops below an alarm occur 0 default Max 100 Alarm is Low Motor Gain Calibrate Time Time for feedfactor calibration 30 300 seconds Refill Timer 2 This timer becomes active when the regular Refill Timer expires If the net weight is still below the Refill Request point after this timer expires the controller will display ...

Page 74: ...rvice Variable Index Continued Service variable index and value listing con t Quad Old Style SAB addr For Quad SAB applications 0 is the correct value for current SAB apps MDU Status Indicates operational status of programmable motor drives Hex value See related software programmable motor controller ...

Page 75: ...e Mass Vol is active plus any function key for a machine Any variable that can be edited on the machine is allowed to be changed under this protection SP Run Stop is active Mass Vol is active only Only the Setpoint of the machine can be changed SP and Alarm Run Stop is active Mass Vol is active plus Alarm Ack Clr is used The following variables can be changed LWF Machines Mass Flow Error Mass Flow...

Page 76: ...eys pop up when the Edit key is pressed and a variable is highlighted Edit Mode F5 F6 F7 F8 F1 F2 F3 F4 POWDER LWF Frequency I O M01 08 FREQUENCY OUTPUT 1 Not Assigned FREQUENCY OUTPUT 2 Not Assigned FREQUENCY OUTPUT 3 Not Assigned FREQUENCY INPUT 1 Not Assigned FREQUENCY INPUT 2 Not Assigned FREQUENCY INPUT 3 Setpoint FREQ INPUT 1 VALUE 0 000 Hz FREQ INPUT 2 VALUE 0 000 Hz FREQ INPUT 3 VALUE 0 00...

Page 77: ...Setpoint Weight on Scale Dev from Setpoint Drive Command Screw Speed Undefined Dynamic Feed Factor These outputs can be configured for a number of different functions as shown The scaling chart follows this section Default value is Not Assigned Frequency Input 1 2 Not Used Frequency Input 3 This is the ratio or direct setpoint input for the controller if use Frequency Input 1 3 Value These variabl...

Page 78: ... provide the ratio or direct control signal as set on page 07 The procedure on how to set this value is described in DCS 322 Range of Values 0 to 999 Default value is 1 000 Frequency In 3 Deadband This value sets the variation level at which the frequency signal will be ignored For example if the entry is set to 10 Hz any frequency input to Input 3 that varies less than 10 Hz will be recognized as...

Page 79: ... Fo 5000 Hz Setpoint Fo Operating Setpoint FSS 10kHz ex Fo 3000Kg Hr 10000Kg Hr 10kHz Fo 3000 Hz Weight on Scale Fo 10kHz Scale Range Actual Net Weight ex Fo 10kHz 120kg 43Kg 3583 Hz Deviation from Setpoint Fo 5Khz 10kHz Massflow Error FSS ex Massflow error 50 Kg Hr Fo 5 kHz 10kHz 50 10000 4950Hz Note sign of the massflow error Drive Command Fo 10Khz Current Drive Command 100 ex 10kHz 43 100 4300 ...

Page 80: ...page Page 09 layout This diagram shows the data layout The second row of keys pop up when the Edit key is pressed and a variable is highlighted Edit Mode F5 F6 F7 F8 F1 F2 F3 F4 POWDER LWF Control Parameters M01 09 WEIGHT SAMPLE TIME msec 1000 000 MASSFLOW STD DEVIATION 15 000 DESIRED STD DEVIATION 0 560 MOTOR CONTROL GAIN 70 MASSFLOW FILTER LENGTH 5 sec ADAPTIVE TUNING ENABLED On FEEDER RUN TIME ...

Page 81: ...ction of the gross scale range the larger this number should be The value 4500 msec is the maximum entry If the Adaptive Tuning is Enabled this value is calculated for you automatically Range of Values 500 to 4500 msec Massflow Standard Deviation This value represents the square root of the 2 sigma weight residual calculations as done by the Kalman filter The larger the number the poorer the envir...

Page 82: ...gish control This number is calculated by the Kalman filter when the Adaptive Tuning is enabled Range of Values 01 to 500 Motor Control Gain This number sets the Integral gain of the controller The large the value the more aggressive the control action This number is calculated by the Kalman filter when the Adaptive Tuning is enabled Range of Values 1 to 999 Massflow Filter Length The larger this ...

Page 83: ...daptive Tuning be left on for all operations Selecting off results in no updating of the Kalman filter data and potential less than optimal performance by the feeder controller Default value is Off Feeder Run Time This is the length of time in hours that the feeder has been running since the variable was cleared Enter the value of 0 to clear the variable Drive Command Ceiling Sets the maximum moto...

Page 84: ...e Scroll keys to move from page to page Page 10 layout This diagram shows the data layout The second row of keys pop up when the Edit key is pressed and a variable is highlighted Setpoint can be edited directly from this page F5 Change Value SET POINT 1000 00 MASSFLOW 999 98 Alarm Ack F5 F6 F7 F8 F1 F2 F3 F4 POWDER LWF Overview M01 10 Net Weight 130 67 Grav Mode Vol Mode Clear Alarm DRIVE COMMAND ...

Page 85: ...the hopper emptying as the feeder is running The very top of the hopper represents the Scale Range When the feeder is running the lower long tube turns green and when an alarm occurs this section turns red When you acknowledge an alarm the tube turns yellow The value of net weight is displayed next to this icon DRIVE COMMAND 57 77 DRIVE COMMAND 57 77 This graphic shows drive command The point to t...

Page 86: ...hown above the bar The setpoint can be changed by using the F5 Edit Change Value key as before MASSFLOW 999 98 MASSFLOW 999 98 This graphic shows the actual value of massflow with the Massflow and alarm limits indicated The alarm level pointers are red The value of current massflow is shown at the top of the bar Page 10 special key list Key Number Key Name Description F3 Alarm Acknowledge When pre...

Page 87: ... this controller Use the Scroll keys to move from page to page Page 11 layout This diagram shows the data layout The second row of keys pop up when the Edit key is pressed and a variable is highlighted F5 F6 F7 F8 F1 F2 F3 F4 POWDER LWF SPC Set Up M01 11 SPC VARIABLE TO LOG MFA SPC X BAR SAMPLE WIDTH 5 CHART SCALING FACTOR 1 0000 of SAMPLES IN SIGMA F5 F6 F7 F8 Change Value ESC Continued on next p...

Page 88: ...NONE MFA Selecting any one will permit trending of the variable MFA Actual Mass Flow The default value is None SPC X Bar Sample Width 5 10 20 50 100 Determines the number of individual values from the variable selection process to be averaged in each point on the graph The default value is 5 Chart Scaling Factor This entry scales the chart A value of 1 is default of Points in Sigma ONLY POINTS ON ...

Page 89: ...8 M ore K eys F1 S tart of Log F2 End Log Add New F 3 Cycle Snapshots Basics of SPC operation Each point indicated on the chart is an average of the number of samples of the selected variable specified by the sample width parameter set on pg Mcn 11 Samples are taken every two seconds The amplitude of the points on the chart in pixels is equal to Amplitude 2000 chart scaling factor Deviation from t...

Page 90: ...ics of SPC operations displayed values There are a number of values displayed on the screen Value Meaning Located SPC Values Upper Control Limit Computed value of the upper control limit from all previous data points The top number located just under the upper dashed line SPC Values Lower Control Limit Computed value of the lower control limit from all previous data points The bottom number just u...

Page 91: ...rrent data values and new data points are replacing old ones as time moves along SPC Message Display Frozen Indicates that the current display is of old data and that new data point additions are suppressed The displayed values do not change when the chart is shifted SPC Message Start of Log Indicates the current display includes the oldest point in the log and the display cannot be moved further ...

Page 92: ...er F5 SPC End of Log Add New Point Key Shifts the display to the present time The display then continues to add new data points as the feeder runs F8 SPC More Keys Displays new functions for keys F1 F3 F1 SPC Start of Log Key Shifts the display to show the oldest data in the ram card F2 SPC End of Log Add New Points Key Shifts the display to the present time The display then continues to add new d...

Page 93: ...ight feeder identifies the software part numbers for this controller Use the Scroll keys to move from page to page Page 13 layout This diagram shows the data layout The second row of keys pop up when the Edit key is pressed and a variable is highlighted F5 F6 F7 F8 F1 F2 F3 F4 POWDER LWF SW Part Numbers M01 13 CONTROLLER SW PART C9700 20000 V Continued on next page ...

Page 94: ...tion The number shown on this page is for the software that is used in the controller identified by the first two numbers in the Machine line paging ex 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 ...

Page 95: ...ctor alarm 1 1 External alarm active 2 2 Unassigned 4 3 Lo Motor Gain 8 4 Unassigned 16 5 Unassigned 32 6 Battery Low 64 7 Nak d due to feeder running 128 8 Net Weight Low alarm 256 9 Scale Overrange 512 10 Scale Underrange 1 024 11 Refill Timer Expired 2 048 12 Rate Setpoint 4 096 13 Rate Setpoint 8 192 14 Drive Command DHS 16 384 15 Drive Command DLS 32 768 16 Ext Channel Range Error 65 536 17 E...

Page 96: ... do not want a Int Channel Range Error to shutdown the feeder I would then subtract the Int Channel Range Error decimal value from the default value and enter the new value 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 ...

Page 97: ...initions 1 Density Array 1 Density Array On Off 17 Determining scale range for entry on page 05 47 DISA 5 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 Drive Command 1 13 Drive Command High Alarm Limit 40 Drive Command Low Alarm Limit 40 Drive Command Low Message 36 E Edit Mode 3 Ext Totalizer Increment...

Page 98: ...t 45 Page 06 layout 51 Page 06 variable list 52 Page 07 layout 55 Page 07 variable list 56 Page 08 layout 70 Page 08 variable list 71 Page 09 layout 74 Page 09 variable list 75 Page 10 graphic description 79 Page 10 layout 78 Page 10 special key list 80 Page 11 layout 81 Page 11 variable list 82 Page 12 layout 83 Page 13 description 88 Page 13 layout 87 Pending Alarm 37 PERT 5 Pert Residual 67 Pol...

Page 99: ... retrieval 85 SPC Start of Log Key 86 SPC Values Lower Control Limit 84 SPC Values Standard Deviation 84 SPC Values Upper Control Limit 84 SPC Variables to Log 82 SPC X Bar Sample Width 82 SPC Zoom In Key 86 SPC Zoom Out Key 86 Special addressing for SFT s using the Quad Controller 54 Speed Pick up Gear Teeth 58 Standard keys and their functions 3 Standard keys and their functions con t 4 Start up...

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