K-TRON K-Vision Programming Instructions Manual Download

Page: 83 / 121

Docu-No.: 0590020601-EN Rev. 1.6.0

Page 83

Appendix 5

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.

Pert Value shows the signal/noise ratio in percentage to the setpoint.

Please refer to the next table to determine system performance.

5.1.4

Pert values and control response

Reasons for massflow deviation may include:

• Feeder measures the product flow and the noise (e.g. Side wind on

hopper, vibration at the scale, wiring contact, pressure and vacuum
effects)

• Reference scale measures only the product flow without the noise.

Note:

• Review sections

1.4.2

5.1.4

and

5.1.5

for acceptable control

values.

Pert Value

Control Action/Response

Adaptive Gain

0-33%

Very good control response

80%

33-67%

Good to fair control response

50%

67-100%

Fair to poor control response

20%

100-250%

Very poor control action

10%

Over 250%

Most likely no control

Be aware on accuracy tests the massflow results from the reference
scale and feeder can deviate.

Summary of Contents for K-Vision

Page 1: ... 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 KCM LWF Programming M text text Software Version 2 0 ...

Page 2: ...of actions which have to be executed step by step This symbol identifies a general safety note If an error or ommission is found please contact documentation ktron com Reference to another manual Important information This symbol indicates that tools are required for the following task Specifies where information or a situation must be checked Docu No 0590020601 EN Datum 2011 Jan 03 Original 05900...

Page 3: ... sub menu 30 1 6 2 SFT sub menu 31 1 6 3 Manual addressing of SFTs 33 1 7 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 40 1 7 8 Motor sub menu for univer...

Page 4: ... drive 68 4 Alarm Messages Cause and Remedy 69 4 1 System alarms 69 4 2 LWF alarms 76 4 3 Display messages 77 4 4 Feeder won t start displayed messages 77 4 5 Feeder won t run in GRAV 77 4 6 Massflow variances in LWF feeding 78 5 Appendix 80 5 1 Special KCM LWF features 80 5 1 1 Automatic Gear Switching for LWF 80 5 1 2 SFT Addressing 82 5 1 3 LWF tuning for the KCM 83 5 1 4 Pert values and contro...

Page 5: ...cu No 0590020601 EN Rev 1 6 0 Page5 5 4 6 Actiflow drive hex status codes 100 5 5 Loading language file 101 5 6 Service variables 102 5 7 LWF PSR Map 104 5 8 LWF ASR Map 106 5 9 Parameter listing LWF 112 ...

Page 6: ...Page 6 Docu No 0590020601 EN Rev 1 6 0 ...

Page 7: ... 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 0490020611 KCM KD KSU II operation with calibration procedures 1090020602 KCM GD operation with calibration procedures 0690020604 K Vision o...

Page 8: ...ue shown as Param Value Menu name as Menu NAME Alarm message as Alarm Message Display indication or key action result as INDICATION 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 For KSL and KSC functions keys...

Page 9: ...s HCU and internal motor drives KCM K Tron control module the SmartConnex II integrated feeder controller KCM KCM with local keypad and display 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 K Vision K Tron line interface for up to 16 fee...

Page 10: ...l sub menu Motor sub menu Service setup sub menu Performance sub menu Actiflow sub menu appears when a actiflow is connected to KCM I O Setup menu Digital Input sub menu Digital Output sub menu Setpoint Input sub menu Analog Output sub menu Modbus I O sub menu Loader menu hidden if HCU or LSR is connected HCU Loader menu appears when HCU is connected to KCM LSR Loader menu appears when LSR is conn...

Page 11: ...ed if the feeder runs otherwise it is disabled Default DISABLED REFILL MAX Refill Level Maximum Input of the upper refilling limit at which refilling is stopped Warning Do not exceed the hopper capacity or scale capacity when entering the top refilling limit See section 3 1 1 Input range 0 95 x Gross scale range Default 0 06 kg REFILL MIN Refill Level Minimum Input of the lower refilling limit at ...

Page 12: ...and the GEARSWITCH is on Auto Lo the gear will switch to high and the GEARSWITCH parameter changes to Auto Hi Auto Lo When entering a setpoint which will generate a drive command of less than 10 and the GEARSWITCH is on Auto Hi the gear will switch to low and the GEARSWITCH parameter changes to Auto Lo AUTO TARE This command allows the current weight value to be entered into the TARE memory when t...

Page 13: ...hine For KSU II KCM select this parameter press ENTER twice and then press RUN For KSL press MORE F5 then press then press RUN For KSC press then RUN Attention Refilling and feeding errors during calibration reset the program pa rameter FF INIT to 0 and activate the FEEDFACTOR ERR alarm CALIB REMAIN s A count down timer for the auto calibrate cycle It shows how many seconds are left in the Calibra...

Page 14: ...The value VOL RATE is found in the Service Variable Index When the feeder runs in gravimetric control the BULKDENSITY parameter will reflect the current material bulk density EMPTY FDR Empty feeder function When started the feeder runs at a drive command of 70 The feeder stops automatically if no weight loss is detected Note Empty Drive Cmd may be changed by the Service Variables This command will...

Page 15: ...libration routine will run a frequency sweep on the ActiFlow to find the mechanical resonance point of the feeder During the calibration is no material fed Its important to have the feeder filled with material to a normal operating level before running this step because the resonance point is significantly affected by material SCREW FILL When started the motor will run At the Calib DC until weight...

Page 16: ...lated as follows not for vibratory feeders DriveCommand 100 x Setpoint Initial Feedfactor The starting feed factor can also be calculated with the command variable AUTO F F CALIB Value of 0 will cause an Feedfactor Alarm see page 21 The feeder will not run with a Feedfactor of 0 Input range 0 to 99999 Default 100 kg hr AVG FF Average Feedfactor The value shows the estimated mass flow value expecte...

Page 17: ... II KCM select this parameter press ENTER twice and then press RUN For KSL press MORE F5 then press then press RUN For KSC press then press RUN Attention Refilling and feeding errors during calibration reset the program pa rameter FF INIT to 0 and activate the FEEDFACTOR ERR alarm CAL PROD FED Calibrate Product Fed Shows the amount of material discharged during calibration cycle as calculated by t...

Page 18: ...iability of the calibration data A value of 100 means that the weight samples taken during calibration are extremely uniform indicating smooth product discharge and no weight disturbances Input range Display only CAL CORR LIM Calibrate Corr Limit Note Not used for vibratory feeders If the CALIB CORRELATION is below this limit value the feedfactor will be set to 0 the calibration test aborted and a...

Page 19: ...e feed factor otherwise the FF array is cleared If the feed factor changes more than 15 0 5 times the service variable RefArr DevLim the refill array is cleared FEED FACT 1 5 9 FF Hopper Full FF Hopper Mid FF Hopper Empty Display of the feeding factor values in the refilling feedfactor array These factors are calculated in the gravimetric mode and used during refilling in the volumetric mode when ...

Page 20: ...bratory FF 12 MF 17 DC Vibratory FF 17 MF 23 DC Vibratory FF 23 MF 33 DC Vibratory FF 33 MF 50 DC Vibratory FF 50 MF 70 DC Vibratory FF 70 MF 100 DC Vibratory FF 100 These individual values are calculated automatically by the function AUTO FF CALIB When the setpoint change exceeds the SEPT CHG LIM the controller switches to using the appropriate MF value at the Drive Command expected ...

Page 21: ...d Low alarm is triggered when Actual Drive Command is below this value Input range DRIVE CMD HI to 0 Default 0 FF DEV LIM Feedfactor Deviation Limit Maximum permissible difference between the AVG FF Average Feedfactor and the INIT FF Initial Feedfactor Not for vibratory feeders Input range 0 to 100 Default 0 MAX REF TIME sec Refill Time Max or Refill Time Maximum Input of the maximum refilling tim...

Page 22: ... NW HI LIMIT Net Weight High Limit Maximum product level by weight above which an alarm is immediately triggered If this condition is triggered the controller switches to volumetric control Input range 0 to scale range Default 0 kg no alarm Parameter Definition Table page 2 of 2 ...

Page 23: ...n a stop occurs Select No if alarms are not to be cleared during a Stop action Default No ALR Number of Selected Alarm Input of the alarm number which can be selected from the list in the appendix With the programming variable ALARM MODE the selected alarm number can be influenced Input range See section 4 2 ALR Name of Selected Alarm Shows the alarm function for the selected alarm number ALARM MO...

Page 24: ...y pressed ALS Input Alarm shutdown input caused the stop Run DISA Run Enable input caused the stop Stop input External bit input stop function MDU DISA Drive disabled stopping the output Calib Controller has completed its calibration routine Watchdog an internal timer failure reset the KCM CPU Zero SP The setpoint went to zero while the machine was running Emptying The emptying function when compl...

Page 25: ... CTRL GAIN Selections Manual Very Slow Slow Moderate Normal Aggressive Very Aggressive Default Aggressive DISPLAY FILTER Display Filter Input of the time over which the mass flow display is determined The greater the value the smoother the massflow display reading This value has no effect upon feeder control response Input range 0 to 999 seconds Default 30 seconds CTRL GAIN Motor Control Gain The ...

Page 26: ...sents a more stable weight display albeit slower control response When the Adaptive Tuning is On this value is automatically set User can change this entry when Adaptive Tuning is Off Input range 0 033 Hz to 9 999 Hz Default 0 4 Hz PERT VALUE Pert Value Pert Value shows the signal noise ratio of scale disturbance in percentage to the setpoint It is a measure of scale disturbance relative to setpoi...

Page 27: ...ult 10 V AGIT PERIOD If there is a detectable weight disturbance signal with approximately the same period as the the agitator interval time in seconds the software algorithm will work to cancel it out The algorithm self synchronizes around the entered time period Alternatively the synchronization can be made with an optional digital input from a sensor that delivers 1 impulse per agitator turn Th...

Page 28: ...x Gross scale Default 0 06 kg REFILL MIN Refill Level Minimum Input of the lower refilling limit at which refilling is started See section 3 1 2 for more information Warning Feeding behavior can be affected if the refilling limit is set too low Do not uncover feeder horizontal agitator Input range Refill Maximum Default 0 05 kg POST REFILL DELAY Post Refill Vol Grav Delay Delay time before the fee...

Page 29: ... is the time in milliseconds that it takes the valve to actually close plus the time the material falls Input range 0 to 9999 msec Default 0 msec FLT CLEAR TM Blow Off Time Time in milliseconds to provide a pulse to use for a filter clearing function on a vacuum loader or a jet filter A digital output must be assigned for BlowOff Not for HCU controlled loaders Input range 100 9999 msec Default 100...

Page 30: ...Span Input of the span correction factor for fine compensation of mechanical scale weighing errors This value may automatically change if the Auto Span feature is used in the CALIBRATION menu Input range 0 4 to 2 5 Default 1 000 NET WEIGHT Net Weight Display of the current weight of the feeding material on the scale Net weight Gross Weight Tare Range Display only 0 to scale range kg GROSS WT Gross...

Page 31: ...o readdressed automatically See section 5 1 2 for more information For KSU II KCM press key for KSU II KCM SFTs SFT Configuration The addresses and error signals of the connected weighing cells are displayed Typically the parameter will appear as 1 D or 123 D The number representing the address of the SFT Other codes in place of the SFT address include Invalid response from SFT No SFT at this addr...

Page 32: ...PE SFT Type Displays the type of the selected SFT Input range Display only SFT STATUS SFT Status SFT error display The Process Status Word of the selected SFT is displayed Any status word except 00000183 or 00000181 indicate SFT failure For mor informations see chapter 5 4 5 Input range Display only SFT SFT Software Display of the software version of the selected SFT Input range Display only HW Di...

Page 33: ... View SFTs variable to verify the SFT is now at the desired address To manually change the address of a properly installed SFT to a new defined address follow the next procedure 1 Select SCALE menu SFT sub menu 2 View SFTs variable to verify the SFT address to be changed is present 3 Select SFT SELECTED 4 Enter the SFT address seen from step 2 5 Select SFT ADDRESSED 6 Select Off 7 View SFTs variab...

Page 34: ...point Input of a maximum permissible setpoint value This value depends on the maximum throughput performance of the feeder Note This value also scales the ratio setpoint input and massfow and setpoint analog outputs Input range 0 to 999999 kg h Default 7200 kg hr UNITS Units Selection Selection of the desired units Note This selection change automatically all weight specific units Setup kg h kg mi...

Page 35: ...ar 5 Select Confirm 6 Press ENTER to load new application APPLICATION Control Type or Application Type Input of the application type Selection LWF WBF SFM PID VOL LWB WBB SFB XTR Confirm Input range See list Default LWF for LWF LANGUAGE Only in KSU II KCM Selects the desired language for the Display Choices are English German French Spanish Italian and Custom SCREEN SAVER Only in KSU II KCM When s...

Page 36: ...ting the screen saver to ON or in case it is already ON whenever a key is entered a 12 hour timer starts to count down 2 If the 12 hour timer has counted down to 0 the screen is set to its lowest brightness level The screen data displayed is unchanged The 12 hour timer restarts 3 If the 12 hour timer has counted down again to 0 the KSU II is set to the Home page and the screen is cleared A screen ...

Page 37: ...d if the Auto Gear Reduction function is used This entry must be the total reduction value between the drive motor and the feed screw This entry is the highest reduction or simply provides the lowest screw speed for any given motor rpm This entry is checked against the GEAR REDUC value to be sure that the magnitude of the entry is correct Input range 0 to 999 Default 0 PICK UP TEETH Speed Pickup T...

Page 38: ...Input range Drive specific Default drive specific See nameplate on motor for value MDU STATUS MDU Status The MDU status codes reveal operational condition of the Drive See listing of MDU status codes in section 5 4 1 DC CEILING Drive Command Ceiling Limitation of the drive command output to the motordrive Input range 10 to 125 Default 110 Parameter Definition Table page 2 of 2 ...

Page 39: ...en the drive motor and the feed screw This entry is the highest reduction or simply provides the lowest screw speed for any given motor rpm This entry is checked against the GEAR REDUC value to be sure that the magnitude of the entry is correct Input range 0 to 999 Default 0 PICK UP TEETH Speed Pickup Teeth Input of the number of teeth on the pick up gear This gear is used for measuring the speed ...

Page 40: ...or vibratory tray displacement The displacement must be measured at the vibratory and the SPAN calculated according following formula NewSpan OldSpan x Expected_Displacement Measured_Displacement Input range 0 5 to 2 0 Default 1 000 VIB DRIVE VIB FREQ Hz MDU STATUS MDU Status The MDU status codes reveal operational condition of the Drive See listing of MDU status codes in section 5 4 2 DC CEILING ...

Page 41: ... Teeth Input of the number of pulses per revolution of the optical encoder This encoder is used for measuring the speed Input range 0 to 9999 Default 400 ACTUAL POWER watts Actual Motor Power Displays the actual consumed stepper motor power Input range Display only W MAX MOT POWER watts Max Motor Power This entry sets the maximum output power to the stepper motor See nameplate on motor for this va...

Page 42: ...splayed in the parameter SCREW SPEED Input range 0 to 999 Default 0 PICK UP TEETH Speed Pickup Teeth Input of the number of pulses per revolution of the optical encoder This encoder is used for measuring the speed Input range 0 to 9999 Default 400 MAX MOT SPEED rpm Maximum Motor Speed Input of the maximum motor rpm for 100 drive command Input range Drive specific Default 60 See table 1 7 10 for va...

Page 43: ... 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 Feeder Type Max Motor RPM Maximum Power Setting W Required Stepper Drive BSP100 60 49 0000001430 0000005987 BSP135 60 194 0000004568 0000005987 BSP150 S 120 194 0000004568 0000005987 KM T12 150 43 0000005987 0000001430 ...

Page 44: ...ort using HyperTerminal When Stop is selected the data can be read from the KCM at any time as long as power to the KCM is not interrupted Restarting of the TRACETICK can be done without losing data if done within 1 hour of stopping the trace 1 sample Each sample point of data is recorded No more than five minutes of data can be stored without older data being over written 1 4 second 4 samples per...

Page 45: ...e 0 means the feeder is never in Gravimetric mode INT CHANNEL Internal Channel The internal channel performance is calculated in two parts the bandwidth load and the error counter where it considers 10 errors per minute as bad and 100 load as bad Both values are taken in square as follows IntChanPrf 100 1 Load 0 1 Err min 2 Example 5 errors min and 50 load 75 performance Expect normal values of 75...

Page 46: ...ndicate the remaining life the following formula is calculated once per second Brush_Remain Brush_Remain 100 3600 5000 MotorPower Nominal_Power Where 100 indicates in percent 3600 5000 expected life in seconds Motor_Power Nominal_Power The current power ratio limited to 0 1 If the motor is new one should enter 100 in BRUSH REMAIN Also after checking the brushes the parameter can be modified on the...

Page 47: ...ctiFlow off Easy Easy flowing material little vibration Medium Medium flowing material Hard Hard flowing material hard vibration Manual Manual setting ACF Floor Minimum vibration ACF Ceiling Maximum vibration Standard Medium STATUS The actiflow status codes reveal operational condition of the controller See listing of status codes in section 5 4 6 ACF FLOOR only displayed if manual Minimum Vibrati...

Page 48: ... inputs are by level indicates a digital output that can be mapped to DIGOUT MAP CPU_In1 CPU_In4 are for the programmable digital inputs on the CPU pcb terminal block J8 MDU_In1 MDU_In2 are for the programmable digital inputs on the MDU Drive pcb terminal block J1 CPU_Out1 CPU_Out4 are for the programmable digital outputs on the CPU pcb terminal block J8 MDU_Rel1 MDU_Rel3 are for the programmable ...

Page 49: ...ut Range See list Default CPU_In_1 Start CPU_In_2 Stop CPU_In_3 ALS Input Note Ref Cmd is only functional if refill is enabled and net weight is Refill Max weight Ref Bypass is only functional if the Refill is Enabled If refill is active and running initiating a Refill Command input will terminate the refill If the refill is not active initiating the Refill Command input will cause the Refill cycl...

Page 50: ...red Loader Blow_Off HiLo_Gear Input Range See list Default CPU_Out_1 Feeder Run CPU_Out_2 Refill CPU_Out_3 Hard Alarm CPU_Out_4 Drive Enable MDU_Relay1 None MDU_Relay2 Refill MDU_Relay3 None STATE Digital Output State Displaying the actual status of the selected digital output Input range Display only Off or 0 not active On or 1 active POLARITY Polarity The selected digital output changes the func...

Page 51: ... possible choices 0 5 Vdc 0 10 Vdc 0 20 mA if CPU_Analog is the input selection AIN VALUE Analog Input Value Display of the actual input value in percentage of the maximum value AinMax as defined below Input range Display only AIN MIN Analog In Value Min Scaling of the analog output for the minimum value Offset adjustment e g 20 for 4 mA This value can be used also to invert the analog input Input...

Page 52: ...etpoint x Actual setpoint MASSFLOW 20mA Max setpoint x Massflow NETWEIGHT 20mA Scale range x net weight DRIVE COMMAND 20mA 100 x Percent drive command MOTOR SPEED 20mA Max Mot RPM x Act Mot Spd FEEDFACTOR 12mA Init FeedFactor x actual feedfactor Input range See list Default None AOUT VALUE Analog Output Value Display of the actual output value in percentage of the maximum value Input range Display...

Page 53: ...ion of each connected external Modbus I O device Node Select 80 81 82 83 Type Select Anlg In Anlg Out Dig In and Dig Out are the possible functionality for connected modules I O Point 1 8 Up to 8 points of the same type are possible at any address REBIND NOW When the I O functions have been configured press the ENT key twice to rebind variables to the I O points installed Note If alarm 39 occurs E...

Page 54: ... then once everything is powered select REBIND NOW parameter to permit module binding 3 Verify that at the module preset address the specific module is found by name at the parameter ADDR80 83 e g 80 WAGO 4 Open the DETAILS menu 5 Enter module address at NODE SELECT 6 Open TYPE SELECT 7 Note that if the automatic binding was done properly the module will have each I O point already set to a KCM in...

Page 55: ...er Definition LOADER FUNCTION Loader Function Selects whether loader runs or not Select KCM IO or EXTERNAL to run OFF to stop MAX LOAD TIME Max Load Time Load time in seconds to reach the high level proximity sensor An alarm will occur if the high level is not reached in this time Default 30 seconds SHUTDOWN TIME Shutdown Time Time in seconds for the motor to wind down at the end of the load cycle...

Page 56: ... commands can be selected and be executed with the ENTER key None No function Run Starts the conveying cycle Stop Stop the conveying cycle Clr Alrm Deletes all pending alarms Disch On Starts discharge Disch Off Stops discharge Conveying starts if you press ENTER at the selection RUN The process can be stopped only by selection of the command stop The START STOP key on the control unit does not hav...

Page 57: ... KCM and HCU interrupted Input range Display only PARAM NUM Only in KSU II KCM Input of the parameter number The name and value represented by the parameter number will be displayed under the variables PARAM DESC and PARAM VALUE respectively Input range see section 5 3 and manual 0290023601 PARAM VALUE Parameter Value Input of the desired value for the selected PARAM NUM input range see section 5 ...

Page 58: ...t a pre loaded file built in See manual 0590020611 for details Input range Kgr File Small Full Default Kgr File IP IP Adress Only present when an Ethernet Host board is installed If the KGR file is used this parameter is read only NM Net Mask Only present when an Ethernet Host board is installed If the KGR file is used this parameter is read only GW GateOnly present when an Ethernet Host board is ...

Page 59: ...ut of the protocol for the following Diag KMB Config User IF Input range see above Default User IF Notes Select KMB for ParamStore Select Config for SmartConfig activities Select User IF for PC access to KCM parameter data via the Conf port Select Diag is used for diagnostic trace functions and for loading a language file Parameter Definition Table page 2 of 2 Parameter Definition SELECT ONE Selec...

Page 60: ...om 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 0000003413 03900 20202 Vibratory drive 0000000684 04900 20212 Universal stepper drive 0000005987 02900 26200 LoPo stepper drive 0000001430 02900 26200 HiPo stepper drive 0000004568 ...

Page 61: ...ur programming is verified and complete Parameter Definition PASSWORD Entered Password Password to access the ACTION function of saving and recalling data from a K PROM Default 1234 See section 1 11 5 on how to change this entry ACTION Backup Action Action functions are Save Recall SAVE stores active operational data to the back up storage area of the K PROM RECALL places into active operational m...

Page 62: ...RD WR will be de activated immediately by programming the ACCESS TYPE Menus marked with are hidden by default Parameter Definition PRODUCT CHANGE CALIBRATION ALARM TUNING REFILL SCALE MACHINE SETUP I O SETUP LOADER HCU LOADER SYSTEM FDR BEING VIEWED AccessType Permission RD WR Reading and writing possible READ Read only possible HIDE No access menu Menu is not visible TOTAL KEY Select Clear Only R...

Page 63: ...d When the settings are made and the key switch is opened the security menu and all the menus set to read only will be read only To prevent that an operator can disable the key switch in the I O menu the I O menu should be set to read only or to hidden For additional information see manuals for KCM Electronics manual and for KSU II 0490020604 Programming procedure 1 Close key switch 2 Select SECUR...

Page 64: ...1 6 0 2 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 For KSL operation use manual 0590020613 ...

Page 65: ...y that the horizontal agitator if the feeder is so equipped is not uncovered at any time Adjust the value if necessary 3 1 3 Setting the Post Refill Delay Note Only adjust this value if the feeder is unstable noted by highly varying motor speed immediately after a refill 1 Select the REFILL menu 2 Select POST REFILL DEL parameter 3 Enter a value that is twice the entered value 4 Execute a refill t...

Page 66: ...t 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 4 Select the ALARM menu 5 Select the sub menu ALARM LIMITS 6 Select MAX REFILL TIME parameter 7 Enter a value 1 25 the stop watch value ...

Page 67: ...n analog output do the following In this example setpoint is the output parameter Have your calibration meter connected to the analog output 1 Enter Setpoint 0 2 Modify the min value so that the actual analog output is correct Note for a 4 20 mA signal this will be around 20 3 Enter Setpoint Max Setpoint Adjust Aout max value so that analog output is exactly correct 4 Double check with Setpoint 0 ...

Page 68: ... Interface drive board is installed 2 In the ANALOG OUTPUT sub menu set the following ANALOG NUM CPU Note The CPU outputs 0 20 mA only FUNCTION Drive Command DEADBAND 0 25 AOUT MAX 100 This is the output span value AOUT MIN 20 This is the offset value 3 Make the wiring connects per the provided drawing 4 Run the feeder in volumetric control 5 Adjust Aout Max to get the desired motor speed for a gi...

Page 69: ... this message will occur after updating or changing firmware on the KCM Check KCM CPU Clear alarm and try unit 01 KPROM MEM FAIL The K PROM cannot be accessed by the KCM CPU Correctly insert K PROM Replace with known good K PROM 02 KPROM KGR FAIL Checksum error in kgr file area Verify K PROM is properly installed Replace K PROM 03 POWER GLITCH Power dip detected CPU did not reset Verify AC mains a...

Page 70: ...eck drive pcb LEDs for correct function Check Internal channel connections Replace drive or CPU pcb 10 MOTOR ALARM The KCM CPU lost the motor drive on the internal channel while in operation Check drive pcb LEDs for correct function Check Internal channel connections Replace drive or CPU pcb 11 MDU SERIAL TIMEOUT Motor drive has lost communication with the KCM CPU and then turns off all digital ou...

Page 71: ...heck motor brushes Replace motor if required Replace KCM drive board Check for excessive line voltage Reduce operating temperature 17 MDU UNCONTROLLED Speed feedback but no motor voltage applied Replace drive board 18 MDU EEPROM FAILED EEPROM checksum failed Cycle power If error persists replace drive pcb 19 MDU DRIVE FAILED MDU drive pcb has failed vibratory drive only Drive coil current too high...

Page 72: ...r Hopper Low input has been active on for more than the allowed load cycles The Buffer Hopper Low signal going inactive clears the load cycle counter If P20 Discharge Mode 02 LWF mode then Discharge Request input has been on for more than the allowed load cycles The Discharge Request signal going inactive clears the load cycle counter Check Parameter P25 Number of load cycles Check conveying rate ...

Page 73: ...ll correct host communications pcb 35 KPORT FAIL K Port has failed Replace K Port comm pc card 36 KPORT FAIL INIT K Port communication pcb could not be initialized Replace K Port comm pc card 37 KPORT ILLEGAL BD Host communication pcb is installed on the wrong port location K Port Check host communications pcb for proper mounting location 38 KGR PARAM ERROR One or more feeder parameters are not co...

Page 74: ...ue Check for proper feeding of material See if another alarm DRIVE CMD LO is present 44 MASSFLOW LOW The current massflow is below the tolerance entered in ALARM menu parameter MF ERR Increase the alarm start delay time in the ALARM menu Increase the tolerance MF ERR value Check for proper feeding of material Re range the feeder to achieve the desired feedrate Lower the operating setpoint SP See i...

Page 75: ... LO Limit in the ALARM menu Raise the operating setpoint SP Increase the DRV CMD LO value in the ALARM menu 48 CHECK_MOTOR_B RUSHES DC motor brushes may be wearing out and ready to fail Motor brushes need inspection and replacement if worn If brushes are OK re enter a relevant brush life number in the Performance sub menu 49 Reset while running It is set if the feeder was running before the power ...

Page 76: ...erial weigh in the hopper is above the limit set in the ALARM menu NW HI LIMIT Check for proper hopper filling Check the tare value Check for scale or weigh bridge measurement errors 56 NETWT LIMIT The material weigh in the hopper is below the limit set in the ALARM menu NW LO LIMIT Check for proper hopper filling Check the tare value Check for scale or weigh bridge measurement errors 57 REFILL EX...

Page 77: ...er before making the entry Message Cause Remedy Wait No setpoint is entered Feedfactor if required is 0 Interlock has failed Enter an operating SP Enter an Initial Feedfactor Check interlocks Alsh Automatic alarm shutdown because of an alarm Correct alarm problem and then clear the alarm with the ALARM key Disa Start via bit input disabled Interlock or Run enable Check interlocks to the KCM Messag...

Page 78: ...egular discharge Install different feeder screws when operating at low feeder screw speeds Check for material flow problems such as bridging in the feeder hopper Irregular motor speed Re enter start feeding factor INIT FF in the PRODUCT CHANGE menu and check in volumetric mode if the speed is constant Is the speed constant If so Re calibrate the new feeding factor reduce the CTRL GAIN in the TUNIN...

Page 79: ...s to the scale they must be flexible The scale may not touch anything Replace scale Improve ventilation install a pressure compensator on the ventilation connection during the suction process During Refill MASSFLOW LOW Fluidized material caused by the vortices of air in the hopper during refilling Continuous trickle from the refilling device The weight can be adversely affected if refilling is not...

Page 80: ...tage that not correct entered parameters or a hardware fault e g a power failure will not reverse the motor while it is running Gear switching is automatically enabled if in the programming a digital output is assigned to HI LO Gear When gear switching is enabled the following parameters are visible in the menu MACHINE SETUP menu MOTOR sub menu GEAR RED LOW and additionally in the PRODUCT CHANGE m...

Page 81: ...operate the gear switch automatically the user can select Auto Hi or Auto Lo to the GEARSWITCH parameter in the PRODUCT CHANGE menu When entering a setpoint which will generate a drive command of more than 50 and the GEARSWITCH is on Auto Lo the gear will switch to high and the GEARSWITCH parameter changes to Auto Hi When entering a setpoint which will generate a drive command of less than 10 and ...

Page 82: ...uto Readdress Automatically readdresses all SFT s from 1 to n Auto addressing rules 1 Auto addressing takes place on power on with a present spare SFT on address 0 2 If an SFT is found on address 0 it gets readdressed to the next available address 3 If one or more new spare SFT s are found on address 0 they get readdressed to the next available address 4 A single SFT on any address 0 stays at the ...

Page 83: ...ns for massflow deviation may include Feeder measures the product flow and the noise e g Side wind on hopper vibration at the scale wiring contact pressure and vacuum effects Reference scale measures only the product flow without the noise Note Review sections 1 4 2 5 1 4 and 5 1 5 for acceptable control values Pert Value Control Action Response Adaptive Gain 0 33 Very good control response 80 33 ...

Page 84: ... longer time yields a smoother massflow display Note This variable does not influence control response SFT Cut Off Freq Filter setting from gross weight Normally with Self Tuning set to On the SFT Cut Off Freq will automatically adjust to give the best possible gravimetric control Self Tuning On Setting is dependent on setpoint On small setpoint values it will be reduced towards 0 033 Hz Self Tuni...

Page 85: ...randomly added to the feeder The KCM is always in gravimetric control mode The KCM switches to Volumetric control when the hopper weight drops below the Net Weight Low NW Low value If the Refill Window remains active the Refill Timer times out and activate the refill timer output As shown above the value RT is the Refill Timer setting When the net weigh drops below the NW Low value the controller ...

Page 86: ...rom an automated refill system At point 1 the refill timer expires and the refill timeout alarm activates This resets the Refill Window At point 2 the Refill Timer alarm has been cleared by the operator Note PRD post refill delay time Fig 5 2 Auto refill function diagram Refill Max Net Weight Low Empty Refill Min Hopper Weight Refill Window active high VOL active high Refill Alarm active high 2 Ti...

Page 87: ...xpires and the refill timeout alarm activates This resets the Refill Window At point 2 the Refill Timer alarm has been cleared by the operator Clearing the Refill Alarm reactivates the refill window when the weight is below Refill Minimum as shown at point 3 Notes PRD post refill delay time Fig 5 3 Auto terminate refill function diagram Refill Max Net Weight Low Empty Refill Min Hopper Weight Refi...

Page 88: ...is full the high level proximity input is activated This must happen before the programmable Maximum Load Time otherwise it will generate an alarm The high level proximity input must be activated for 2 seconds until it stops the motor Alarm conditions High level proximity input does not get activated after the maximum load time High level proximity input is not activated before a refill A normal r...

Page 89: ... hopper fails Notes Loading restarts after refill or after alarm clear VCT valve close time MLT maximum load time Prox Switch input High no material at probe Fig 5 5 Normal refill but failed loading function diagram Refill Max Refill Min Hopper Weight Refill Window active high Loader Motor Hi On Prox SW input Hi no material Time MLT VCT Loader Alarm ...

Page 90: ...ith empty loader due to failed proximity switch Notes DT discharge time Prox Switch input Low material at probe Fig 5 6 Refill with empty loader due to a failed high level prox switch Refill Max Refill Min Hopper Weight Refill Window active high Loader Motor Hi On Prox SW input Low material Time DT Loader Alarm ...

Page 91: ...fill during loading of the loader hopper Note VCT valve close time ST shutdown time for the loader motor Fig 5 7 Refilling while loading the hopper loader function diagram Refill Max Refill Min Hopper Weight Refill Window active high Loader Motor Hi On Prox SW input Hi no material Time ST Loader Alarm VCT ...

Page 92: ...he weight level there is a programmable Discharge Timer parameter If the valve is open for this time it will close so the loader can start After the loader is full and the motor stops it waits for a programmable Motor Shutdown Time After this time it will reopen the valve This cycle continues until the refill is completed Fig 5 8 Loading an empty loader and refilling function diagram Refill Max Re...

Page 93: ...will stop and start based on this signal 1 Connect the motor contactor to a relay output of the Drive Board e g REL 3 2 Connect the Refill valve to a relay output of the Drive Board e g REL 2 3 Connect the level indicator to a bit input of the Drive Board e g IN 1 4 In the I O menu program the following parameters MDU IN1 to Loader Level MDU REL 3 to Loader MDU REL 2 to Refill 5 In the security me...

Page 94: ...0 sec 0 1 sec 1 sec P12 Input Filter Remote Start In Strt 0 1 sec 10 sec 0 1 sec 0 5 sec P13 Input Filter Remote Stop In Stop 0 1 sec 10 sec 0 1 sec 0 5 sec P14 Input Filter Discharge Valve Switch In DisV 0 1 sec 10 sec 0 1 sec 1 sec P15 Input Filter Filter Pressure Switch In FiPs 0 1 sec 10 sec 0 1 sec 1 sec P16 Input Filter Discharge Request In DiRe 0 1 sec 10 sec 0 1 sec 1 sec P17 Input XOR Mas...

Page 95: ...n 0002 2 1 Drive enable input closed 0 open 0004 3 1 Bit 1 Input activated low level 0 not activated high level 0008 4 1 Bit 2 Input activated low level 0 not activated high level 0010 5 1 Relay 2 energized 0 off 0020 6 1 Relay 3 energized 0 off 0040 7 1 Serial Master Time out 0080 8 1 Thermal pre alarm 70C 0100 9 1 Relay 1 energized 0 off 0200 10 1 Speed deviation 0400 11 1 Current limit 0800 12 ...

Page 96: ...able input closed 0 open 0004 3 1 Bit 1 Input activated low level 0 not activated high level 0008 4 1 Bit 2 Input activated low level 0 not activated high level 0010 5 1 Relay 2 energized 0 off 0020 6 1 Relay 3 energized 0 off 0040 7 1 Serial Master Time out 0080 8 1 Thermal pre alarm 75C 0100 9 1 Relay 1 energized 0 off 0200 10 1 Displacement deviation 0400 11 1 Current limit feedback failed 0800...

Page 97: ... 0002 2 1 Drive enable input closed 0 open 0004 3 1 Bit 1 Input activated low level 0 not activated high level 0008 4 1 Bit 2 Input activated low level 0 not activated high level 0010 5 1 Relay 2 energized 0 off 0020 6 1 Relay 3 energized 0 off 0040 7 1 Serial Master Time out 0080 8 1 Thermal pre alarm 70C 0100 9 1 Relay 1 energized 0 off 0200 10 Not used 0400 11 1 Motor rotation failure 0800 12 1...

Page 98: ...witch closed 0 open 0002 2 1 Drive enable input closed 0 open 0004 3 1 Bit 1 Input activated low level 0 not activated high level 0008 4 1 Bit 2 Input activated low level 0 not activated high level 0010 5 1 Relay 2 energized 0 off 0020 6 1 Relay 3 energized 0 off 0040 7 1 Serial Master Time out 0080 8 1 Thermal pre alarm 75C 0100 9 1 Relay 1 energized 0 off 0200 10 Not used 0400 11 Not used 0800 1...

Page 99: ... Group mode 0001 1 1 Group leader 0002 2 Not used 0004 3 1 Continuous mode 0008 4 1 Error received 0010 5 1 Baud Rate range error 0020 6 1 Not used 0040 7 1 Filter on 0080 8 1 Weight conversion complete 0100 9 1 EEPROM read or write error 0200 10 1 K FFP Fast Frequency Processor error 0400 11 1 Ft temperature frequency out of range 0800 12 1 Fw weight frequency out of range 1000 13 1 Weight window...

Page 100: ... 1 1 safety switch closed 0 open 0002 2 unused 0004 3 1 Bit 1 Input activated low level 0 not activated high level 0008 4 1 Bit 2 Input activated low level 0 not activated high level 0010 5 unused 0020 6 unused 0040 7 1 Serial Master Time out 0080 8 unused 0100 9 1 Relay 1 energized 0 off 0200 10 1 Displacement deviation 0400 11 1 Current limit short circuit 0800 12 1 Spring failure 1000 13 1 Gene...

Page 101: ...em cable to the config port and run a terminal program like Windows HyperTerminal with 19200 8 n 1 3 Press enter on the PC to start the interactive menu Next press 2 to select Flash File Information 4 Press 4 to erase the previous file and y to confirm the erase 5 Press 3 to download the file then load the file with Z Modem from HyperTerminal It is important to erase any previous file before downl...

Page 102: ...nternal channel SFT MDU LDR Actiflow loading in percent 50 IntCh Node Internal channel SFT MDU LDR Actiflow last failed node IntCh Opcode Internal channel SFT MDU LDR Actiflow last opcode KpromWriteCount Counter for the write cycles to the Kprom RefArr Dev Lim LWF Only Sets the maximum FF deviation allowed in the refill array If the FF deviation from Refill Complete to Refill Request is greater th...

Page 103: ...s allows to interface the AC board to 3rd party vibratory drive If set to 1 that is used to unhide the menu parameters for the tuning and calib ScaleRange Input from the scale range RefillRepTm This parameter is zero by default When 0 the refilling functions are all the same as before To enable this feature auto restart this new parameter must be set to a non zero value such as 60 seconds and the ...

Page 104: ...Feeder received a start command but is waiting 20 START_OK Start input will start feeder 21 STARTED Started status 22 K LINK INIT COMPLETE K Link initialization has been com pleted 23 KSU II PRESENT KSU II is connected to KCM 24 LOC EXT If in External Setpoint mode value is 1 25 RAT DIR If in Direct Setpoint mode value is 1 Only valid if Bit 24 is set to 1 32 HCU_ALARM HCU loader alarm 33 HCU_REC_...

Page 105: ...nabled 52 BLOWOFF_OUT Filter blowoff function set 64 DISP_PRESENT KCM KD internal display present 65 CPU_INIT_CPL CPU initialization complete 66 MASS_MODE Unit in Grav mode 67 CALIB Currently running an auto calibrate routine 68 PERT Unit in PERT condition 69 REFILL Feeder is refilling by automatic means 70 REF_TIMEOUT Refill timer has expired 75 LOADER_FULL Loader full input to control 76 LOADING...

Page 106: ...et 05 INT CHAN FAIL Internal channel has failed to communicate between the CPU and drive boards also SFTs and HCU 06 WT PROC FAILURE SFT s failed Serial communication to the load cell interrupted f SFT internal failure communica tion OK t No communication from the SFT to the controller board Not valid answer from SFT 07 INCORRECTNUM S FT Number of SFTs found during polling does not equal that requ...

Page 107: ...is exceeded Note The Safety switch is not designed to be used as a normal way of interlocking the KCM It is used for safety control only 15 MDU SAFETY RELAY Safety relay failed to close contacts on power up and contacts remained closed after power down 16 MOTOR ENCDR FAIL Dual tach signals connected one failed Over voltage on drive power supply Motor voltage applied but no speed feedback Drive tem...

Page 108: ...l pressure across the filter is too high indicating a clogged filter 27 05 HCU CYC COUNT AL If P20 Discharge Mode 01 Fill mode then Max numbers of load cycle exceeded because Buffer Hopper Low input has been active on for more than the allowed load cycles The Buffer Hopper Low signal going inactive clears the load cycle counter If P20 Discharge Mode 02 LWF mode then Discharge Request input has bee...

Page 109: ... KPORT FAIL INIT K Port communication pcb could not be initialized 37 KPORT ILLEGAL BD Host communication pcb is installed on the wrong port location K Port 38 KGR PARAM ERROR One or more feeder parameters are not correct for the specified feeder 39 EXT IO FAIL The MODBUS I O connection has failed 40 EXT ALR ACTIVATED Digital input on KCM selected for External Alarm is active 41 INTERLOCK FAIL Dri...

Page 110: ...B RUSHES DC motor brushes may be wearing out and ready to fail 49 RESET_WHILE_RU N It is set if the feeder was running before the power down or reset occurred 50 ACF_FAIL Actiflow has an alarm 52 FEEDFACT BAD Feedfactor is zero or feeding condition changed so that the feedfactor exceed the set limit in the ALARM menu FF DEV LIMIT 53 SCALE OVERRANGE The weight on the scale is above the scale gross ...

Page 111: ...ETWT LIMIT The material weigh in the hopper is below the limit set in the ALARM menu NW LO LIMIT 57 REFILL EXPIRED The programmed refilling time program parameter ALARM menu MAX REFILL TIME was exceeded without refilling being completed 58 LOADER TIMEOUT Loader hopper is empty 61 LOW CONTROL GAIN Adaptive gain is 10 or below ASR Alarm number Description Table page 6 of 6 ...

Page 112: ... 5 9 Parameter listing LWF Menu Variable Value Home SP MF 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 113: ...eedfactor Cal Product Fed Act Product Fed Span Cal Correla Cal Corr Limit Cal DC Cal Time sec Calibration Menu Feedfactor sub Refill Array FeedFactor 1 Feedfactor 5 Feedfactor 9 For vibratory only FF 8 FF 12 FF 17 FF 23 FF 33 FF 50 FF 70 FF 100 Alarm Menu Limits sub Massflow Err Massflow Err Drive Cmd Hi Drive Cmd Lo Menu Variable Value ...

Page 114: ...Limit Max Refill Time NW Hi Limit NW Lo Limit Alarm Menu Set up sub Alarm Delay sec Startup Delay sec Stops Clrs Alarms ALR Number ALR Mode Stop By Read only Tuning Menu Method Display Filter CTRL Gain Adaptive Tune Adaptive Gain Sample Time SFT Cutoff Frq Pert Value Modulation Vibratory only SP Change Limit Menu Variable Value ...

Page 115: ...u 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 SFT Weight SFT Type SFT Status SFT SFT SN SFT Temperature Menu Variable Value ...

Page 116: ...hours Fdr Address Machine Menu General sub Application Language Screen Saver Machine Menu Motor sub Gear Reduction Gear Reduction L Pick Up Teeth Actual Power Maximum Motor Power Maximum Motor Voltage Maximum Motor Speed MDU Status DC Ceiling Vibratory only KV Device Vibratory only Vib Span Machine Menu Service sub Tracetick Menu Variable Value ...

Page 117: ...sting LWF 5 9 Machine Menu Performance sub Control Grav Ratio Int Channel KCM Temperature Torque Brush Remain Machine Menu Actiflow sub Displace Min Max Status Voltage Current Frequency I O Menu Digital Inputs CPU1 CPU2 CPU3 CPU4 MDU1 MDU2 Ext1 Menu Variable Value ...

Page 118: ...age 118 Docu No 0590020601 EN Rev 1 6 0 Ext2 Ext3 Ext4 Ext5 Ext6 Ext7 Ext8 I O Menu Digital Outputs CPU1 CPU2 CPU3 CPU4 MDURelay1 MDURelay2 MDURelay3 I O Menu Digital Outputs con t Ext1 Ext2 Ext3 Ext4 Ext5 Ext6 Ext7 Ext8 Menu Variable Value ...

Page 119: ...ut Map Setpoint sub Source AinValue Ain Min Ain Max Deadband Analog Out Menu sub Aout Num Function Aout Value AoutMin AoutMax Deadband I O Menu Modbus I O Menu sub Address 80 Address 81 Address 82 Address 83 Loader Menu Loader Function Max Load Time Shutdown Time Discharge Time Menu Variable Value ...

Page 120: ...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 SW HW MDU Password Security Menu Product Change Calibration Alarm Tuning Refill Scale Machine Set Up I O Set Up Loader Menu Variable Value ...

Page 121: ...Docu No 0590020601 EN Rev 1 6 0 Page121 Appendix 5 Parameterlisting LWF 5 9 HCU Loader System Fdr Being Viewed Tot Key SP Access Vol Alarm Clear Menu Variable Value ...

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