K-TRON KCM Operating And Maintenance Instructions Manual Download

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OPERATING AND

MAINTENANCE INSTRUCTIONS

Read this manual prior to opera-
ting or servicing the equipment.
This manual contains all safety
labels and warnings.

Original operating instructions

1090020601-EN Rev. 1.2.1

KCM

KCM

II 3D Ex tc IIIC T65°C

0590024903-D X
1190021904-A X

Summary of Contents for KCM

Page 1: ...S Read this manual prior to opera ting or servicing the equipment This manual contains all safety labels and warnings Original operating instructions 1090020601 EN Rev 1 2 1 KCM KCM KCM II 3D Ex tc IIIC T65 C 0590024903 D X 1190021904 A X ...

Page 2: ...ctions 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 1090020601 EN Datum 2012 Juli 09 Original 10900206...

Page 3: ...emoval from service 13 2 Assembly and Function 14 2 1 Field of application 14 2 1 1 Explosion proof marking 14 2 1 2 Zones and device categories gas 14 2 1 3 Zones and device categories dust 15 2 1 4 Dust deposits and glow temperature 15 2 1 5 Abbreviations 16 2 1 6 Additional programming information 17 2 2 Overview 18 2 3 Structure 19 2 3 1 Enclosure 19 2 3 2 Circuit assemblies 20 2 4 Safety devi...

Page 4: ... 10 7 DC motor drive feedback J2 40 4 10 8 Change DC motor shaft rotation 40 4 10 9 Stepper drive specific connections 41 4 10 10 Universal stepper motor drive power J6 41 4 10 11 LoPo HiPo stepper motor drive power J6 41 4 10 12 Stepper motor drive feedback J2 42 4 10 13 Stepper drive rotation error 42 4 10 14 Vibratory drive power J6 43 4 10 15 Vibratory drive feedback J2 43 4 10 16 Vibratory dr...

Page 5: ...pes listed 59 5 3 DC drive set up 60 5 3 1 DC drive selection notes 60 5 3 2 DC motor selection table by drive type and line voltage 60 5 3 3 450 1600 Watt DC drive pc board DIP switch settings 61 5 3 4 Additional jumper settings for 450 watt drive 61 5 4 AC drive set up 62 5 4 1 AC drive interface pc board DIP switch settings 62 5 5 Stepper drive set up all types 63 5 5 1 Stepper motor programmin...

Page 6: ...003413 78 9 3 9 Stepper drive interface fuse location 0000005987 78 9 4 Battery replacement 79 9 5 KCM service connections 80 9 5 1 Forcing the Config Port to UserIF protocol 80 9 5 2 USB 80 10 Troubleshooting 81 10 1 General information on fault detection 81 10 2 KCM CPU LEDs 82 10 2 1 CPU pc board LEDs 83 10 2 2 K Port LEDs 83 10 3 KCM Drive and Power Supply Details 84 10 3 1 Drive board LEDS 84...

Page 7: ...t port wiring 107 12 4 9 KCM to BM 85 Host port wiring 108 12 4 10 450 watt DC drive wiring example 0000007405 109 12 4 11 KCM without SIB board dc motor 0000002610 110 12 4 12 Remote KCM with SIB pcb at feeder 111 12 4 13 Field wound DC motor wiring example 113 12 4 14 Stepper drive wiring example for 0000005987 114 12 4 15 Encoder Line Driver Board 115 12 4 16 Vibratory feeder wiring example 000...

Page 8: ...Page 8 Docu No 1090020601 EN Rev 1 2 1 ...

Page 9: ...ramming of the specified equipment should only be undertaken by qualified personnel DANGER indicates a extremely hazardous situation which if not avoided could lead to heavy bodily injury or to death WARNING indicates a potentially hazardous situation which if not avoided could lead to heavy bodily injury or to death CAUTION with safety alert indicates a potentially hazardous situation which if no...

Page 10: ...osion protection For install and the mounting for explosion proof equipment following and observe the standards and directives Standards 99 92EG ATEX 137 Ensure that only qualified and trained personnel work with the device Establish personnel responsibilities for operation and maintenance Ensure that personnel have read and understood the operating instructions to all installation components part...

Page 11: ...use the equipment in a manner not intended by the manufacturer Do not use the equipment in a manner not intended by the manufacturer The equipment must be protected against direct sunlight Observe the safety notes for the connected feeding devices In addition to the operating instructions always comply with generally prescribed safety regulations governing accident prevention and environmental saf...

Page 12: ...of high voltage components Only qualified electricians may work on the electrical equipment of the equipment High voltage may be present on the line power cables of the device Switch off the power to the device for 3 minutes before any disassembly maintenance and repair work replacing the drive Protect the device against moisture entrance Modifications to the equipment are prohibited The operator ...

Page 13: ...Docu No 1090020601 EN Rev 1 2 1 Page13 SafetyNotes 1 Removal from service 1 11 1 11 Removal from service The operator is responsible for the proper removal and disposal of the equipment from service ...

Page 14: ...ch the device may be used 2 1 2 Zones and device categories gas The owner is responsible for ensuring that the system is installed in the intended zone The corresponding category is described in the declaration of conformity Zone Description Use of KCM Zone 0 An area in which an explosive atmos phere i e a mixture of air and flamma ble gases vapours or mists is either fre quently or constantly pre...

Page 15: ...ngerous explo sive atmosphere in the form of a cloud of flammable dust suspended in the air may form at times under normal operat ing conditions Allowed Observe the requirements of the standard IEC EN 60079 14 Chapter 5 6 3 1 with regard to reduced glow temperature at dust deposits In case of dust deposits of up to 5 mm Glow temperature of the material at a thickness of the layer of dust 5 mm max ...

Page 16: ...D KCM with local Keypad and graphic display since 2010 before 4x20 characters display KCM SD KCM with Status Display only KGR host communication file residing in KCM K PROM parameter and k link file storage in the KCM KSC K Tron Smart Commander a PC based HMI system for use with up to 30 feeders KSL K Tron line interface for up to 8 feeders K Net KCM serial data connection to KSU II KSL K Vision o...

Page 17: ...owing documents for more detailed programming information Operation for LWF WBF PID SFM VOL Feeder Operation for LWB WBB SFB GWB Feeder LWF Programming WBF programming PID programming SFM programming VOL programming LWB programming WBB programming SFB programming GWB programming The K Tron s supplied operating instructions describe how to use the connected feeder ...

Page 18: ...rily of a cpu pc board and a drive pc board Drive choices include a 1600 watt DC drive a 450 watt DC drive a vibratory drive for KV1 KV3 vibratory trays a stepper drive for feeders that utilizes a stepper bi phase motor and lastly an AC drive interface pc board for use with variable frequency drives VFD or remote DC drives This manual will describe the full family of KCM components including all d...

Page 19: ...s are housed in an Aluminium profile or stainless steel housing with a swing out cast cover The enclosure is designed to mount directly to a feeder or be located in a control panel All cabling is brought through the side of the housing incorporating cable glands The enclosure is Nema 4 IP 65 rated Wiring access is made through IP cable glands at the underside of the KCM Fig 2 1 KCM KD Fig 2 2 KCM ...

Page 20: ...ase permits operation of the KCM without any other external components and is suited for simple machine mount installations where operator interaction is required at the controller The second case requires the addition of one or more of the following KSU II KSC K Vision or KSL user interface The choice depends upon application If communications to a host computer or PLC is required a Host Communic...

Page 21: ... following safety messages are supplied For operation in the allowed hazardous zone only use certified explosion proof cable glands and blind covers ATEX category 2GD The front cover is Part of the ignition protection and it must not be opened unless power has been removed and no explosive atmosphere is present Fig 2 4 KCM safety label Make all ground PE connections to these points as indicated Pr...

Page 22: ...e declaration of conformity Service application KCM must only be installed in an industrial or manufacturing power environment Connection in a residential power system is not permitted Power line supply 103 264 VAC Line frequency 47 63 Hz Inrush current maximum 20A Size H x T x B 325 x 130 x 310 mm Weight 7 2kg 16lb Operating temperature 0 to 50 C 32 to 122 F KCM for 1600W DC Drive in stainless st...

Page 23: ...rive 250 VA at 115 230 Vac Stepper drive 0000005987 150 VA at 115 230 Vac Stepper drive 0000004568 100 VA at 115 230 Vac Stepper drive 0000001430 75 VA at 115 230 Vac Internal fuse ratings DC motor 1600 watt drive F1 F2 12 5 AT 5x20 mm DC motor 450 watt drive F1 F2 6 3 AT 5x20 mm Vibratory Drive F1 2 0 AT 5x20 mm Stepper drive 0000005987 F4 2 0 AT 5x20 mm AC Interface F1 F2 6 3 AT 5x20 mm Specific...

Page 24: ... 0000001430 1 4 A coil peak per at nominal line voltage 49 watts Current range selected from motor power settings DC motor output voltage With 115 Vac supply 160 Vp square wave PWM 0 99 6 With 230 Vac supply 322 Vp square wave PWM 0 99 6 Stepper motor output voltage 48 V maximum PWM 24 V maximum PWM For 0000005987 drive For 0000004568 and 0000001430 drives Motor field output dc Pulsing DC at 2A 16...

Page 25: ...ley DF1 ProfibusDP Profinet ModbusPlus ModbusTCP AB DeviceNet AB EtherNet IP For SFT connections six SFT permitted K Port1 and K Port2 Requires communication adapters specific to the protocol Surge immunity Meets EN61000 4 5 Criteria C Motor may stop during a surge or transient condition Relay K1 K3 contact ratings 5 A 250 Vac 5 A 30 Vdc Maximum switching power 1250 VA 150 W Relay K1 K2 are SPDT R...

Page 26: ...ency input ratings input frequency range 0 20 kHz Minimum pulse width 15 sec on off Logic level 5 12 Vdc for true With 24 Vdc use 2 2 kOhm Resistor in series KCM CPU pc board AC MDU speed frequency input rating Vmax 25 Vdc Vmin 4 0 Vdc Ion typ 15 mA Opto isolated input 24 Vdc supply ratings I max out 500 mA 5 Vdc supply rating I max out 50 mA For speed sensor 12 Vdc supply I max out 250 mA For SFT...

Page 27: ... and warnings 2 4 Vibration 0 49m sec2 0 05G 10 to 50 Hz all directions MTBF MTTR 45000 hours 15 minutes Approvals Met labs to UL 61010 1 CSA Canada CE Europe Label KCM only ATEX devices Label KCM SS only ATEX devices Specification Limitations Notations Table page 6 of 6 ...

Page 28: ...into operation only by authorized personnel KCM mounting must be vertical and protect from direct sunlight Minimum lateral mounting spacing between KCMs is 25 mm support rail to support rail Minimum vertical mounting spacing between KCMs is 75 mm case to case If no SFT Interface board is used the KCM must be mounted within 30 m 100 Ft of the feeder The following tools are recommended when working ...

Page 29: ... 3 4 3 Dimensions KCM Notes Slot A holds a M6 hex head bolt Use 8 bolts per KCM for secure mounting Cable gland hole sizes are 12 x M16x1 5 mm 4 x M20x1 5 mm Fig 4 1 Dimensions in mm 305 295 252 265 311 5 KCM 43 3 26 7 18 3 132 122 153 6 233 A A 18 3 B A 10 29 6 24 18 3 ...

Page 30: ...d and the controller is fixed to the cable channel with a clamping plate The cables are directly slotted through four drill holes 1 from the cable channel to the controller and the connection is sealed with an O ring 2 This means that the cable channel and the ATEX controller form a single unit and may be regarded as part of the housing Thus the same regulations apply to both the cable channel and...

Page 31: ...pecified connectors Specification Ratings and limitations Maximum wire size 2 5 mm2 or 12 AWG max according to regulations in your country Minimum wire size 24 AWG or 0 2 mm2 Maximum rated contact current 12 A Maximum rated contact voltage 250V Maximum screw terminal torque 0 5 Nm Fig 4 4 Power pc board keying diagram Fig 4 5 KCM cpu keying diagram Fig 4 6 K Port keying diagram 6 5 4 3 2 1 J3 6 1 ...

Page 32: ...2 Programmable via the user interface J8 3 Digital Input 3 Programmable via the user interface J8 4 Digital Input 4 Programmable via the user interface J8 5 Com Ground reference J8 6 Digital Output 1 Programmable via the user interface J8 7 Digital Output 2 Programmable via the user interface J8 8 Digital Output 3 Programmable via the user interface J8 9 Digital Output 4 Programmable via the user ...

Page 33: ... CPU to Drive J11 Terminal Function Notes J11 1 Power 24Vdc power from Drive power supply J11 2 Common Ground common from Drive power supply J11 3 RxD Internal data channel to Drive J11 4 RxD Internal data channel to Drive J11 5 TxD Internal data channel to Drive J11 6 TxD Internal data channel to Drive ...

Page 34: ... to a KCM use a separate 24 Vdc power supply for that KSU II For host connections see the appropriate communication adapter card manual For host communication applications that use the K Port comm use the following connection information Device K Port Use Protocol KCM Action Configuration KSU II 1 2 KMB Slave node Fixed 38 4 kbaud 8E1 KSC 1 KMB Slave node Programmable baud rate 8E1 K Vision 1 2 KM...

Page 35: ...8 4 K Port 1 connections J14 4 8 5 K Port 2 connections J15 Terminal Function Notes J14 1 Power 24Vdc power supply for KSU II J14 2 Common Ground common from Drive power supply J14 3 TxD K Port1 RS485 TxD J14 4 TxD K Port1 RS485 TxD J14 5 RxD K Port1 RS485 RxD J14 6 RxD K Port1 RS485 RxD Terminal Function Notes J15 1 Power 24Vdc J15 2 Common Ground common from Drive power supply J15 3 TxD K Port2 ...

Page 36: ... CPU circuit card In the case of Modbus RTU or AB DF1 protocols the K Port1 is used 4 9 2 Host connections for AB DF1 and Modbus using K Port1 For the host port protocols of Modbus TCP Ethernet IP DeviceNet ModbusPlus ProfibusDP Profinet please refer to the following man uals for wiring details Protocol Document Number DeviceNet 0590020609 Ethernet IP Modbus TCP Profinet 0590020610 ModbusPlus 0590...

Page 37: ...on Notes J1 1 24 Vdc DC voltage supply at 500 mA fused J1 2 Safety Switch Input Connect J1 2 to J1 1 to energize internal safety relay J1 3 24 Vdc Same as J1 1 J1 4 Drive Enable Sig Connect J1 4 to J1 3 to permit a run enable See next J1 5 Drive Enable Sig Connect J1 5 to J1 6 to permit a run enable J1 6 Common Ground or common connection J1 7 24 Vdc Same as J1 1 J1 8 Input signal 1 This input is ...

Page 38: ...to CPU J3 4 TxD Internal data channel to CPU J3 5 RxD Internal data channel to CPU J3 6 RxD Internal data channel to CPU For the 450 watt dc motor drive SFTs connect only to J4 Terminal Color Functio n Notes J4 7 8 1 Gray Power 12 Vdc power from drive power supply J4 7 8 2 Pink Common Ground common from drive power supply J4 7 8 3 Green TxD Internal data channel to SFT J4 7 8 4 Yellow TxD Internal...

Page 39: ... Relay 1 common J5 2 Relay 1 N O J5 3 Relay 1 N C J5 4 Relay 2 common J5 5 Relay 2 N O J5 6 Relay 21 N C J5 7 Relay 3 common J5 8 Relay 3 N O These relays are found only with the AC interface drive pcb Relay K4 Run Enable out Relay K5 Alarm Reset out Relay K6 AC line switching out double pole Contact ratings 250 Vac 30 Vdc 5 A maximum Terminal Function J9 6 Relay K4 COM J9 7 Relay K4 N O J9 8 Rela...

Page 40: ...f the motor armature leads either at the KCM DC Drive or at the motor Do this only with power removed from the KCM Connections for both the 450 and 1600 watt dc motor drives Terminal Function Notes J6 1 Motor Power DC motor voltage J6 2 Motor Power DC motor voltage J6 3 PE GRD Earth ground J6 4 PE GRD Earth ground J6 5 PE GRD Earth ground J6 6 Neutral Neutral leg of a 115 Vac line or 230 Vac J6 7 ...

Page 41: ...of the stepper drive J6 3 Stepper drive Phase 2 Phase 2 of the stepper drive J6 4 Stepper drive Phase 2 Phase 2 of the stepper drive J6 5 PE GRD Earth ground J6 6 PE GRD Earth ground J6 7 PE GRD Earth ground J6 8 Neutral Neutral leg of a 115 Vac line or 230 Vac J6 9 L2 Second leg of a 230 Vac line J6 10 L1 Line input hot either 115 Vac or 230 Vac Terminal Function Notes J6 1 Stepper drive Phase 1 ...

Page 42: ...change is to be made Notes Stepper motor mounted optical encoder provides 400 pulses per revolution quadrature For BSP150 S use a gear reduction of 2 00 This list may change Review stepper motor label before selecting stepper drive and power programming Terminal Function Notes J2 1 5 Vdc 5 Vdc power at 100 mA for sensor power J2 2 Frequency In A Input channel A from velocity sensor Also used if th...

Page 43: ... Variable amplitude and frequency power to vibratory feeder drive coil J6 2 Vibratory feeder coil Variable amplitude and frequency power to vibratory feeder drive coil J6 3 Vibratory feeder ground PE Earth ground J6 4 PE GRD Earth ground J6 5 PE GRD Earth ground J6 6 Neutral Neutral leg of a 115 Vac line or 230 Vac J6 7 L2 Second leg of a 230 Vac line J6 8 L1 Line input hot either 115 Vac or 230 V...

Page 44: ...und J6 6 Neutral Neutral leg of a 115 Vac line or 230 Vac J67 L2 Second leg of a 230 Vac line J6 8 L1 Line input hot either 115 Vac or 230 Vac For AC Drive frequency feedback input Vmax 25 0 Vdc Vmin 4 0 Vdc Ion typ 15 mA Terminal Function Notes J2 1 5 Vdc 5 Vdc power at 100 mA for sensor power J2 2 Connect to J2 1 Positive side of the opto isolator Configured for current sinking tachometer J2 3 T...

Page 45: ...ternal drive at 500 mA dc maximum source J9 2 Analog current output For drive command control to external drive J9 3 Frequency Out For drive command control to external drive 5 Vdc amplitude J9 4 Frequency Out For drive command control to external drive J9 5 24 Vdc Maximum current 500 mA fused J9 6 See section 4 10 5 J9 7 See section 4 10 5 J9 8 See section 4 10 5 J9 9 See section 4 10 5 J9 10 Com...

Page 46: ... Fig 4 7 Safety switch wiring Drive Notes The maximum voltage drop across the contacts is 2 0 Vdc Safety input wiring is made at terminal strip J1 on the drive pcb The Safety Input must be at 24 Vdc to engage the safety relay and permit KCM drive output Failure of this input will cause 15 MDU_SRelay alarm Safety Switch In 24 Vdc Drive J1 1 2 Fig 4 8 Drive enable wiring Drive Notes The maximum volt...

Page 47: ...east 5 Vdc to operate A low input provides an ON condition with Normal polarity Function is programmed as MDUin1 or MDUin2 Drive digital input wiring is made at terminal strip J1 on the drive pcb MDUin1 J1 8 MDUin2 J1 11 Input 1 2 PE 24 Vdc 5 Vdc Com Com F J1 8 1 J1 11 2 K1 K2 drive board relay wiring Notes Relay 1 and Relay 2 are SPDT types while Relay 3 is a SPST type Relay function is programma...

Page 48: ...terface relay K5 is an alarm reset relay When an alarm is cleared this relay energizes for 2 seconds after an alarm clear command from the user interface Notes Relay connections on the AC drive pcb are at terminal strip J9 K5 NO J9 9 K5 COM J9 8 Fig 4 12 AC interface relay K5 N O COM K5 Relay contacts F J9 9 J9 8 AC Interface relay K6 serves to interlock AC line power to an external drive through ...

Page 49: ... Connections are made at the CPU pcb terminal strip J8 CPUout1 J8 6 CPUout2 J8 7 CPUout3 J8 8 CPUout4 J8 9 Dig Out 4 7nF Vx PE Com F CR CPUout1 J8 6 CPUout2 J8 7 CPUout3 J8 8 CPUout4 J8 9 J8 Fig 4 15 CPU digital input example This is an example of one of the four programmable digital inputs on the KCM CPU circuit card Notes Maximum current from terminal 3 24 Vdc all connections is 350 ma A low inp...

Page 50: ... output function is programmed via the I O menu Analog Output sub menu I Output J9 3 I Output J9 4 Fig 4 16 CPU analog output circuit Analog Out F Com Analog Out 12Vdc 49 9 CPU J9 J9 3 J9 4 This circuit shows the selectable range analog input that is available at the CPU pcb at terminal J9 The input function is programmed via the I O menu Setpoint Input sub menu as parameter SOURCE CPU Analog Use ...

Page 51: ...t terminal J9 The input function is programmed via the I O menu Setpoint Input sub menu as parameter SOURCE CPU 0 10kHz See the specific application programming manual for exact programming Logic level 5 12 Vdc for a true For 24Vdc Power supply use an additional 2 2kOhm resistor in series Frequency range 0 20 kHz Minimum pulse width 15 sec Freq input J9 1 Freq input J9 2 2 2k Frequency Input F CPU...

Page 52: ...cessible for service Use of solid conductor wire is not permitted Wire insulation must be suitable for the applicable service Cables are not included in the items supplied The cables for the speed pick up or tachometer and data connections have to be shielded For some applications it is beneficial to shield the drive power lines as well Follow wire length limitations as specified Use only the prov...

Page 53: ... 30 m See section 12 1 for more information KV1 KV3 vibratory Maximum 2 5 mm2 or 12 AWG shielded 50 m Minimum 1 0 mm2 or 16 AWG shielded 30 m See table in appendix Relay K1 K6 Maximum 2 5 mm2 or 12 AWG 35 m Minimum 1 0 mm2 or 16 AWG 25 m Velocity feed back single ended Maximum 1 3 mm2 or 16 AWG 30 m shielded Minimum 0 5 mm2 or 24 AWG 30 m shielded Velocity feed back differential SIB installed with...

Page 54: ... fused Connect the neutral wire to N For 2 phase 220 240VAC applications in the US connect the first leg to L1 and the second leg to L2 which is also fused Each KCM must have its own power mains disconnect or circuit breaker The disconnecting means or circuit breaker must be in close proximity to the equipment and within easy reach of the operator The disconnecting means or circuit breaker must be...

Page 55: ...ed explosion proof cable glands and blind covers ATEX category 2GD on the KCM Connect the shields of all cable connections to low impedance equi potential bonding 0 1 ohm via the cable glands on both sides Lay the shielding 1 evenly over the O ring 2 If the KCM SS used in conjunction with the Hygiene mounting must be read the instructions in section 4 5 Fig 4 19 Cable gland shielding 2 1 ...

Page 56: ... the required voltage or current location JP Normal Position Function JP 1 1 2 1 2 normal processor operation 2 3 processor reset JP 2 1 2 Connect 1 2 for 0 10Vdc analog input JP 3 1 2 Connect 1 2 for 0 5 Vdc analog input JP 4 1 2 Connect 1 2 for 4 20 mA analog input JP 5 1 2 1 2 RS485 4 wire to Drive 2 3 RS485 2 wire to Drive JP 6 1 2 1 2 RS485 4 wire K Port1 2 3 RS485 2 wire K Port1 JP 7 1 2 1 2...

Page 57: ...ia the user interface 5 1 4 K Port 1 function via KCM CPU DIP switch positions 6 8 Off 0 On 1 for each switch position Address SW1 SW2 SW3 SW4 SW5 0 Off Off Off Off Off 1 On Off Off Off Off 2 Off On Off Off Off 3 On On Off Off Off 4 Off Off On Off Off 5 On Off On Off Off 31 On On On On On K Port 1 Function SW6 SW7 SW8 Software controlled Off Off Off Set for KSU II use On Off Off Set for KSL use Of...

Page 58: ...ease ESC and 9 to increase the display brightness manually The K PROM stores the actual data only on power shutdown not on CPU reset The K PROM must be installed on the KCM CPU pc board and it will be loaded by the Config port connection for communications or via the user interface for operations The K PROM can be moved from a failed KCM to a replacement KCM as the parameter and communication data...

Page 59: ...r on board jumpers See drive specific charts for those as well Off 0 On 1 for each DIP switch position AC Drive 450 1600W DC drive and vibratory DIP switch address setting is different from the Stepper drive 450 W DC 1600 W DC Stepper s Vibrator y AC Normal Position Function JP 3 JP 1 JP 1 JP 3 JP 1 1 2 1 2 RS485 4 wire to SFTs 2 3 RS485 2 wire Position 1 2 is normal JP 1 JP 3 JP 2 JP 1 JP 3 1 2 1...

Page 60: ...esponds to a max nameplate of 1600 W The 450 W drive includes a voltage doubler that allows it to drive 180 V 200 V motors from a 115 VAC input The 1600 W drive does not have a voltage doubler so to drive 180 V 200 V motors it must have a 230 VAC input DC drives auto detect the input line voltage 5 3 2 DC motor selection table by drive type and line voltage Drive Rating Watts Nominal AC Input VAC ...

Page 61: ...Action Switch Pos Range Tachometer Pulses per revolution 1 Off 100 On 120 Tachometer signal type 2 Off single channel encoder On dual channel encoder Drive address 3 4 5 345 000 0 001 1 010 2 011 3 111 7 Not used 6 JP Normal Position Function JP 4 1 2 1 2 SLM KCM control 2 3 K10S protocol Position 1 2 is normal JP 5 1 2 1 2 SLM KCM control 2 3 K10S protocol Position 1 2 is normal ...

Page 62: ... 4 1 AC drive interface pc board DIP switch settings Action Switch Pos Range Analog Output 1 Off 0 20 mA On 4 20 mA Function of MDU Input 2 2 Off KCM programmable On MDU alarm input Output frequency range 3 4 34 00 10 kHz 10 15 kHz 01 20 kHz 11 25 kHz Drive address 1 4 5 6 56 00 1 10 2 01 3 11 4 ...

Page 63: ...987 BSP125 60 49 or 194 0000004568 194 watts 0000001430 49 watts 0000005987 BSP135 60 194 0000004568 0000005987 BSP150 S 120 194 0000004568 0000005987 KM T12 150 43 0000005987 0000001430 Action Switch Pos Range Drive address 0 3 1 2 12 00 0 10 1 01 2 11 3 Output current at STOP condition 3 Off 0 current to stepper motor during a stopped condition On 50 current to stepper motor to hold its position...

Page 64: ...12 Drive Command MF 17 Drive Command MF 23 Drive Command MF 33 Drive Command MF 50 Drive Command MF 70 Drive Command MF 100 Drive Command Enter a starting setpoint according to the following chart Setpoint to enter For loss in weight feeding or loss in weight batching only Action Switch Pos Range Drive address 1 7 1 2 3 123 000 0 001 1 010 2 011 3 111 7 Operating mode 4 Off normal operation On res...

Page 65: ... displacement from label on vibratory drive 4 Calculate Vib Span according to the following formula Vibratory span formula New Vib Span Displayed Vib Span expected displacement Actual displacement 5 Enter calculated new Vib Span in the MACHINE menu Example Vibratory type KV2 actual displacement 1 1 mm displayed Vib Span 1 000 New Vib Span 1 00 1 0 mm 1 1 mm 0 9 3 2 1 0 ...

Page 66: ... The increase in weight in the collector container is measured The weight information from the scale is used to control the feeders 5 7 1 GWB Hardware overview Each ingredient feeder requires a KCM Drive board All KCM Drive boards are usable 450 watt DC motor drive 1600 watt DC motor drive Stepper motor drive Vibratory drive AC Interface Each motor drive board must be uniquely addressed from 1 to ...

Page 67: ...witches When using the KCM GWB with several motor drive boards MDU it is critical to address the MDU boards It is important to have the motor drives start with address 0 0 0 There are eight ingredient feeders possible with the GWB and the motor drive boards have addresses selected by three or two dip switches The board addresses based on the switches range from 0 7 and represent ingredient feeder ...

Page 68: ...es used for setting the address of the board as shown below 5 7 5 Setup AC Drive Boards The AC Interface board has a 6 position DIP switch There are only two DIP switches used for setting the address of the board these are switches numbered 5 and 6 as shown below 0 1 1 4 1 0 0 5 1 0 1 6 1 1 0 7 1 1 1 8 SW1 SW2 Ingredient Address 0 0 1 0 1 2 1 0 3 1 1 4 SW5 SW6 Ingredient Address 0 0 1 0 1 2 1 0 3 ...

Page 69: ... saved packing material provided in the original shipment and re package the KCM as received 6 2 Notes on storage To store the KCM secure unit in the anti static packing materials The storage location must be clean and dry and not exceed the rated storage temperature limits as stated 6 3 Notes on disposal If the KCM is to be disposed follow procedures for industrial electronic disposal as required...

Page 70: ...nning the KCM controller Do not open the KCM unless power has been removed and no explosive atmosphere is present Allow 3 minutes for power to dissipate prior to opening the enclosure Do not operate machinery unless all guards are in place and all safety checks have been made Keep people away from the machine while in operation The KCM must only be installed wired programmed and put into service b...

Page 71: ...Power check Illuminates when the feeder system has been switched on but no feeding operations are currently in process ALARM LED When an alarm is first detected the LED il luminates Pending alarm condition If the alarm persists once the alarm delay time has passed the LED flashes to indicate a hard alarm The alarm relay will activate if programmed HEARTBEAT LED Blinks as the KCM CPU is running Whe...

Page 72: ...its main power The main switch should be within easy reach of the operator To shutdown the KCM quickly switch off the appropriate main switch 7 3 Switching ON and OFF Use the main switch to remove or apply power to the KCM Use the front mounted LEDs to verify power has been applied Review the project manual to operate the feeding equipment respectively ...

Page 73: ...h the KCM internal printed circuit boards The front cover is Part of the ignition protection and it must not be opened unless power has been removed and no explosive atmosphere is present If the KCM SS used in conjunction with the Hygiene mounting must be read the instructions in section 4 5 Remove all power and wait 3 minutes before opening enclosure for internal cleaning Do not use corrosive cle...

Page 74: ...he security of all connections and cable glands Check the operational readiness of all external safety switches or interlocks The front cover is Part of the ignition protection and it must not be opened unless power has been removed and no explosive atmosphere is present If the KCM SS used in conjunction with the Hygiene mounting must be read the instructions in section 4 5 During operation and im...

Page 75: ...t the problem prior to re applying power Self resetting fuses may automatically reset if the problem is resolved even without disconnecting line power Drive pcb numbers are shown for identification 9 3 1 Auto resetting drive fuses Each drive uses auto resetting fuses Follow the next procedure to permit reset 9 3 2 Resetting auto resetting fuses 1 Switch off KCM power 2 Find the source of overload ...

Page 76: ...per drives 0000004568 and 0000001430 only F1 Failure will cause power loss of 24 Vdc at the I O F2 F3 Failure will cause power loss to the KCM CPU AC Drive Interface F3 Failure will cause power loss of 24 Vdc at the I O F4 F5 Failure will cause power loss to the KCM CPU Note The fuses described next are replaceable 9 3 4 Replacing fuses 1 Disconnect power from the KCM via approved lock out tag out...

Page 77: ...location 000000684 Following fuses are 5x20 mm slow blow used F1 F2 12 5AT 5x20 mm 250Vac fuse Fig 9 1 Fuse location 1600 W DC motor drive J6 J5 F1 F2 K1 SPDT Following fuses are 5x20 mm slow blow used F1 F2 6 3AT 5x20 mm 250Vac fuse Fig 9 2 Fuse location 450 W DC motor drive J6 J5 F1 F2 Following fuses are 5x20 mm slow blow used F1 2 0AT 5x20 mm 250Vac fuse Fig 9 3 Fuse location vibratory drive J...

Page 78: ...rive interface fuse location 0000005987 Following fuses are 5x20 mm slow blow used F1 F2 6 3AT 5x20 mm 250Vac fuse Fig 9 4 Fuse location AC interface J6 J5 F1 F2 K1 SPDT Following fuses are 5x20 mm slow blow used F4 2 0AT 5x20 mm 250Vac fuse Note The HiPo and LoPo stepper have no replaceable fuses Fig 9 5 Fuse location Stepper Drive J6 J5 K1 SPDT F4 ...

Page 79: ...ection and it must not be opened unless power has been removed and no explosive atmosphere is present Danger of an explosion exists if battery is incorrectly replaced Order Batteries directly from K Tron 9104 40001 or Is it recommend to replace batteries every five years or when an alarm on the KCM states Battery Low Replace battery only with the same or recommended equivalent type Dispose of used...

Page 80: ...ort J13 or the RS 232 port P1 A PC with K Tron applications such as Loader SmartConfig and ParamStore are used with the KCM to upload new application programs upload custom KGR data communications files and to download entered operating parameters respectively To access the Config ports merely open the KCM front cover The Config DB 9 port and the USB port is on the cpu pc board on the back of the ...

Page 81: ...front cover is Part of the ignition protection and it must not be opened unless power has been removed and no explosive atmosphere is present Immediately after shut down the capacitors and therefore the conducting parts of the KCM are under high voltage For this reason before opening the KCM Disconnect the KCM from the power supply Wait the prescribed time of 3 minutes ...

Page 82: ...oard Fig 10 1 KCM CPU LED locations J10 J8 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 J9 J11 JP4 JP3 JP2 1 0 20ma Analog In Select 0 5V 1 0 10V 1 JP1 1 Reset Run JP5 1 4 Wire 2 Wire BootLoad Port 1 2 9 10 K Prom Memory Installed CPU 68340 1 2 33 J3 1 2 3 4 5 6 7 8 ON SW1 OPEN OFF Alive TxD RxD Alarm Alive Error COMMUNICATION HOST BOARD DB 9 Config P1 1 Pwr GND TxD TxD RxD RxD 1 Pwr GND TxD...

Page 83: ...nal data channel CPU is the channel master Alarm Alarm function KCM pc board has an alarm condition LED Function Notes TxD1 Data transmitting from K Port 1 Data is being sent to a KSU II KSL or KSC user interface If a problem check K Port 1 programming RxD1 Data received into K Port 1 Data is received from a KSU II KSL or KSC user interface If a problem check K Port 1 programming TxD2 Data transmi...

Page 84: ...3 1 Drive board LEDS The next image is the 1600 watt DC motor drive showing LED positions Other drives will have the LEDs in different locations Please be careful Fig 10 2 1600 watt DC drive LED locations 0000002610 K4 uC Heatsink K4 K6 K5 K7 8 7 6 5 4 3 2 1 J6 8 7 6 5 4 3 2 1 J5 F1 F2 2 wire 4 wire K3 SPST K1 SPDT K2 SPDT 24 Vdc PS 1 OFF 1 2 3 4 5 6 ON S1 J3 1 2 3 4 5 6 JP2 1 3 p d p u JP3 1 3 p ...

Page 85: ...AC current input of the KCM as the control of the motor takes place via pulse width modulation and the current to the motor cannot be mea sured using conventional instruments 10 3 4 Measure and adjust speed frequency signal The speed signal is a square wave signal from 0 to 10 8 kHz 5 V DC The signal can be measured at the following locations At the feeder connect oscilloscope between common and s...

Page 86: ... its connection at KCM Check motor cables Replace motor Check for alarms that might stop the machine Check display status for Wait Disa Alsh Check that KCM has power Motor runs at maximum speed Speed sensor has failed If scale interface pc board SIB is used the SIB has failed Setpoint is too high Check signal replace sensor Check signal if pick up is OK and SIB is used replace SIB If signals are O...

Page 87: ...ty switch on the feeder or its connection at KCM Check vibratory power cables Replace motor Check for alarms that might stop the machine Check display status for Wait Disa Alsh Check that KCM has power Tray runs at maximum displacement Displacement sensor has failed Setpoint is too high Check signal replace sensor If signals are OK replace KCM Reduce setpoint Tray displacement does not reach desir...

Page 88: ...heck display status for Wait Disa Alsh Check that KCM has power Motor does not run Alarm LED is On Motor cable fault Motor short Motor is overloaded Check motor cable and motor Check reason for motor overload and correct Motor does not reach desired speed Inadequate motor power Setpoint is too high Motor speed not smooth Check load on motor Verify motor power programming against label on stepper m...

Page 89: ...ription Number of Blinks EEPROM failure Invalid EEPROM data detected upon power up 1 Over temperature Motor Drive IC indicates a thermal warning Temperature at motor driver chips is 145 C Clear fault and re start drive 2 Reserved 3 Serial master time out No valid messages from the KCM CPU in 10 seconds 4 Safety switch open Open safety switch result in a feeder stoppage or the start command to be i...

Page 90: ...place motor Check for alarms that might stop the machine Check display status for Wait Disa Alsh Check that KCM has power Verify contactor is functional if used Check F1 and F2 on AC interface drive pcb Replace AC drive Motor runs at maximum speed Speed sensor has failed If scale interface pc board SIB is used the SIB has failed Setpoint is too high Check signal replace sensor Check signal if pick...

Page 91: ...08 0590020607 Modbus Plus 0000005107 0590020608 Ethernet IP or EthernetTCP 0000005106 0590020610 Modbus RTU or AB DF1 0000001737 Use this document see K Port Comm Board Profinet 0000023130 1190020601 Differential speed signals that come from the Scale Interface pcb are converted to single ended inputs for the KCM drive boards by the use of the Differential Receiver Encoder Interface pcb Fig 11 1 D...

Page 92: ...ency and field loading as the DC output utilizes filter capacitors to minimize ripple The unit can be configured for either 115 Vac or 230 Vac single phase Two different modes of operation may be used Mode 1 Constant Field JP1 and JP2 are installed and JP3 and JP4 removed Field power is present as soon as line power is applied to the power supply No connection to X3 is required Mode 2 Controlled F...

Page 93: ...en more than one SFT is to be connected The expander card plugs into J4 of the 450 watt dc drive card The expander card mounts into the KCM housing and provides three SFT connections as shown Fig 11 3 SFT Expander The daisy chain connector permits easy cabling of K Net connections from one KCM to another without having to have 2 wires in any terminal point This connector plugs into either K Port 1...

Page 94: ...on 95 98 W 180V 200V 0 6A 0 75A 300 300 Baldor 95 124 W 180V 200V 0 86 A 0 75 A 300 300 Lenze 250 W 180V 1 7A 300 300 Seramel 370 W 180V 2 6A 257 300 Stephan 370 W 180V 2 4A 278 300 Baldor 450 W 200V 2 5A 267 300 ABB 780 W 180V 4 1A 162 272 Baldor 1000 W 200V 5 6A 118 198 Baldor 2000 1600 W 200V 11 5A 9 2A 56 71 95 120 Motor Voltage Ratings Current Ratings Cable length for a diameter of 1 5 mm2 or...

Page 95: ... meters of transmission distance between feeder and controls is required Pick Up Encoder Pick up Type Cable length without Line Driver in SIB in meters Cable length with Line Driver in SIB in meters Jaquet FTG 1088 01 Ex 30 300 W S Lenze Motor 55W HGI 490 063600 30 300 HP Bison Motor 95 98W HEDS 5600 C06 30 300 HP Baldor Motor 95 124W HEDS 5600 C06 30 300 US Digital HEDS 9100 H00 30 If motor coil ...

Page 96: ...ne Start Stop ALS None CPU Output 1 CPU Output 2 CPU Output 3 CPU Output 4 J8 6 J8 7 J8 8 J8 9 Run Alarm Relay ALS Out Drive Enable Run Alarm Relay ALS Out Drive Enable Run Alarm Relay ALS Out Drive Enable Run Alarm Relay ALS Out Drive Enable CPU Freq Input J9 1 2 Ext Setpoint Ext Setpoint Ext Setpoint Ext Setpoint CPU Analog Output J9 3 4 None None None None CPU Analog Input J9 5 6 None None None...

Page 97: ...lt batcher SFM Smart Flow Meter flow indicator and controller SFB Smart Flow Meter batcher PID process controller VOL volumetric controller XTR Extrusion Control For Analog output For Analog input All All All All LWF LWB PID SFM SFB WBF WBB WBF WBB WBF WBB LWB WBB SFB LWB WBB SFB PID LWF LWB SFM SFB SFM SFB WBF WBB WBF WBB XTR XTR None Setpoint Massflow Drive Command Motor Speed Feedfactor Prefeed...

Page 98: ...fill Expired Tare Run Prefeeder Bypass Blow off Loader Hi Low Gear Dribble Batch Complete FDR Ena All All All All All All All All All Not VOL XTR XTR All All All All All LWF LWB LWF LWB LWF LWB WF WB All Not XTR WBF WBB WBF WBB WBF WBB SFM SFB SFM SFB LWB WBB SFB LWF LWB LWF LWB None Start Stop Interlock Run Enable ALS Input Ack Alarm Clr Alarm Start Stop VOL Mode MAN Mode Local External Ratio Dir...

Page 99: ...programmed to any digital input ALSH Indicates the Alarm shutdown digital input is high All START commands are ignored A start commend is required after alarm shutdown digital input is cleared This function can be programmed to any digital input Run Enable input issues a STOP command when activated WAIT Start command is issued but feeder cannot run This can be from setpoint 0 feed factor 0 or the ...

Page 100: ...If the state is WAIT a start command is not required On power up KCM is Stopped A Start Command is always required If the host communications is reading the CondensedProcStatus the KCM state can be determined from the following bits in the status word Assuming the word starts at bit 0 bits 2 and 3 would help identify the state ...

Page 101: ...formation only Your system may be wired differently Please be careful SIB means scale interface circuit board mounted at the machine for speed signal interfacing Line voltage input is 115 230 Vac single phase 50 60 Hz Wire colors if shown may change for your application Refer to your provided electrical diagrams for specific colors Fig 12 1 KCM to KSU II wiring example If the KSU II is more than 1...

Page 102: ... 1090020601 EN Rev 1 2 1 12 4 3 KCM to KSL wiring at K Port 1 K Port 1 is to be used only Fig 12 2 KCM to KSL wiring KCM K Port 1 1 2 3 4 5 6 KSL DB 9 RS485 1 2 3 4 5 6 7 8 9 COM Rx Tx Rx Tx Vcc Rx Rx Tx Tx COM KCM K Port KSL DB 9 2 3 4 5 6 8 3 7 2 6 J14 ...

Page 103: ... Digi card The wiring may be different for other RS485 serial communication cards K Port 1 is to be used only Fig 12 3 KCM to KSC wiring with Digi RS485 serial port KCM K Port 1 1 2 3 4 5 6 KSC DB 9 RS485 1 2 3 4 5 6 7 8 9 Rx Tx Rx Tx COM Rx Tx Rx Tx Vcc J14 KCM K Port KSC DB 9 2 3 4 5 6 6 7 8 9 Digi RS485 Serial ...

Page 104: ...xa card The wiring may be different for other RS485 serial communication cards K Port 1 is to be used only Fig 12 4 KCM to KSC wiring with Moxa RS485 serial port KCM K Port 1 1 2 3 4 5 6 KSC DB 9 RS485 1 2 3 4 5 6 7 8 9 Tx Tx COM Rx Rx COM Rx Tx Rx Tx Vcc J14 KCM K Port KSC DB 9 2 3 4 5 6 5 3 4 2 1 Moxa RS485 Serial ...

Page 105: ...ing may be different for other RS485 serial communication cards K Port 1 is to be used only Fig 12 5 KCM to KSC wiring with interface 9191 700550 serial converter KCM K Port 1 1 2 3 4 5 6 DB 9 RS422 1 2 3 4 5 6 7 8 9 Tx Tx COM Rx Rx COM Rx Tx Rx Tx Vcc J14 KCM K Port Converter DB 9 2 3 4 5 6 8 3 7 2 6 9191 700550 RS232 to RS422 Converter ...

Page 106: ...ort 2 Refer to WAGO manual 750 138 for more information Only K Port 2 is used WAGO bus coupler must be configured to function with the KCM Fig 12 6 KCM to WAGO coupler wiring KCM K Port 2 1 2 3 4 5 6 WAGO DB 9 RS485 1 2 3 4 5 6 7 8 9 Rx Tx COM Rx Tx COM Rx Tx Rx Tx Vcc J15 KCM K Port WAGO DB 9 2 3 4 5 6 5 2 7 3 8 ...

Page 107: ... port wiring This example shows the comm circuit card in the Host slot on the KCM CPU circuit card The AB KF2 module is wired to J1 connector Fig 12 7 AB KF2 to KCM wiring example Host Port J1 1 2 3 4 5 6 7 8 AB KF2 Module DB 25 1 2 3 4 5 6 7 COM TxD RxD RS 232C Comm board KCM K Port KF2 2 7 8 7 3 2 ...

Page 108: ...is example shows the comm circuit card in the Host slot on the KCM CPU circuit card The Modicon BM 85 multiplexer module is wired to J1 connector Fig 12 8 Modicon BM 85 to KCM wiring example Host Port J1 1 2 3 4 5 6 7 8 Modicon BM 85 DB 9P 1 2 3 4 5 6 7 8 9 COM TxD RxD RS 232C Comm board KCM K Port BM 85 2 7 8 5 3 2 ...

Page 109: ...07405 Not all terminal blocks are shown in this example Fig 12 9 450 watt DC drive wiring example K4 DPDT KCM 450 W DC Drive J2 5Vdc Com Sig Safety Drive Enable L1 PE N PE Mtr Mtr Vac line in DC Motor J4 1 2 3 4 5 6 J6 8 7 6 5 4 3 2 1 SFT White Yellow Green Pink Grey Brown 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 Speed Sensor J1 ...

Page 110: ... Not all terminal blocks are shown in this example Fig 12 10Feeder mounted KCM wiring example 1600 W DC Drive Speed Sensor J1 12 11 10 9 8 7 6 5 4 3 2 1 K4 DPDT J8 J7 J4 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1 SFT Safety Drive Enable Blue Yellow Red Gray Pink Yellow Green White Brown KCM 1600 W DC Drive 4 3 2 1 J2 5Vdc Com Sig J6 L1 PE N PE Mtr Mtr Vac line in DC Motor 8 7 6 5 4 3 2 1 ...

Page 111: ...e SIB pcb example with differential receiver on J2 8 7 6 5 4 3 2 1 J6 L1 PE N PE Mtr Mtr Vac line in DC Motor KCM 1600 W DC Drive 43 44 Blk or Blu Red Wht or Yel Speed Pick up 21 22 23 48 47 LK 3 Com Sig 5V LK 4 LK 1 SFT2 12 V Com Tx Tx Rx Rx SFT Pink Gray Brn Wht Yel Grn LK 2 SFT3 12 V Com Tx Tx Rx Rx SFT LK 4 9191 601650 SIB 42 41 1 2 3 4 5 6 1 2 3 4 5 6 J1 12 11 10 9 8 7 6 5 4 3 2 1 Safety Driv...

Page 112: ...Fig 12 12 Fig 12 11 wiring shows the speed connection signals using the encoder interface circuit card Fig 12 12Differential input for DC motor drives wiring Encoder Interface The Encoder Interface pcb functions with all drives except the AC interface drive when used to connect the KCM to the feeder mounted scale interface pcb KCM Drive Encoder Interface 1 2 3 4 1 2 3 4 Enc A Enc B Com 5Vdc Spd 1 ...

Page 113: ... discharge resistor R2 from the circuit If no motor is connected caution must be observed to assure that no parts of the body come in contact with the high voltage areas of the circuit board until the output circuit is fully discharged Fig 12 13Field supply wiring The 12 Vdc power supply needs to source at least 100 ma F F are the field connections to the field wound DC motor K4 DPDT DC Motor Fiel...

Page 114: ... for standard cable Alpha 2463C Color codes may change Please refer to provided wiring diagrams For the stepper drives 0000001430 and 0000004568 Line power is made to terminals 7 and 8 on J6 All other wiring is the same Refer to section 12 5 5 for details Fig 12 14KCM stepper drive field wiring example Red Black 5Vdc Com SigA J6 L1 PE N PE PH1 J1 K4 DPDT J8 J7 J4 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 ...

Page 115: ...ncoder Line Driver Board For cable length 2 m the Encoder Line Driver Board 0000020276 is installed at the stepper motor Fig 12 15Encoder Line Driver Board 5VDC 5VDC 5VDC COMMON COMMON 5VDC CHA CHB CHA CHB INDEX INDEX 1 2 3 4 5 J1 CON5 J1 CON5 9 8 1 2 3 4 5 J2 CON5 J2 CON5 1 2 11 10 3 4 ...

Page 116: ... blocks are shown in this example Fig 12 16KCM vibratory drive field wiring example K4 DPDT J8 J7 J4 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1 SFT Gray Pink Yellow Green White Brown KCM Vibratory Drive J1 12 11 10 9 8 7 6 5 4 3 2 1 Safety Drive Enable J2 Displacement FB Coil J6 L1 PE N PE Coil Coil Vac line in Vibratory Tray Coil 8 7 6 5 4 3 2 1 2 1 ...

Page 117: ...PN tachometer current sinking input as a frequency source and a current output to the remote variable frequency AC drive VFD CR is a contactor for the 3 phase AC line to the VFD Fig 12 17KCM AC interface wiring example 4 3 2 1 J2 NPN Speed Sensor 5Vdc Com Sig 8 7 6 5 4 3 2 1 J6 L1 PE N PE L1 L2 J1 Vac line in Safety Drive Enable KCM AC Drive J9 10 9 8 7 6 5 4 3 2 1 CR Motor Contactor Iout Iout Set...

Page 118: ...erlock When any of the three KCMs goes into alarm all shutdown This assumes that the KCM programming is proper KCM programming example for ALS interlock wiring CPU digital input 3 programmed for ALS Input CPU digital output 3 programmed for ALS Out Terminal 10 is common ALS Digital Output is programmed for either Timed Stop or Immediate Stop Fig 12 18KCM interlock wiring for ALS K4 DPDT KCM 1 J8 1...

Page 119: ...d gearbox is used Set up is as follows Program correct gear reductions in MACHINE menu Program MDU Relay 1 function as Hi Lo Gear polarity normal Program MDU Relay 2 function as Hi Lo Gear polarity inverse Connect KCM DC drive inputs as shown in Fig 12 9 Test function and re connect DC motor wiring if screw speed changes are reversed Fig 12 19HiLo gear selection wiring M Drive DC Drive DC CR1 CR2 ...

Page 120: ...e Typical system wiring diagram for interconnecting a pneumatic loader using an LSR controller to the KCM Refer to the HCU electronics manual for additional wiring information Fig 12 20HCU wiring example KCM SFT 1 2 3 4 5 6 1 2 3 4 5 6 7 HCU J1 J2 Pnk Yel Grn Brn Wht Pnk Yel Grn Brn Wht Grd Refer to the LSR manual for additional wiring information Fig 12 21LSR wiring example KCM SFT 1 2 3 4 5 6 1 ...

Page 121: ...1 2 3 4 5 6 1 2 3 4 5 6 GRD S1 S2 S3 S4 V re g 5 V d c 28 5 Vdc COM T x Tx Rx Rx T x R x Yel Red Speed Slip GRD 5 Vdc 12 Vdc JU 1 JU 2 Com SFT Tx SFT Tx SFT Rx SFT Rx Spd Spd Slip S l i p Aux 1 Aux 2 Aux 3 Aux 4 To Controller L K 4 SFT Disable Sw Com Tx Tx Rx Rx SFT Cable Shields SFT 4 LK 2 LK 1 SFT 3 LK 3 Motor Speed B e l t S l i p Auxiliary 26LS31 U1 U2 26LS33 SFT 1 SFT 2 SFT 3 SFT 4 11 3 Vdc C...

Page 122: ...g for WBF and WBB applications See the WBB or WBF programming manual for specific programming for belt slip operation Fig 12 23Belt slip wiring example Motor Speed Sensor Blue Yellow Red 4 3 2 1 J2 5Vdc Com Sig On Motor Drive pcb Drum Optical Sensor Brown White Green Fin Fin 6 5 4 3 2 1 J9 KCM CPU pcb ...

Page 123: ... DC J11 Internal channel DC power 1 Power 24Vdc Dig In 1 Fin 0 10kHz 14 to 40 Vdc 24 Vdc from Drive pcb 2 Common Dig In 2 Fin Common Common 3 TxD RS485 Dig In 3 Aout 0 20mA Earth PE RxD RS485 4 TxD RS485 Dig In 4 Aout RxD RS485 5 RxD RS485 Common Ain 0 5 10 Vdc 0 20 mA TxD RS485 6 RxD RS485 Dig Out 1 Ain TxD RS485 7 TxD RS232 Dig Out 2 8 RxD RS232 Dig Out 3 9 Dig Out 4 10 Common ...

Page 124: ... J5 Relays 1 24 Vdc 24 Vdc to KCM Relay 1 Com 2 Safety Input Common Relay 1 NO 3 24 Vdc power TxD RS485 Relay 1 NC 4 Drive Ena TxD RS485 Relay 2 Com 5 Drive Ena RxD RS485 Relay 2 NO 6 Common RxD RS485 Relay 2 NC 7 24 Vdc power Relay 3 Com 8 MDU In 1 Signal Relay 3 NO 9 Common 10 24 Vdc power 11 MDU In 2 Signal 12 Common Only J4 is used on the 450 watt DC drive Not for PID or VOL applications J4 J7...

Page 125: ...Motor 1 5 Vdc DC Motor 2 Frequency In A DC Motor 3 Frequency In B PE GRD 4 Common PE GRD 5 PE GRD 6 Neutral 7 L2 8 L1 J2 Encoder J6 Line Power Motor 0000005987 J6 Line Power Motor 0000001430 and 0000004568 1 5 Vdc Phase 1 Phase 1 2 Frequency In A Phase 1 Phase 1 3 Frequency In B Phase 2 Phase 2 4 Common Phase 2 Phase 2 5 PE GRD PE GRD 6 PE GRD PE GRD 7 PE GRD Neutral L2 8 Neutral L1 9 L2 10 L1 ...

Page 126: ... Displacement coil feedback Vib Coil 3 PE GRD 4 PE GRD 5 PE GRD 6 Neutral 7 L2 8 L1 J2 Encoder J6 Line Power Motor J9 Drive Interface 1 5 Vdc MDU L2 Power Control Relay NO I Out 2 Frequency Input MDU L1 Power Control Relay NO I Out 3 Frequency Input PE GRD Freq Out 4 Common PE GRD Freq Out 5 PE GRD 2 4Vdc 0 2 A 6 Neutral Drive Ena Relay Common 7 L2 Drive Ena Relay NO 8 L1 Alarm Reset Relay Com 9 A...

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