Project Manual

Customer: Raymor Nanotech

PO Number: 3653N
Project No: 1067696

Table of Contents
Chapter 1: Installation / Overviews Documentation
Chapter 2: Op Interface Documentation
Chapter 3: Feeder Documentation
Chapter 4: Pneumatic Documentation
Chapter 5: Weighing Documentation
Chapter 6: Drive Documentation
Chapter 7: Comm Documentation
Chapter 8: Utilitites Documentation
Chapter 9: Reference Documentation
Chapter 10: Spare Parts Documentation

Page 1 of 1
 Chapter 1:
Install / Overview
Documentation
 104
Unpacking K-Tron Equipment

K-Tron Unpacking,
Pre-Assembly
Recommendations and
Equipment Identification
Listing

Rev: Produced by the K-Tron Institute

104
Unpacking K-Tron Equipment

“No part of this publication may be reproduced or transmitted in any form or by any
means electronic or mechanical including photocopy, facsimile or computer generated
distribution without written permission from the K-Tron Institute. All translation
rights are reserved by the K-Tron Institute . The K-Tron Institute has made every effort
to ensure the accuracy and validity of this document. However, errors and omissions
may have occurred. If an error or omission is found, please contact the K-Tron Institute
at (856) 256-3267.

Information in this manual is correct as of the date of publication. K-Tron assumes no

responsibility for damages resulting from misuse of the equipment or negligence on the
part of operating personnel.”

Rev: Produced by the K-Tron Institute

 104
Unpacking K-Tron Equipment

Table of Contents

Unpacking, Checking and Merging of K-Tron Equipment ................................................... 1

Index............................................................................................................................................... 3

Rev: Produced by the K-Tron Institute

 104.1
Unpacking K-Tron Equipment

Unpacking, Checking and Merging of K-Tron Equipment

Intro
This section gives instruction on unpacking your K-Tron equipment,
checking invoices and sorting equipment to merge proper assemblies.

Unpacking
Carefully remove cardboard boxes from pallets with tin snipes to cut
the banding. Lift the carton vertically to clear enclosed machinery.
Discard carton.

Un-band or unbolt equipment from pallet and pick off using a forklift
for larger items. Be careful not to mar the paint surfaces. Do not pick-up
by junction boxes or other mounted electrical components.

Locate all materials from any single pallet together as these items are
related and will be field assembled. Do not mix items from different
pallets unless markings instruct you to do so. In some cases, feeders are
shipped with support structures on another pallet. They will be marked
to enabling mating later.

Control panels are shipped laid flat on their back. Floor panels have
lifting rings that can be used for removing the panel from the pallet.
Wallmount panels must be removed manually. Two people are
required.

Set the unit aside. Note the equipment numbers marked on the machine
enclosure. These numbers will be used later to assemble into complete
feeder units. See the section on merging assemblies.

Checking the invoice

The invoice is in a clear packet on one of the pallets or boxes. Remove
and check the invoice that came with shipment. Verify that all
equipment has been received and that no damage is sustained. If
damage is found, report the damage to the carrier.

Continued on next page

Rev: Produced by the K-Tron Institute

104.2
Unpacking K-Tron Equipment
Unpacking, Checking and Merging of K-Tron Equipment, Continued

Merging of feeder assemblies

Use the enclosed assembly drawings to merge the proper hoppers,
controls and feeders together at the job site.

Feeders and associated mechanical assemblies are marked with a

number like F1…F4 etc. Marry all F1 components together to build
feeder F1. If any questions arise, refer to installation diagrams provided
with the job.

Controls for feeder F1 will carry a designation of C1. Motor drives carry
no such designation and thus you must check the applied voltage label
on the drive and the motor to which it will be wired. The following
table will help.

Motor Drive Line Voltage Drive Motor Voltage-DC

115 Vac 90 -100 Vdc
230 Vac 180-200 Vdc

Other electronic assemblies will not be marked and the installer will
need to match those with the supplied wiring diagram.

Project documentation
In many cases, project documentation, equipment manuals and
installation drawings will be shipped with the equipment. If so, the a
tag entitled " K-TRON PROJECT DOCUMENTATION ENCLOSED"
will be attached to the box or pallet that contains the documentation.
Remove the documentation and set it aside in a protected place. Please
be sure that this material is not lost while uncrating and moving
equipment to the job-site. This material is costly to replace.

Rev: Produced by the K-Tron Institute

 104.3
Unpacking K-Tron Equipment

Index

C P
Checking invoice, 1 Project documentation, 2

M U
Merging of feeder assemblies, 2 Unpacking, 1

Rev: Produced by the K-Tron Institute

 103
Safety, Tools and Test Equipment

K-Tron Precautionary
Warning Issues, Tool and
Test Equipment
Recommendations

Rev: A Produced by the K-Tron Institute

103
Safety, Tools and Test Equipment

“No part of this publication may be reproduced or transmitted in any form or by any
means electronic or mechanical including photocopy, facsimile or computer generated
distribution without written permission from the K-Tron Institute. All translation
rights are reserved by the K-Tron Institute . The K-Tron Institute has made every effort
to ensure the accuracy and validity of this document. However, errors and omissions
may have occurred. If an error or omission is found, please contact the K-Tron Institute
at (856) 256-3267.

Information in this manual is correct as of the date of publication. K-Tron assumes no

responsibility for damages resulting from misuse of the equipment or negligence on the
part of operating personnel.”

Rev: A Produced by the K-Tron Institute

 103
Safety, Tools and Test Equipment

Table of Contents

Precautions and Equipment for K-Tron Equipment Installation.......................................... 1

Overview ............................................................................................................................... 1
Precautions ............................................................................................................................ 2
Tools and Test Equipment .................................................................................................. 6
Index............................................................................................................................................... 7

Rev: A Produced by the K-Tron Institute

 103
Safety, Tools and Test Equipment

Precautions and Equipment for K-Tron Equipment

Installation

Overview
This section outlines the necessary precautionary measures to be
followed in order to minimize injury while making the K-Tron
equipment ready for production.

This section will also specify the tools and test equipment
recommended to install and service your K-Tron equipment.

Rev: A Produced by the K-Tron Institute

103.2
Safety, Tools and Test Equipment

Precautions

Intro

The following advisory notes should be read and adhered to. Failure to
do so could result in personal injury or damage to the equipment.

Precautions during installation

!
Caution! During Equipment Installation

• Wear gloves when handling machinery.

• Do not power any equipment until it is securely mounted.

• Do not cause any motors to rotate until feed throats, etc. are clear.

• Be careful of footing and handle large items carefully to prevent

hand and finger injury.

Operator responsibility

!
Caution! Operator Responsibilities

• Ensure that only qualified and trained personnel work with the
metering equipment.

• Have damaged or missing components replaced immediately.

• The operator is responsible for compliance with applicable

accident prevention and safety regulations.

Continued on next page

Rev: A Produced by the K-Tron Institute

 103.3
Safety, Tools and Test Equipment

Precautions, Continued

Proper Use

!
Caution! Proper Use

• Only operate the metering device in conjunction with a suitable

K-Tron motor controller.

• When processing dangerous materials, also comply with the safety

notes which govern the handling of such materials.

• Never use a K-Tron metering device to process materials which

may cause a chemical reaction with the material of the metering
device.

• Only operate K-Tron equipment in accordance with the specified

technical data. Any modifications aimed at increasing the
performance of the metering equipment is prohibited.

• Comply with the respective operating instructions and observe

the conditions of maintenance.

Protection devices
!
Caution! Protection Devices

• Never alter the mechanical protection devices or the electrical

control system for the safety devices.

• Only operate the K-Tron metering equipment if all safety devices

are installed and fully functional.

• Check that all safety devices operate properly before each usage.

• Check that the warning instructions attached to the hopper and

discharge tube are intact and clearly legible before each usage.

• Never open or remove covers or hoods while the equipment is in

operation.

Continued on next page

Rev: A Produced by the K-Tron Institute

103.4
Safety, Tools and Test Equipment

Precautions, Continued

Protection devices, con't

• When changing fuses, use only the specified fuse types.

• Replace damaged cables and connection immediately.

• Modifications to the metering equipment if prohibited.

High voltage
!
Caution! High Voltage

• Only qualified electricians should work on the electrical parts of

the K-Tron metering devices.

• Protect the electrical components of the metering equipment from

moisture.

• Always ensure the electrical power is turned off before working

on the metering equipment.

Continued on next page

Rev: A Produced by the K-Tron Institute

 103.5
Safety, Tools and Test Equipment

Precautions, Continued

Warning labels on feeders

!
Caution! Warning Labels

• The following typical warning instructions are attached to the

feeder. Observe all warning labels.

Rev: A Produced by the K-Tron Institute

103.6
Safety, Tools and Test Equipment

Tools and Test Equipment

Intro
This section specifies the recommended tool set and test equipment to
be used for installation and maintenance of your K-Tron equipment.

Tools

This is a comprehensive tool list for your K-Tron system.

• 6mm-19mm box and open end wrench set

• 8mm-19 mm socket set with short and long extension plus ratchet
• allen wrench set to 6 mm, an individual piece set is recommended
over the combined set on a handle.
• 6 mm allen ball wrench on a "T" handle
• Flat and phillips screwdrivers in two sizes for screws used in
electronic assemblies and for larger screw sizes
• Wire strippers for 24AWG to 12 AWG wire
• Wire cutters for 24AWG to 12 AWG wire
• 4 ft. spirit level
• Straight edge - 24" long
• Tape measure - 12ft.
• Tools for installation of rigid and flexible conduit
• 9/16" and 7/16" combination wrenches
• 9/16" and 7/16" deep socket and ratchet with long extension

Test equipment
These test instruments are recommended.

PC with Procomm communication software and one serial port and

data cable, required for SCM diagnosis
DVM with frequency readout
Speed pick-up tester*
SFT tester*
10 mHz oscilloscope - single channel*

*optional but very helpful for troubleshooting activities

Rev: A Produced by the K-Tron Institute

 103.7
Safety, Tools and Test Equipment

Index

P S
Precautions Safety
High voltage, 4 Caution Operator Responsibilities, 2
Operator responsibility, 2
Precautions during installation, 2
Proper Use, 3
T
Protection devices, 3 Test equipment, 6
Warning labels on feeders, 5 Tools, 6

Rev: A Produced by the K-Tron Institute

 401
Basics of Feeding

Basics of Feeding

Rev: C Produced by the K-Tron Institute

401
Basics of Feeding

No part of this publication may be reproduced or transmitted in any form or by any

means electronic or mechanical including photocopy, facsimile or computer generated
distribution without written permission from the K-Tron Institute. The K-Tron Institute
reserves all translation rights. The K-Tron Institute has made every effort to ensure the
accuracy and validity of this document. However, errors and omissions may have
occurred. If an error or omission is found, please contact the K-Tron Institute at (856)
589-0500.

Rev: C Produced by the K-Tron Institute

 401
Basics of Feeding

Table of Contents

BASICS OF FEEDING.................................................................................................... 1
Overview.......................................................................................................................................................................1

Feeding of Bulk Materials...........................................................................................................................................6

Gravimetric Feeding of Bulk and Liquid Materials...............................................................................................11

Determining the Repeatability of your Feeder .......................................................................................................18

INDEX ........................................................................................................................... 22

Rev: C Produced by the K-Tron Institute

 401.1
Basics of Feeding

Basics of Feeding
Overview

Introduction This chapter provides a basic understanding of the two techniques of

feeding and to determine in what processes they work best. You will
also be able to determine the role that bulk solids play in the feeding
accuracy.

Rev: C Produced by the K-Tron Institute

401.2
Basics of Feeding

Material Feeding

Introduction These section details the basic concepts used to feed materials.

Definition of Feeding is defined as the addition of substances to production processes

feeding according to density, flow cross-section and time.

Mass Flow = A•V•D = throughput per unit time

where A = Material cross-section
V = Material flow velocity
D = Density

The task of the designer and constructor is to meet the requirements

defined in the above equation. It is important to realize that a constant
mass flow has to be formed on the basis of variable factors. Certainly
the issues of accuracy - repeatability, linearity and stability - must be
addressed in the final analysis.

Density The density can vary over a wide range, since raw material
characteristics may fluctuate and preliminary mixtures can differ in
composition. Atmospheric humidity and compression also have an
affect on density. And certainly the issue of how density is measured
can result in calculation that is in error of reality. Is it measured loose or
packed? If packed, how much pressure and compaction time is the
sample subjected?

Particularly, in a screw feeder, the product density may be affected by

hopper design that surrounds the screw, agitation and material velocity
in the hopper above the discharge screw.

Continued on next page

Rev: C Produced by the K-Tron Institute

 401.3
Basics of Feeding

Material Feeding, Continued

Material cross- Material cross section is also a parameter which cannot be taken as
section constant. Deposited material on the metering / measurement device,
material bridging and excessive rotational speeds can easily affect the
material cross-section. The angle of repose will have an influence
particularly when the material is unconstrained.

Product flow In order to ensure constant mass flow, one of the two factors A or V
velocity must be continuously adjusted. The easiest parameter to adjust is the
velocity V, in other words the mass flow is controlled by the speed
adjustment. Many early feeding devices varied A because low cost,
high performance motion control systems were not available.
Pneumatic or other mechanical servo systems controlled the height of a
gate, for example, to set the value of A, while the motion control system
maintained a fixed speed.

Continued on next page

Rev: C Produced by the K-Tron Institute

401.4
Basics of Feeding

Material Feeding, Continued

Weighing In the following example, the weigh cell measures the weight of
example material passing over it. The control system based upon that
information controls the speed of the belt conveyor to maintain a given
setpoint of mass flow. The speed sensor merely provides closed loop
feedback for the motion control system.

Example:
Motion

Sensor

Motor

Measuring Controller
Cell

Continued on next page

Rev: C Produced by the K-Tron Institute

 401.5
Basics of Feeding

Material Feeding, Continued

Weighing One can also modify one's thinking to look at the same issue but with a
example con't screw feeder as the mover of bulk solids. In this case, the turn of the
screw or auger moves a volume of material ( theoretical volumetric
capacity - f(x) of pitch and major and minor diameters) and if the bulk
density number is applied against that value, one gets a factor of grams
/ screw revolution or pounds / screw revolution. Once this number is
obtained, by merely applying the speed of the screw in RPM, the feed
rate in grams per minute or pounds per minute are known. An
example is relevant:

A screw has a volumetric capacity of 0.001 ft^3 per revolution. If the

bulk density of the product being metered is 40 lb/ft^3, then the
capacity of the screw is 0.04 lb / revolution is the weight delivered per
screw revolution. If the screw was rotating at 100 rpm, then the mass
flow rate would be 4.0 lb per minute.

The same issue can be developed for vibrating pan - tray feeders where
material velocity is a function of tray displacement in each tray
oscillation and the number of tray oscillations per minute. For example,
if a tray displaced 1 mm or about 0.040 inch and did that 60 times per
second, the full tray motion would be .040" * 60 * 60 = 144 inches per
minute or 12 ft / minute.

By placing material in the tray, the action becomes that like a belt feeder
with the formula for mass flow = tray motion * area of material * bulk
density.

Note: * means multiply, ^ means to the power of

Rev: C Produced by the K-Tron Institute

401.6
Basics of Feeding

Feeding of Bulk Materials

Introduction This section explains the concepts of feeding bulk materials.

Factors that The feeding unit used for any specific application must be designed so
affect feeding that it is suitable for as many different characteristics as possible. In case
of doubt, feeding tests can be carried out in the laboratories of leading
producers. Based on the product characteristics, a decision can then be
taken as to which type of feed unit is most suitable to ensure reliable
operation.

So first of all we will examine a few of the product characteristics

affecting feeding. There are others that could be described but those are
discussed in another class.

• PARTICLE SIZE - INCHES OR MICRONS

• AIR ENTRAINMENT OR GAS PERMEABILITY - FT/SEC
• BULK DENSITY - ƒ - KG/L OR LB/FT^3
• ANGLE OF REPOSE - DEGREES

Particle size
The particle size is described in sieve sizes or in linear dimensions. If
the particle is of multiple dimensions, then list all dimensions. With
powders, a knowledge of the percent of fines of various sieve sizes is
helpful to understand flow properties.

Continued on next page

Rev: C Produced by the K-Tron Institute

 401.7
Basics of Feeding

Feeding of Bulk Materials, Continued

Gas This is a measure of the air velocity through a bulk solid and is affected
permeability by the time of consolidation in a bin. Units are in ft/sec and the
or air measurement is made when the differential gas pressure is equal to the
entrainment
value of bulk density. Gas permeability increases with moisture content
and within normal ranges changes little with consolidation pressures.

Bulk density This is the measure of weight of product versus its volume. Both loose
density and packed density information are useful. Loose density
results from lightly filling a small container of known volume and
measuring the resulting weight. BD (∂)= weight / volume. If packed
density information is to be gathered, the consolidation force and
consolidation time over which the sample is subjected must be
recorded. Typical units of bulk density are lb/ft^3 and kg/liter. For
liquids, one uses the same technique of weight per unit volume, but the
reference is to water which has a specific gravity of 1.0. So liquids are
rated in specific gravity. For example a liquid with a specific gravity of
0.8 would float on water and its weight is about 50 lb / ft^3.

Continued on next page

Rev: C Produced by the K-Tron Institute

401.8
Basics of Feeding

Feeding of Bulk Materials, Continued

Angle of This is the flow angle of unconstrained bulk material as it flows onto a
repose flat surface. This measure is useful for figuring the width of conveyor
belt needed to contain material flow given a certain inlet opening onto
the belt or in figuring the amount of material that will fit into a bin. The
two examples are shown. This measure is highly affected by the kinetic
energy applied to the material. When many materials are accelerated,
they will have differing angles of repose with different acceleration.
Powders and pellets will behave differently. Be careful when using this
measure. It has limited benefit.

Material on A Belt

Angle
of Repose

Angle of
Repose

Continued on next page

Rev: C Produced by the K-Tron Institute

 401.9
Basics of Feeding

Feeding of Bulk Materials, Continued

Material An important role is played by the cohesion and adhesion forces, shape
characteristics and characteristics of the grains or particles. Feeding equipment has to
be adapted to suit the flow behavior as affected by the above features.
Fine powders behave differently than granular materials. In general the
flow behavior is defined as follows:

• FLOODING
• EASY FLOWING
• DIFFICULT FLOWING
• COHESIVE, CLUMPY, STICKY

Floodable These materials have to be treated in the same way as liquids. In order
materials to generate the feed flow, rotary airlock systems are used such as:

• Rotary valves
• Twin screw feeders
• Rotary airlock feeders

Easy flowing For these materials practically all types of feed unit can be used. The
materials particle size of the product always has to be taken into account. In
general the main aspects to be considered for this kind of product are of
an economical nature.

The following types of metering devices can be used for this type of
product:
• Belts feeders
• Vibratory trays
• Single spiral screws
• Paddle screws
• Rotary tables
• Rotary valves
• Rotary airlock feeders

Continued on next page

Rev: C Produced by the K-Tron Institute

401.10
Basics of Feeding

Feeding of Bulk Materials, Continued

Difficult These are the products which can cause feeding problems. The filling
flowing level of the feed hopper has to be kept as constant as possible by means
materials of loosening and homogenizing devices upstream of the feeder. The
feeder itself can comprise any of the following devices: * Note: twin
screw feeders can attain a relatively low flow rate because of their
unique screw design.

• Vibratory tray
• Rotary airlock feeder
• Single spiral screw
• Paddle screw
• Twin screw
• Twin spiral screw

Cohesive, Successful handling of these types of product requires the ultimate in

clumpy and feeding technology. Only in very few cases can any precise recipe be
sticky given, and to find the best way of feeding such materials trial and error
materials
is still the only feasible method. This is where the K-Tron Tech Center
and its laboratories best come into play. Only by testing materials, can
one determine the best device to use for the highest performance.

The following types of metering devices are suitable for these materials:

• Twin screw
• Twin spiral screw
• Rotary airlock feeder with extraction aids
• Special devices such as rotary table feeders

In many cases, these units have special agitation in the feed hoppers to
ensure proper material presentation to the ultimate discharge
mechanism.

A later section discusses concepts of bin design and focuses upon issues
which can cause serious difficulties in feeding materials. If the bin or
feed hopper cannot insure proper and complete discharge of the
material, feeding accuracy is a moot point.

Rev: C Produced by the K-Tron Institute

 401.11
Basics of Feeding

Gravimetric Feeding of Bulk and Liquid Materials

Introduction This feeding process involves continuous measurement of the feeder

flow (gravimetry=measurement of gravitational force). In principle any
type of conveyor or volumetric feeder can be operated in this mode.

Feeding by By using suitable control equipment with continuous feed comparison

weight of setpoint and actual values, the speed of the feeder can be
immediately corrected by the control element as soon as a deviation is
detected. In the end the quality of the feeder flow depends on the
precision and reliability of the measuring and control equipment. It
goes without saying that gravimetric control equipment is much more
complex than volumetric control gear.

Continued on next page

Rev: C Produced by the K-Tron Institute

401.12
Basics of Feeding

Gravimetric Feeding of Bulk and Liquid Materials, Continued

Types of Basically there are two different types of gravimetric feeder. These are
gravimetric the weigh-belt feeder and the loss-in weight feeder. The two basic
feeders types of feeder can be combined as required to make up complex
feeding plants.

The weigh- In the speed-controlled weigh-belt feeder the weight is continuously

belt feeder measured over a defined length of belt. The belt speed is regulated as a
function of the selected feed rate. The weight-controlled weigh-belt
feeder works at variable belt speed, and the product is fed on to the
band using an inlet slide gate or automatic pre-feeder.

Mass Flow = Belt Speed x Belt Loading

Continued on next page

Rev: C Produced by the K-Tron Institute

 401.13
Basics of Feeding

Gravimetric Feeding of Bulk and Liquid Materials, Continued

Weigh belt In the special case of the weigh-belt meter the speed remains constant,
metering and all material flowing over the measuring distance is totalized.

From the point of view of design, the various forms of weigh-belt

feeders are suitable for positioning directly underneath the silo or
hopper outlet. In many cases this means optimizing the inlet to suit the
specific material (flow thickness, inlet width, angle of repose, etc.). This
direct extraction and feeding possibility is required for a number of
applications. Such applications include plastics processing, the
foodstuffs, animal feed and detergents industries, etc.

Weigh-belt feeders can be used for feed rates ranging from 50 lb/h to
several hundred thousand pounds per hour.

The nominal setpoint adjustment range is normally 1:20

Weigh belt The maximum attainable precision is about ±0.50%-1.00%, although for
feeder difficult products the precision has to be determined by carrying out
accuracy tests.

The weigh-belt feeder is a relatively simple, extremely reliable

gravimetric feeder. Apart from its high feeding precision it offers all the
advantages of efficient process monitoring and high reliability.
Maintenance:

Weigh-belt feeders must be regularly inspected and serviced. Cleaning

is a big issue with belt feeders and they must be inspected regularly to
insure that they are clean. Materials sticking to the weighing surfaces or
belt may cause zero shifts and tracking belt problems.

Continued on next page

Rev: C Produced by the K-Tron Institute

401.14
Basics of Feeding

Gravimetric Feeding of Bulk and Liquid Materials, Continued

Loss-in weight One of the main types of gravimetric feeding systems used in modern
feeders practice is the loss-in-weight feeder. This feeding system employs a
storage container with feeder unit suitable for the product and feed
rate. The feeder unit and storage container are installed on the scales
and are tared so that the entire nominal capacity of the scale is available
for the product itself. Or in the case of the KDFT systems or D scales,
the user has no way to alter the tare and must use the gross capacity of
the scale without change.

Storage
Hopper
supported
by others

Refill Valve

Vent
Flex

Loss-in Weight
Feeder

Screw Feeder

Scale

Continued on next page

Rev: C Produced by the K-Tron Institute

 401.15
Basics of Feeding

Gravimetric Feeding of Bulk and Liquid Materials, Continued

Loss-in weight During feeding the loss in weight is monitored by continuous weighing,
feeders con't and compared to the electronic control system with the preselected feed
rate. If deviations are detected between the two values, the speed of the
feeder unit is altered almost instantaneously until the setpoint value
and actual value are identical.

The Flow rate is calculated as;

Flow Rate = Weight difference [ lb ] / Time difference [ T ]

And Setpoint = Mass Flow

Depending on the system, the storage container above the scales must
be refilled from time to time. When the preselected minimum filling
level has been reached, the refilling relay is automatically activated.
Refilling takes place from a feed aggregate situated above the scales.

Refill
Max

Material
Weight

Refill
Min

Gravimetric Refill
Feeding
Time

Continued on next page

Rev: C Produced by the K-Tron Institute

401.16
Basics of Feeding

Gravimetric Feeding of Bulk and Liquid Materials, Continued

Loss-in weight During refilling, volumetric feeding takes place. i.e. during this phase
feeders con't the feeder operates at constant speed. This speed corresponds to the
main value of the latest effective setpoint factors. When the preselected
maximum filling level has been reached, the electronic controls
automatically switch off the refilling system. After a delay time
(stabilizing period) the control unit switches back to gravimetric
feeding.

In order to ensure the highest possible feeding precision, the volumetric

feed phase should be kept shorter than the gravimetric phase. It is
recommended that the refill time occur over a period of 6-10 seconds for
best operation.

During normal operation the scales react to any external interference -

such as unintentional touching, etc. - by briefly switching over to
volumetric mode.

The main advantage of this type of dosing system is that only the actual
feed material is measured.. This means that extremely sticky products
can be fed, in fact every product which can be conveyed by any means
at all. Any adhesion of the product to the storage container has no effect
on measurement, since only the material actually extracted is weighed.

Loss-in-weight feeders are suitable for feed rates ranging from about 0.5
kg/h to 20,000 pounds per hour. The maximum feed rate is usually
limited by the number of fillings required. The setpoint adjustment
range is up to 1:50.

Continued on next page

Rev: C Produced by the K-Tron Institute

 401.17
Basics of Feeding

Gravimetric Feeding of Bulk and Liquid Materials, Continued

Accuracy of The attainable feeding precision is approximately ±0.25-1.0 %,

the loss-in- depending on the product. Long-term precision is excellent since it
weight feeder remains unaffected by dust accumulation or other product-related
influences (such as baked-on material, etc.) Although the loss-in-weight
feeder is a relatively complex gravimetric feeding system, it offers the
advantage of high precision and can be used without limitation for
practically all kinds of products.

Maintenance Loss-in-weight feeders must be regularly inspected and serviced.

Accuracy problems develop because of problems with refilling systems
and an environment that adds vibration and shock to the weighing
system. Also, the feeding system that is mounted to the scale system,
must be free to move and not be bound by flexible connections that are
no longer flexible for example.

Rev: C Produced by the K-Tron Institute

401.18
Basics of Feeding

Defining the Accuracy and Precision of your Feeder

Introduction Very few people correctly define accuracy of feeders. You need to
consider two issues, repeatability or precision as well as accuracy.

For a very in depth discussion of these topics, refer to the text

book“Feeding Technology” written by Dave Wilson.

What is
Repeatablity?
When talking about repeatability in feeders, we are referring to a
consistency in material flow. Determining the repeatability of material
flow is a very important procedure to decide if your feeder design
matches your characteristics of your product. This is normally done in
volumetric control or constant speed. If the material flow is not
sufficiently repeatable or “consistent” then maybe you’ve chosen the
wrong feeder design or type.

For a screw feeder, you can think of this in terms of consistent screw fill
from one flight of the screw to the next. If you could sample the
material in each screw flight, would each sample be the same? If not,
how much variation is there from sample to sample? If the samples
vary greatly, this is referred to as poor repeatabilty.

Screw
flight

Continued on next page

Rev: C Produced by the K-Tron Institute

 401.19
Basics of Feeding

Defining the Accuracy and Precision of your Feeder, Continued

What is
Accuracy?
Normally you think of feeder performance in regards to accuracy. You
take some samples, take an average and compare the average to the
setpoint. The greater the number of samples, the better the average.
Also the length of time for each sample will affect the way your
accuracy statement appears.

Number of samples & Time length of samples

If you take 3 one minute samples and compare the average to 7 one
minute samples, the second average will appear to be better than the
first. If you take 5 ten second samples and compared it to the average of
5 one minute samples you would find that the second average is better
than the first.

Target and
Sampling
You can also think of repeatability in terms of a target and the grouping
of the shots from a rifle.

Example of poor repeatability but may represent good accuracy

The poor repeatability shown here can not be corrected with an
adjustment to the sight on the rifle. When calibrating a feeder, we talk
about adjusting the weight span. If your weight samples looked like
this, you could not fix the problem of poor repeatability by simply
adjusting a calibration factor on the controller. This is probably related
to material flow problems and the feeder mechanics. You might have
the wrong screw type or size. You might have the wrong hopper design
or agitation design or the wrong feeder type all together.

Continued on next page

Rev: C Produced by the K-Tron Institute

401.20
Basics of Feeding

Defining the Accuracy and Precision of your Feeder, Continued

Target and
Sampling,
cont,

However; if we took enough samples and averaged them, we might

find that the average distance from the shots to the target are acceptable
in regards to accuracy. In other words, maybe the diagram below is the
size of the bull’s eye. You may have first looked at it and decided that
the center circle was the bulls eye. If we decide that the outer circle is
the bull’s eye, than this is a very accurate shooting.

Target and
Sampling,
cont.,
Example of good repeatability but poor accuracy.
This shooter has a very repeatable or consistent grouping of his shots. A
simple adjustment or calibration of the sight could probably fix the
minor problem and his grouping will be right on the bull’s eye. If this
represented a group of feeder catch samples, we would say that the
feeder is controlling the product flow or it is repeatable but not reaching
the setpoint. A simple adjustment to the feeder weight span, a
calibration factor, will bring the samples to setpoint.

Continued on next page

Rev: C Produced by the K-Tron Institute

 401.21
Basics of Feeding

Defining the Accuracy and Precision of your Feeder, Continued

Calculation of
Repeatability.
Repeatability % = (Standard Deviation / Average) x 100

Normally you can calculate the “standard deviation” using a

spreadsheet program like Excel© or a scientific calculator.

The repeatability% should be less than 2% while running your feeder in

volumetric mode.

Procedure for
calculating
repeatability
Step Action
1 Run the feeder in volumetric mode until you have a
consistent flow of product.

2 Be prepared to take at least 7 samples. If you are testing a

product and a material for the very first time and want to
validate the performance of the feeder you really need to
take 30 samples.

3 Use the equation above to calculate the percentage of

repeatability.

4 If the repeatability% is greater than 2% you should consider

trying a different feeder mechanical configuration.

Rev: C Produced by the K-Tron Institute

401.22
Basics of Feeding

Index

A W
Accuracy of the loss-in-weight feeder, 17 Weigh belt feeder accuracy, 13
Angle of repose, 8 Weigh belt metering, 13
Weighing example, 4
B
Bulk density, 7

C
Cohesive, clumpy and sticky materials, 10

D
Definition of feeding, 2
Density, 2
Difficult flowing materials, 10

E
Easy flowing materials, 9

F
Factors that affect feeding, 6
feeding bulk materials, 6
Feeding by weight, 11
Floodable materials, 9

G
Gas permeability or air entrainment, 7

L
Loss-in weight feeders, 14

M
Material characteristics, 9
Material cross-section, 3

P
Particle size, 6
Product flow velocity, 3

R
Repeatablity, 18

T
The weigh-belt feeder, 12
Types of gravimetric feeders, 12

Rev: C Produced by the K-Tron Institute

 401.1
Basics of Feeding

Rev: C Produced by the K-Tron Institute

 TECHNICAL INSTRUCTION

SmartConnex II System Overview

text text

Read this manual prior to operating or

servicing the equipment. This manual
contains all safety labels and warn-
ings.

0490020614-EN Rev. 1.0.0

 Service:
If you need assistance, please call your local service center or
K-Tron (Switzerland)
Industrie Lenzhard Tel. (062) 885 71 71
CH-5702 Niederlenz, Fax (062) 885 71 80
K-Tron (U.S.A.)
Rt. 55 and Rt. 553 Tel. (856) 589 -9083
Pitman, NJ 08071, Fax (856) 589 - 5664
Web: http://www.ktron.com

Before you call, gather the following information…

« Do you have alarm displays? What are they exactly?
« Are you able to eliminate the cause of the alarm displays?
« Have you modified part of the system, product or operating mode?
« Have you tried to remedy the fault in accordance with the operating and
service instructions?
« Record the six digit project or job number located on the machine and
in the project manual.
– Example: 403214

Use of the manual:

« This arrow is used for identifying one-step actions or actions that have
no specific order.
1. Numbers in a list identify tasks that have sequences you have to follow.
V This icon indicates a general cautionary note.

Indicates an electrical hazard.

Reference to another manual section.

Marks helpful information.

Indicates that tools are needed for the task.

Specifies where information or a situation must be checked.

Indicates where power is applied or removed.

Don’t place hands or other body parts into machine.

Order no.: 0490020614-EN “K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part of
operating personnel. Further, reference is made to the purchase order, acceptance or other document that contains
the express K-Tron disclaimer of warranties for a statement of the provisions limiting or disclaiming certain warranties
Date:2006/02/17 with respect to the Company's equipment. Except as otherwise expressly provided by K-Tron in any such document,
K-TRON MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NOR
Original: ANY OTHER WARRANTY, EXPRESS OR IMPLIED, WITH RESPECT TO THE EQUIPMENT.”
If an error or ommission is found, please contact: documentation@ktron.com.
KIT Project No: 217
 Table of Contents

1 Safety Notes ...................................................................................................................... 1

1.1 Safety symbol definitions .................................................................................................... 1
1.1.1 Related safety/electrical icons ............................................................................................ 1
1.2 Proper use .......................................................................................................................... 2
1.3 Organizational measures .................................................................................................... 2
1.4 Operator responsibilities ..................................................................................................... 2
1.5 Safety-conscious operation ................................................................................................ 3
1.6 Safety devices .................................................................................................................... 3
1.7 High voltage ........................................................................................................................ 3
1.8 Additional equipment .......................................................................................................... 4
1.9 Removal from service ......................................................................................................... 4
1.10 Customer service and repairs ............................................................................................. 4
1.11 Warranty ............................................................................................................................. 4
1.12 Applied safety signs and placards ...................................................................................... 4
1.12.1 Selected safety signs on machines .................................................................................... 4

2 SmartConnex II System Design ....................................................................................... 6

2.0.1 Terminology and definitions ................................................................................................ 6
2.0.2 Abbreviations ...................................................................................................................... 8
2.0.3 Document notation .............................................................................................................. 9
2.0.4 Figure notation .................................................................................................................... 9
2.1 Sample SmartConnex II system ....................................................................................... 10

3 KCM Overview ................................................................................................................. 11

3.0.1 Summary of SmartConnex II features .............................................................................. 12
3.0.2 KCM/KD element list ......................................................................................................... 14
3.0.3 KCM/SD element list ......................................................................................................... 15

4 KSU-II Overview .............................................................................................................. 18

4.0.1 KSU-II element list ............................................................................................................ 19

5 System Configuration Examples ................................................................................... 20

6 Application Information .................................................................................................. 25

6.1 Limitations and other considerations ................................................................................ 25
6.1.1 Channel wiring .................................................................................................................. 25
6.1.2 Node limits ........................................................................................................................ 25
6.1.3 Host protocols supported .................................................................................................. 25
6.2 I-O ..................................................................................................................................... 25
6.2.1 Available Digital I-O .......................................................................................................... 25
6.2.2 Available Analog I-O ......................................................................................................... 26
6.3 Other KCM information ..................................................................................................... 26
6.3.1 KSC to KCM ..................................................................................................................... 26

Docu-No.: 0490020614-EN Rev. 1.0.0 SmartConnex II System Overview Page 1

6.3.2 KSL to KCM ...................................................................................................................... 26
6.3.3 Primary KSU-II to KCM ..................................................................................................... 26
6.3.4 Remote I-O to KCM .......................................................................................................... 26
6.3.5 Host to KCM ...................................................................................................................... 26
6.3.6 Config PC to KCM ............................................................................................................. 26
6.3.7 SFT/HCU to KCM ............................................................................................................. 27
6.3.8 Local KCM display-KCM/KD ............................................................................................. 27
6.3.9 Specific communication details ......................................................................................... 27
6.4 Key KCM and KSU-II installation factors .......................................................................... 28

7 KCM New Features and Functions ................................................................................ 29

7.0.1 LWF automatic Hi/Lo gear switch function ........................................................................ 29
7.0.2 Improved SFM calibration routing ..................................................................................... 29
7.0.3 SFT auto-addressing ........................................................................................................ 31
7.0.4 KCM extended I-O capability ............................................................................................ 32
7.0.5 KCM alarm and process status function ........................................................................... 33

8 Index ................................................................................................................................. 34

Page 2 SmartConnex II System Overview Docu-No.: 0490020614-EN Rev. 1.0.0

 Safety Notes 1
Safety symbol definitions 1.1

1 Safety Notes

Installation, commissioning and programming of the specified

equipment should only be undertaken by qualified personnel.

1.1 Safety symbol definitions

V This is the safety alert symbol. It is used to alert you to the potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

V CAUTION used without the safety alert symbol indicates a poten-

CAUTION tially hazardous situation which, if not avoided, may result in prop-
erty damage.

V CAUTION indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate personal injury.
! CAUTION

V WARNING indicates a potentially hazardous situation which, if not

! WARNING avoided, may result in death or serious personal injury.

V DANGER indicates an imminently hazardous situation, which if

! DANGER not avoided, will result in death or serious injury.

1.1.1 Related safety/electrical icons

This icon is used to indicate an electrical hazard. It is located on cov-

ers and doors. Only qualified personnel are allowed to remove these
covers or open the doors.

This symbol shows where an electrical ground or PE is to be placed.

Docu-No.: 0490020614-EN Rev. 1.0.0 SmartConnex II System Overview Page 1

1 Safety Notes
1.2 Proper use

1.2 Proper use

V Only operate the KCM in conjunction with the feeder equipment

from K-Tron.
V Only operate the KCM in accordance with the specified technical
data.
V Do not operate where there is a risk of explosion.
V Do not use the equipment in a manner not intended by the manu-
facturer.

1.3 Organizational measures

V Observe the safety notes for the connected feeding devices.

V In addition to the operating instructions, always comply with gen-
erally prescribed safety regulations governing accident prevention
and environmental safety.
V Always keep the metering device operating instructions within
easy reach. Ensure that they are always complete and legible.

1.4 Operator responsibilities

V Ensure that only qualified and trained personnel work with the
KCM.
V Establish personnel responsibilities for operation and mainte-
nance.
V Ensure that personnel have read and understood the operating in-
structions to all installation components, particularly these safety
notes.
V The operator must have damaged or missing components re-
placed immediately.
V The operator of the KCM is responsible for compliance with the le-
gally prescribed accident and safety regulations.

Page 2 SmartConnex II System Overview Docu-No.: 0490020614-EN Rev. 1.0.0

 Safety Notes 1
Safety-conscious operation 1.5

1.5 Safety-conscious operation

V Any changes (including changes to operational behavior) which

affect safety must be immediately reported to the responsible
member of staff.
V Perform all operations with safety in mind.
V Do not make any internal adjustments to the KCM while the feeder
is in operation.

1.6 Safety devices

V The electrical safety devices must not be altered. This increases

the danger of accidents.
V Never operate the KCM with the housing open.
V Replace damaged cables and connections immediately.
V Only operate the feeding equipment if all safety devices are in-
stalled and fully functional.
V Check that the safety devices on the KCM and on the feeding
equipment operate properly daily.
V Never open or remove covers or hoods while the feeding equip-
ment is in operation.
V If accessing KCM internal components, allow 3 minutes to lapse
prior to opening the enclosure. This ensures safe discharge of high
voltage components.

1.7 High voltage

Warning! Danger!
! DANGER V High voltage of 230 Vac may be present on the line power cables
of the KCM.
V Switch off the power to the KCM for three minutes before:
– any disassembly, maintenance and repair work
– replacing the motor.
V Only qualified electricians may work on the KCM.
V Protect the KCM against moisture entrance.

Docu-No.: 0490020614-EN Rev. 1.0.0 SmartConnex II System Overview Page 3

1 Safety Notes
1.8 Additional equipment

1.8 Additional equipment

V Modifications to the KCM are prohibited.

V The operator is responsible for complying with all safety regula-
tions related to operation with the feeding equipment.

1.9 Removal from service

V Disconnect the KCM from the power supply before removal from
service.
! CAUTION V The operator is responsible for the proper removal of the KCM
from service.

1.10 Customer service and repairs

V The KCM may only be repaired by

– your authorized K-Tron customer service center
or
– qualified personnel, trained by K-Tron.
V Only use original K-Tron parts for repairs.

1.11 Warranty

V See project specifications and sales agreements for warranty in-

formation.

1.12 Applied safety signs and placards

1.12.1 Selected safety signs on machines

Fig. 1.1 Power applied sign

Page 4 SmartConnex II System Overview Docu-No.: 0490020614-EN Rev. 1.0.0

 Safety Notes 1
Applied safety signs and placards 1.12

Fig. 1.2 Keep hands out sign

Docu-No.: 0490020614-EN Rev. 1.0.0 SmartConnex II System Overview Page 5

2 SmartConnex II System Design
1.12 Applied safety signs and placards

2 SmartConnex II System Design

This section outlines some basics surrounding the SmartConnex II ar-

chitecture and structure.

2.0.1 Terminology and definitions

Element Definition

SmartConnex II This is the system architecture that incorporates the KCM feeder
controller and KSU-II user interface. This technology replaces the
SCM/KSU SmartConnex control system.

KCM K-Tron Control Module. The controller for the machine and includes
the feeder controller or KCM CPU and drive which includes one of
the following; a DC drive (450 or 1600 watts), an AC drive interface,
a vibratory drive or a stepper motor drive. A local user interface that
mimics KSU-II operation may be mounted directly to the KCM IP65
housing.

KCM/KD A KCM with a full Keypad and Display (KD = full keypad and display)
mounted to the KCM. Same operation as the KSU-II but only func-
tions with the KCM to which it is mounted.

KCM/SD A KCM with just a 4 LED Status Display (SD = 4 LED status display)
mounted to the front panel. A KSU-II, KSC or KSL is required to pro-
gram and operate the KCM.

KSU-II User interface for a single KCM. Its outward appearance is much like
the original KSU. The KSU-II has two serial ports; Primary and Ex-
pansion. KSU-II protocol is employed. If the KSU II is the primary
KSU II on the network, it is the master node on that KCM K-Net net-
work.

Primary KSU-II KSU-II immediately connected to a KCM via K-Net. This KSU-II is the
master device on K-Net. The KSU II’s primary port connects to K-
Port 1 or 2 on the KCM.

Expansion KSU-II Downstream KSU-II connected to an upstream or primary KSU-II.

Occurs when two or more KSU-11s are connected together.

KSU-II Primary Port The KSU-II's Primary Port directly connects to the KCM's K-Port via
K-Net or to another KSU-II via the Expansion Channel.

Page 6 SmartConnex II System Overview Docu-No.: 0490020614-EN Rev. 1.0.0

 SmartConnex II System Design 2
Applied safety signs and placards 1.12

Element Definition

KSU-II Expansion Port A downstream KSU-II connects its Primary Port to the Expansion
Port of the upstream KSU-II via the Expansion Channel. A total of 3
KSU-II may be interconnected. (1 Primary and 2 Expansion) Primary
and Expansion KSU-IIs are physically the same and may be logically
connected to any KCM.
Note:
If more than 3 KSU-IIs are connected (e.g. one Primary, three Ex-
pansion), response time will suffer.

Expansion Channel Serial data channel connecting one KSU-II to another KSU-II. Proto-
col is Modbus, RTU, 8, 1, even parity, 4 wire RS485, a slightly mod-
ified KMB protocol with exception codes to control data flow and fail-
ure conditions. This data channel cannot be daisy-chained. Only
point to point connections are permitted.

K-Net Serial data channel from KCM to KCM at K-Port 1 or 2 and to the Pri-
mary KSU-II at its Primary Port. RS485, 4 wire, K-BUS(II) protocol.
Also connects KCM to the KSC with KMB protocol. The channel can
also be configured for K10S protocol to use the KSL with the KCM.
K-Net may be daisy-chained. Up to 31 KCMs may connect to this da-
ta channel. A K-Net network connected to K-Port 1 is defined as K-
Net 1 and a K-Net network connected to K-Port 2 is defined as K-Net
2.

Internal Channel Serial data channel from the KCM to SFTs and HCUs. RS485, 4
wire, SFT protocol.

Host Network Serial data network from KCM to PLC/DCS with a variety of physical
interfaces and protocols.

Host Port Connects the KCM to a PLC/DCS host via various supported proto-
cols on the Host Network.

K-Port 1 Connects KCM via selected protocol to KSU-II, KSC or KSL on K-Net
1.

K-Port 2 Connects KCM via selected protocol to KSU-II, KSC or Modbus I-O
on K-Net 2.

Config Port Connects PC to KCM for applications such as ParamStore, Smart-

Config and Loader. This port can also be configured to view param-
eter data as it would be displayed on the KSU-II using the Load-
er.exe program.

Config Channel The serial channel that connects the user PC into the KCM at the
Config Port.

K-Prom The removable memory module that carries the KCM parameter val-
ues, a back-up copy of all parameter values and *.kgr file.

Docu-No.: 0490020614-EN Rev. 1.0.0 SmartConnex II System Overview Page 7

2 SmartConnex II System Design
1.12 Applied safety signs and placards

Element Definition

KMB Protocol The K-Tron serial protocol that allows the KCM to communicate to
the KSC V4, SCMs, and KSU-II on K-Net.

K10S Protocol The K-Tron serial protocol that allows the KCM to communicate to
the KSL V4 or KSM. (Not to K-Cdr, KLCD or KDU)

Modbus Protocol The serial protocol that supports WAGO and other similar I-O mod-
ules when connected to K-Port 2.

KCM Drive The over-arching term for describing the collective group of support-
ed KCM drive circuit cards. They include the following:
• 1600 Watt DC Motor Drive
• 450 Watt DC Motor Drive
• Vibratory Drive
• AC Motor Drive Interface
• Stepper Motor Drive - three variations

KCM CPU The KCM controller circuit board that supports the control strategy
and data communications

Comm Board The communications circuit board that supports KMB, K10S or Mod-
bus protocol when plugged in to the K-Port slot on the KCM CPU. It
also supports AB DF1 and Modbus when plugged into the CPU Host
slot on the KCM CPU.

Anybus Board The host communications circuit card that supports the following pro-
tocols. Different parts numbers are used for each.
• Modbus/TCP
• ModbusPlus
• ProfibusDP
• DeviceNet
• Ethernet/IP

DC Motor Field Supply The separate dc power supply that provides field voltage to field
wound DC motors.

User Interface applica- The function that permits Loader.exe to display the KSU-II parame-
ter data on the PC screen in a KSU-II format.
tion for Loader

2.0.2 Abbreviations
• CPU = central processing unit
• KGR = host communication set-up file residing in KCM
• pc board = printed circuit board
• SCADA = supervisory, control and data acquisition system-host

Page 8 SmartConnex II System Overview Docu-No.: 0490020614-EN Rev. 1.0.0

 SmartConnex II System Design 2
Applied safety signs and placards 1.12

• HMI = human, machine interface, usually a PC utilizing a commer-

cial SCADA software package
• KSL = K-Tron line interface keypad and display for up to 8 feeders
• KSC = K-Tron Smart Commander, a PC based HMI system for use
with up to 30 controllers.
• SFT = Smart Force Transducer
• WBF = weigh belt feeder
• LWF = loss-in-weigh feeder
• LWB = loss-in-weight batcher
• PID = process controller
• VOL = volumetric controller for screw feeder
• SFM = Smart Flow Meter flow indicator and controller
• VFD = Variable frequency AC motor drive

2.0.3 Document notation

The following is standard through out this document.

• Parameter name shown as <PARAM NAME> variable

• Parameter value shown as <Param Value> value
• Menu name as <MENU NAME> menu
• Key or button as KEY

2.0.4 Figure notation

GRAV LOC LWF01

SP 100.00kg/h
MF 100.05 kg/h

KSU-II KSL-V4 KSC-V4

SCADA
KCM/SD
KCM/KD

PLC SFT
PC
DCS
Modbus
I-O

Fig. 2.1 Graphic symbols

Docu-No.: 0490020614-EN Rev. 1.0.0 SmartConnex II System Overview Page 9

2 SmartConnex II System Design
2.1 Sample SmartConnex II system

2.1 Sample SmartConnex II system

The next example is shown to give an idea of the flexibility of the
SmartConnex II system in a variety of applications.

Expansion Expansion Expansion

Port
Primary GRAV LOC
SP
LWF01
100.00kg/h
GRAV LOC
SP
LWF01
100.00kg/h

Port
MF 100.05 kg/h MF 100.05 kg/h

Primary
Expansion Port
Port KSU-II KSU-II
Expansion
GRAV LOC
SP
MF
LWF01
100.00kg/h
100.05 kg/h

Primary Port Channel

KSU-II To other KCMs

Primary K-Net 1
K-Port 1 K-Port 1

SFT
Config Port
Port KCM/SD
K-Port 2 KCM/KD Host Port
Internal Channel

K-Net 2
Host Network
Config Channel SFT

PC
SCADA
PC for diagnostics
Modbus
I-O

Fig. 2.2 Sample SmartConnex II system

Notes:
• K-Port 1 may be programmed for KSC, KSL, KSU-II
• K-Port 2 may be programmed for KSU-II, KSC or Modbus I/O
• Both K-Net networks can be daisy-chained
• The KSU-II Expansion channel cannot be daisy-chained
• K-Net supports up to 31 KCMs
• A maximum of 3 KSU-IIs may be configured to a single K-Net net-
work.
– Example: three KSU-IIs may connect to K-Net 1 and three others
to K-Net 2.

Page 10 SmartConnex II System Overview Docu-No.: 0490020614-EN Rev. 1.0.0

 KCM Overview 3
Sample SmartConnex II system 2.1

3 KCM Overview

The KCM is the feeder controller member of the SmartConnex II fam-

ily. This family is comprised of a KSU-II remote display unit, a KSL for
up to 8 machines, a KSC for interface for up to 30 feeders.
The KCM is comprised primarily of a KCM CPU pc board, and a KCM
Drive pc board. Drive choices include a 1600 watt DC Motor Drive, a
450 Watt DC Motor Drive, a Vibratory Drive for KV1-KV3 vibratory
trays, a Stepper Motor Drive, in three variations, for feeders that utiliz-
es a stepper bi-phase motor and lastly, an AC Motor Drive Interface
pc board for use with variable frequency drives (VFD), servo drives or
remote DC drives.
The following are two photos of KCM configurations. (Fig.3.1-3.2)

Fig. 3.1 KCM/KD with keypad and display

Docu-No.: 0490020614-EN Rev. 1.0.0 SmartConnex II System Overview Page 11

3 KCM Overview
2.1 Sample SmartConnex II system

Fig. 3.2 KCM/SD with 4 LED status display

See document 0490020605 for more KCM details.

3.0.1 Summary of SmartConnex II features

Key features of the SmartConnex II KCM controller are listed below.
• Supports LWF, WBF, PID, VOL, SFM, LWB and WBB controls.
• Works with stepper drives, vibratory drives, DC drives and with re-
mote drives such as VFDs.
• Handles external HCU loader controls. No HSU is required for pro-
gramming.
• For LWB and LWF applications, a built-in loader controller is provid-
ed.
• Either a local keypad and display or 4 LED status function display
is mounted to the KCM.
• KCM controller houses both the controller and drive, similar to the
SCM.
• Only one master can reside on any one KCM K-Net network. The
KSC, KSL and KSU-II are all master devices.
• Up to 3 KSU-IIs can be networked to a single K-Net network.
• Host support for Modbus, AB DF1, ProfbusDP, Modbus/TCP, Mod-
busPlus, Ethernet/IP, DeviceNet.

Page 12 SmartConnex II System Overview Docu-No.: 0490020614-EN Rev. 1.0.0

 KCM Overview 3
Sample SmartConnex II system 2.1

• Six programmable digital inputs, four programmable digital outputs,

three programmable relay outputs and a Drive Enable and Safety
Input.
• Config port supports a KSU-II look-alike display on the PC plus
Loader, SmartConfig, ParamStore and Diagnostic Toolkit.
• Supports extended auto-addressing and binding I-O via Modbus
link.
• A alarm history and parameter trace function are provided.
• Universal input power from 85-264 Vac, 50/60 Hz.

3 4

5 2
1

Fig. 3.3 KCM with cover open

KCM key item list

1. KCM CPU circuit card
2. KCM Drive circuit card
3. K-PROM
4. K-Port Comm ports using Comm pcb
5. Host port using Comm pcb or Anybus pcb
6. Keypad and display or status display only
Note:
Either the status display or the keypad and display will be mounted to
the back side of the KCM CPU circuit card. (Fig.3.3)

Docu-No.: 0490020614-EN Rev. 1.0.0 SmartConnex II System Overview Page 13

3 KCM Overview
2.1 Sample SmartConnex II system

The following image is a block diagram of the KCM/KD with a full dis-
play and keypad installed. (Fig.3.4)

5 KCM/KD
GRAV LOC LWF01
SP 100.0 kg/hr
MF 100.0 kg/hr
DC 45.88 %

1 4

2 3

K-Port 1
K-Port 2 Host Port

Fig. 3.4 KCM/KD block diagram with keypad and full display

3.0.2 KCM/KD element list

1. CPU circuit board
2. K-PROM pcb
3. K-Port circuit board - using Comm pcb
4. Host port communication circuit board - using Comm pcb or Any-
bus pcb
5. Drive system and unit power supply
6. Display with alphanumeric capability
7. Keypad
Note:
The K-Port, Host Port and Local Display (Fig.3.3) are optional.

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 KCM Overview 3
Sample SmartConnex II system 2.1

The following image is a block diagram of the KCM/SD with a simple

4 LED status display installed. (Fig.3.5)

KCM/SD
5

1 4

2 3

K-Port 1
K-Port 2 Host Port

Fig. 3.5 KCM/SD block diagram with LED status display

3.0.3 KCM/SD element list

1. CPU circuit board
2. K-PROM pcb
3. K-Port circuit board - using Comm pcb
4. Host port communication circuit board - using Comm pcb or Any-
bus pcb
5. Drive system and unit power supply
6. Status display with 4 LED indicators

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3 KCM Overview
2.1 Sample SmartConnex II system

The following is detail of the KCM CPU circuit card. (Fig.3.6)

K-Port 1 K-Port 2 Host Port

KCM
K-Port
2 channels
Host Port CPU
1 channel
#1 and #2

68340 CPU core Status

LEDs
2 MB 1 MB
K-PROM DIP
Flash SRAM
Switch

Local display
Keypad or
Config Port
Status LEDs

I-O Terminals I-O Terms I-O Terms

14-40 Vdc
Field I-O
RS485 Internal Channel
Plus power to Drive

Fig. 3.6 KCM CPU block diagram

Notes:
• The DIP switch sets the KCM address and mode of the K-Port, both
channels. If the DIP switch is set to <0>, then the KCM’s address is
set by the KCM keypad or by KSU II.
• LEDs indicate CPU and Internal channel function
• Internal channel connects to the Drive circuit card

See the appendix for CPU I-O details.

The following graphic is a representation of a simple feeder controller

configured with a KCM showing drive I-O. (Fig.3.7)

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 KCM Overview 3
Sample SmartConnex II system 2.1

SFT KCM CPU

Internal Channel

KCM
Drive
A
B
Drive Control System
Application Specific
C
D
E
F
G Power
Supplies
H

115-230 Vac
Drive Output 1 phase, 50/60 Hz

Feedback

Fig. 3.7 KCM Drive block diagram

KCM Drive I-O definitions:

A – Safety switch – non-isolated
B – Drive Enable-isolated
C – 24 Vdc for I-O use
D – Bit 1 input-non-isolated
E – Bit 2 input-non-isolated
F – Relay 1, Form C
G – Relay 2, Form C
H – Relay 3, Form A
Drive selections include:
• 450 Watt DC Motor Drive
• 1600 Watt DC Motor Drive
• Stepper Motor Drive - in three configurations
• Vibratory Drive for KV1-KV3
• A/C Motor Drive Interface

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4 KSU-II Overview
2.1 Sample SmartConnex II system

4 KSU-II Overview

This section outlines the KSU-II Single User Interface electronic hard-
ware for the KCM control system. This device is the single point for da-
ta entry and viewing feeder parameters. The KSU-II acts as a master
for a KCM feeder controller via K-Net and permits another KSU-II to
be connected for remote viewing and data entry on the Expansion
Channel. (Fig.4.1)
The KSU-II connects to the KCM via the Primary data port and permits
alteration and display of single KCM machine data. If KCMs are daisy-
chained, the KSU-II may view selected, singular KCM data as well.
The KSU-II requires an external nominal power source of 10-40 Vdc
which can be supplied from the KCM if the KSU-II is co-located within
GRAV LOC
SP
LWF01
100.00 kg/h
10 m. Each expansion KSU-II requires a separate power supply.
MF 100.05 kg/h
DRIVE CMD 57.65 %

Fig. 4.1 KSU-II front panel

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 KSU-II Overview 4
Sample SmartConnex II system 2.1

This details shows the block diagram of the KSU-II. (Fig.4.2)

5 KSU-II
GRAV LOC LWF01
SP 100.0 kg/hr
MF 100.0 kg/hr
DC 45.88 %

1 4
7

2 3

TxD TxD
RXD RXD

Fig. 4.2 KSU-II block diagram

4.0.1 KSU-II element list

1. CPU circuit board
2. Primary port connection
3. Expansion port connection
4. Voltage regulator
5. Display
6. Keypad

Note:
For more detailed KSU-II information, see document 0490020604.

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5 System Configuration Examples
2.1 Sample SmartConnex II system

5 System Configuration Examples

The following images show different ways to configure a SmartCon-

nex II system. (Fig.5.1-5.9)

KSU-II Modbus
I-O
GRAV LOC LWF01
SP 100.00kg/h
MF 100.05 kg/h

K-Net 1 K-Net 2

K-Port 1 K-Port 2

Host Port

Internal Host
Channel Channel
KCM/KD
SFT PLC
DCS

Fig. 5.1 KSU-II to K-Port #1, I/O to K-Port #2, Host to Host Port

SCADA
Modbus
I-O
KSC-V4

K-Net 1 K-Net 2

K-Port 1 K-Port 2

Internal
Channel
KCM/KD
SFT PLC
DCS

Fig. 5.2 KSC to K-Port#1, I/O to K-Port #2

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 System Configuration Examples 5
Sample SmartConnex II system 2.1

KSU-II Modbus
I-O
GRAV LOC LWF01
SP 100.00kg/h
MF 100.05 kg/h

K-Net 1 K-Net 2

K-Port 1 K-Port 2

Host Port

Internal Host
Channel KCM/SD Channel

SFT PLC
DCS

Fig. 5.3 KCM/SD with KSU-II on K-Port#1, I/O to K-Port #2 with host-PLC

SCADA

KSU-II
GRAV LOC LWF01
SP 100.00kg/h
MF 100.05 kg/h

KSC-V4

K-Net 1 K-Net 2

K-Port 1 K-Port 2

Internal
Channel
KCM/KD
SFT PLC
DCS

Fig. 5.4 KSC Smart Commander to K-Port#1, KSU-II to K-Port #2 with SCADA at
KSC

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5 System Configuration Examples
2.1 Sample SmartConnex II system

SCADA

KSU-II
GRAV LOC LWF01
SP 100.00kg/h
MF 100.05 kg/h

KSC-V4

K-Net 1 K-Net 2

K-Port 1 K-Port 2

Internal
Channel KCM/SD

SFT PLC
DCS

Fig. 5.5 KSC Smart Commander to K-Port#1, KSU-II to K-Port #2 with PLC at KCM

Modbus
KSL-V4
I-O

K-Net 1 K-Net 2

K-Port 1 K-Port 2

Host Port

Internal Host
Channel Channel
KCM/KD
SFT PLC
DCS

Fig. 5.6 KSL at K-Port #1, I/O at K-Port #2, PLC on host channel

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 System Configuration Examples 5
Sample SmartConnex II system 2.1

KSL-V4 KSU-II
SCADA
GRAV LOC LWF01
SP 100.00kg/h
MF 100.05 kg/h

K-Net 1 K-Net 2

K-Port 1 K-Port 2

Internal
Channel
KCM/KD
SFT

Fig. 5.7 KSL at K-Port #1,KSU-II at K-Port #2, SCADA on host channel of KSL

KSL-V4 KSU-II
GRAV LOC LWF01
SP 100.00kg/h
MF 100.05 kg/h

K-Net 1 K-Net 2

K-Port 1 K-Port 2

Host Port

Internal Host
Channel Channel
KCM/KD
SFT PLC
DCS

Fig. 5.8 KSL at K-Port #1,KSU-II at K-Port #2, PLC on host channel

Docu-No.: 0490020614-EN Rev. 1.0.0 SmartConnex II System Overview Page 23

5 System Configuration Examples
2.1 Sample SmartConnex II system

KSU-II
GRAV LOC LWF01
SP 100.00kg/h
MF 100.05 kg/h

KSC-V4

K-Net 1

Internal
Channel KCM/SD
KCM/KD
SFT

Fig. 5.9 Example of an incorrect system

Since both the KSC and KSU-II are master devices, and since only
one master can be on any given K-Net network, the above example
will not work. (Fig.5.9)

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 Application Information 6
Limitations and other considerations 6.1

6 Application Information

6.1 Limitations and other considerations

6.1.1 Channel wiring

• K-Net 1 and K-Net 2 - 500 meters maximum length
• Internal channel (SFTs/HCU) - 500 meters maximum length
• Host channel - depends upon application
• Expansion channel (KSU II to KSU II) - 500 meters maximum length

6.1.2 Node limits

• KCMs to a single K-Net network: 31 (Address <0> is not allowed)
• KSU-II on a single K-Net network: 3 maximum

6.1.3 Host protocols supported

The following protocols are supported using the various Host circuit
cards available and are indicated here.
Note:
Siemens 3694R protocol is not supported.
• ProfibusDP - Anybus ProfibusDP pcb
• Modbus/TCP - Anybus Ethernet pcb
• ModbusPlus - Anybus ModbusPlus pcb
• Modbus - K-Tron Comm pcb
• AB DF1 - K-Tron Comm pcb
• AB DeviceNet- Anybus DeviceNet pcb
• AB Ethernet/IP - Anybus Ethernet pcb

6.2 I-O
I-O is available from both the KCM CPU and KCM Drive circuit cards.

6.2.1 Available Digital I-O

From KCM CPU circuit card

• Four digital inputs-programmable
• Four digital outputs-programmable

From KCM Drive circuit card-standard I-O

• Two digital inputs, non-isolated, programmable, pull up/down by
jumper, 24 V inputs
• Drive enable input - isolated
• Safety switch input - non-isolated
• Three relay outputs-programmable; two form C, one form A

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6 Application Information
6.3 Other KCM information

6.2.2 Available Analog I-O

From KCM CPU circuit card

• One frequency input (0-20 kHz), programmable
• One analog input (0-20 mA, 4-20 mA, 0-5 Vdc or 0-10 Vdc), pro-
grammable
• One analog output (0-20 mA, 4-20 mA), programmable

From KCM Drive circuit card

• None

Note:
Remote KCM I-O is supported. Please see section 7.0.4.

6.3 Other KCM information

The following is a summary of local communications between the
KCM and other devices.

6.3.1 KSC to KCM

The K-Tron Smart Commander (KSC), an HMI type user interface em-
ploying the iFix SCADA system, uses the KMB driver and connects
only to K-Port 1 or K-Port 2, via K-Net 1 or K-Net 2 respectively.

6.3.2 KSL to KCM

The K-Tron Single Line operator interface (KSL) uses the K10S pro-
tocol, and connects only to K-Port 1 via K-Net 1

6.3.3 Primary KSU-II to KCM

The primary KSU-II connects either to K-Port 1 or K-Port 2 depending
upon what other resources require K-Port 1. Protocol is KSU-II, a
modified, a slightly more complex version of the KMB protocol.

6.3.4 Remote I-O to KCM

Remote I-O using the <Modbus I/O> protocol connects to K-Port 2
only via K-Net 2.

6.3.5 Host to KCM

The host connects to the Host Port via the Host Network with multiple
protocols available.

6.3.6 Config PC to KCM

This port may be set to User Interface (ASCII), Config or KMB proto-
cols. A PC connects to this port for configuration and diagnostic activ-
ity.

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 Application Information 6
Other KCM information 6.3

6.3.7 SFT/HCU to KCM

The Internal channel supports the SFT, HCU and KCM Drive. Protocol
is RS485, 4 wire, SFT.

6.3.8 Local KCM display-KCM/KD

Connects directly to the internal KCM bus thus uses no serial port re-
sources. It has access to all parameters required to program the KCM.

6.3.9 Specific communication details

• KMB protocol is serial Modbus, RTU, 8, even, 1 stop bit, 4 wire
RS485.
• KSU-II protocol is RS485, 4 wire, similar to KMB but slightly more
complex.
• Internal Channel protocol is 9 bit, proprietary, RS485, 4 wire, SFT
specific.
• Modbus I/O protocol is just that.
• K-Port 1 can be forced to a specific protocol by the dip switch on the
KCM CPU board. For software control of the protocol selection, the
DIP switch must be <Off>.
• Using Loader.exe via the Config port, and setting the protocol to
<User Interface>, the application can view/modify the same data as
the local display or KSU-II. The protocol <User Interface> is the de-
fault condition.
• A maximum of 31 KCMs can connect to a single K-Net network.
• A maximum of 3 KSU-IIs can connect to a single K-Net network with
one KSU-II the master and the other two via the Expansion channel.

Device Protocol KCM Action Configuration

KSU II KMB Slave node Fixed, 38.4 kbaud, 8E1

KSC KMB Slave node Programmable baud
rate, 8E1
KSL K10S Slave node Fixed, 19.2 kbaud, 9 bit
WAGO I-O Modbus Master node Fixed 19.2 kbaud, 8E1

Table: 1 K-Net protocols

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6 Application Information
6.4 Key KCM and KSU-II installation factors

6.4 Key KCM and KSU-II installation factors

Find next a simple series of key installation requirements. For more
detail, go to the KCM electronics or KSU-II electronics manuals.
• Operating temperature range: -10 to 50 degree C.
• KCM line voltage range: 85-264 Vac, 50/60 Hz.
• Maximum cable distance between KSU-II and KCM: 500 meters
• Minimum lateral mounting spacing between KCMs: 25 mm
• Minimum vertical mounting spacing between KCMs: 75 mm
• Maximum cable distance between KCM and KSU-II to use KCM DC
power for KSU-II: < 10 meters
• Scale Interface board must be used on the feeder when the KCM is
more that 10 meters from the feeder.
• KCMs must be mounted vertically for proper cooling.

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 KCM New Features and Functions 7
Key KCM and KSU-II installation factors 6.4

7 KCM New Features and Functions

The following is a summary of key features of the KCM controller.

More detail will be found in the respective programming manuals.

7.0.1 LWF automatic Hi/Lo gear switch function

To use the gear switching one must connect a reversing relay to a dig-
ital output of the KCM. If the polarity is set to normal, the output will be
activated on low gear and deactivated for high gear.
Gear switching is automatically enabled if one or more digital outputs
are assigned to <HI/LO Gear>.
When gear switching is enabled, the following parameters are visible
in the menu:
MACHINE SETUP / MOTOR - GEAR RED LOW
PRODUCT CHANGE - GEAR (subscroll: <High>, <Low>, <Auto Hi>,
<Auto Lo>).
To work correctly, in the machine setup - motor menu, the high and
low gear reduction must be entered to the <GEAR REDUCTION> and
the <LOW GEAR REDUCTION> parameters. The lower gear reduc-
tion ranges from 1 to 10 times the high gear reduction.
Switching is only enabled if the feeder is stopped, the KCM Drive has
no run signal and the raw speed from the KCM Drive is < 2 rpm for at
least 2 seconds.
When the gear switches from high to low or vice versa, the initial and
the average feed factor will be set to the average feed factor times the
gear ratio. The screw speed modulation algorithm will automatically
use the correct gear reduction.
To operate the gear switch manually, the user can select <High> or
<LOW> for the <GEAR> parameter in the <PRODUCT CHANGE>
menu.
To operate the gear switching function automatically, the user can se-
lect <AUTO HI> or <AUTO LO> to the <GEAR> parameter in the
<PRODUCT CHANGE> menu.
When entering a setpoint which will generate a drive command of
more than 50% and the gear is on <AUTO LO>, the gear will switch to
high and the gear parameter changes to <AUTO HI>. When entering
a setpoint which will generate a drive command of less than 10% and
the gear is on <AUTO HI>, the gear will switch to low and the gear pa-
rameter changes to <AUTO LO>.

7.0.2 Improved SFM calibration routing

To calibrate the flowmeter throughput, one can take samples and then
enter the massflow span. This is sufficient when the linearization co-
efficients <A0>, <A1> and <A2> are already determined, or when
working in a small range or in the higher, linear range.

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7 KCM New Features and Functions
6.4 Key KCM and KSU-II installation factors

To linearize and calculate <A0>, <A1> and <A2>, one needs to mea-
sure the deviation at 3 different flow rates where the working range
must not exceed the flowmeter’s maximum flowrate.
E.g. working range 1500 - 6000 kg/h, linearize at 1500, 3000, and
6000.
The goal is to provide functions that allow both, calibration and linear-
ization on site.
One important advantage of this new method is this function works in
a similar way as LWF, WBF, and PID by displaying the material fed
during a calibration time and having the user enter the measured
amount of this material.
Two methods of SFM calibration are permitted.
1. Overall MF Span calibration
2. Calibration with A0, A1 and A2

Calibration of SFM mass flow span:

In the first case, the calibration looks similar to a LWF application
when the auto-calibration routine is active.

Calibration with <A0>, <A1> and <A2>

To linearize with coefficients <A0>, <A1>, and <A2>, the CAL MODE
must be set to <LIN PT1>, <LIN PT2> or <LIN PT3> (Linearization
point 1-3). The calibration must be repeated with for all three points.
Each Lin Pt. has a different <CAL DC>, default is 20%, 40%, 60%.
<CAL TIME> is the same for all. The user has to check that the mass-
flow points (CALIB MF at LIN PT2- LIN PT3) are within the desired op-
erating range. After all 3 points are determined, the algorithm will cal-
culate <A0>, <A1>, and <A2>.
If the range does not match the requirements, a single Lin Pt. can be
repeated. After selecting the Lin Pt again, the user can enter a differ-
ent <CAL DC> and repeat calibration for this single step. <A0>, <A1>,
<A2> are recalculated once all 3 CALIB MF values are present and
the DEVIATION changes.
If known, the user can also enter <A0>, <A1>, and <A2> directly as on
the K10S, KSM and SCM.
For testing, <CALIB MF> and <DEVIATION> can be entered manual-
ly.
When entering <CALIB MF>, it will calculate the <DEVIATION> out of
<A0>, <A1>, and <A2>. This allows to see the deviation at a certain
MF.
When entering a <DEVIATION>, it will recalculate <A0>, <A1>, and
<A2> according to the <CALIB MF> and the <DEVIATION> at <LIN
PT1>, <LIN PT2> and <LIN PT3>. This allows to correct a certain de-
viation at a certain MF.

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 KCM New Features and Functions 7
Key KCM and KSU-II installation factors 6.4

This might be also usable to the user because he can enter the linear-
ization based on real measuring of the end product or other measures
(like it used to be with the PC program method).
The <CALIB DC> values are set as shown by default, but can be
changed by the user. There is only one Calib Time parameter that is
used for all three linearization points.
The default values for <CALIB MF> and <Deviation> are set to zero.
Once all six values are filled in for <CALIB MF> and <DEVIATION>,
<A0>, <A1>, and <A2> are calculated.
After this time, if any of the values change, <A0>, <A1>, and <A2> are
recalculated. Finally, there are four different built in Drive Commands
that get used for Calibrate.
• 30% for Overall Span Calibrate
• 20%, 40%, and 60% for linearization Pt1, Pt2, and Pt3 respectively.

7.0.3 SFT auto-addressing

The KCM permits up to 6 SFTs on a single Internal channel. It also
permits mixed ranges and also a mix of older fast SFTs and the new
auto addressing SFT that is version <S> or later.
With version <S> or later SFT software revision, the KCM auto-ad-
dressing function works without manipulating the power line to the
SFT as was done in the SCM. Two special functions exist. They are;
Auto Address and Auto Re-address.
If an installed SFT has an address of <0> (defined as a Spare SFT),
upon power-up or a poll by the user, the SFT will be given the next
available address. Here are the relevant situations.
• One spare SFT is connected at a time while power on and the user
performs a Poll command which shall automatically change the ad-
dress to the next available.
• One or more new spare SFTs are connected and then the system
is powered up, the KCM shall automatically change the address
from zero to the next available.
• One or more used new SFTs are connected. If no spare SFT is
present, the situation is unknown and the KCM may only readdress
the SFTs on user request.
• A spare SFT is connected while correctly addressed SFTs are
present (e.g. one SFT is broken and replaced by a spare SFT). After
power on the KCM shall address the spare SFT to the missing ad-
dress.
• The system consists of a mix with old and new SFTs. As long as
there is only one old SFT on one address, it shall still work. Old
SFTs don't get readdressed automatically. The new ones shall be
readdressed into the available addresses between the old ones.
• The spare SFT is an old SFT and shall still get addressed to the
next available address.

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7 KCM New Features and Functions
6.4 Key KCM and KSU-II installation factors

• One or more SFTs are correctly addressed and the user requests
readdressing by mistake. The final address of the SFTs shall be the
same as it was before.
• After power on if there is no spare SFT present, the system may
only poll and not touch the addresses at all.
Notes:
• If an auto-address or a SFT poll action takes place, if no SFT with
a <0> address is present, the action reports the addresses and
function state of the SFTs on the Internal channel.
• Auto-readdressing changes the addresses of all attached SFTs
from <1 to n>.

7.0.4 KCM extended I-O capability

Use the KCM extended Modbus I-O feature when the standard KCM
I-O limit has been exceeded. This may happen for analog outputs.
The Modbus WAGO or other expansion I/O modules are connected
serially to K-Port 2, when the comm board is installed into the K-Port
slot.
Only Modbus addresses 80, 81, 82, and/or 83 are available for exter-
nal I/O modules. These addresses are automatically scanned at pow-
er-up by the KCM. Any modules found at these addresses are dis-
played in the Expansion I/O menu. The expansion I/O menu looks like:

MODBUS I/O
ADDR.80WAGO
ADDR.81NONE
ADDR.82MISSING
ADDR.83NONE
DETAILS
REBIND NOW
ADDR.80 DETAILS
ADDR.81 DETAILS
ADDR.82 DETAILS
ADDR.83 DETAILS

The first four lines tell the operator what particular I/O module is pres-
ently on the expansion I/O address. The possibilities for this are: <WA-
GO>, <MISSING>, <CONFLICT>, <NONE>.

<MISSING> means that the last time the KCM powered up, there was
a module at that address and now that module is not there. <CON-
FLICT> means that the last time the KCM powered up there was a dif-
ferent module at an address than there is now or that something else
bad happened that affects the binding of that module's Modbus ad-

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 KCM New Features and Functions 7
Key KCM and KSU-II installation factors 6.4

dress. If any of the four Modbus addresses show either <Missing> or

<Conflict>, then there will be an alarm posted by the KCM. This alarm
will remain in place until the operator performs the <REBIND NOW>
function and then clears the alarm.
The KCM will bind external I/O points to KCM internal I/O points. For
example it would bind external digital input point 0 (out of 0 to 3) on an
WAGO module I/O at Modbus node address 80 to the KCM internal I/
O point <EXTIN1>. The KCM internal I/O points appear on the digital
input function assignment variable. The rules for binding are simple.
• The KCM does all binding; the operator does none.
• The KCM binds the lowest found external I/O points to the lowest
internal I/O points (function assignment variables, e.g. <EXTIN2>).
• Binding occurs automatically at power-up when the external I/O
module is first found on the network.
For example, let's say there are two Digital Inputs modules at node ad-
dresses 80 and 81 and each module has four digital inputs. If both of
these modules are discovered at the same power-up, the external I/O
point (80,1) will be automatically bound to internal I/O point
<EXTIN1>. Likewise the external I/O point (80,2) will bind to
<EXTIN2>, and external I/O point (81,1) will bind to <EXTIN5>. All that
remains is to assign the function to the EXTIN# variable.

7.0.5 KCM alarm and process status function

The alarm and process status information has been simplified as com-
pared to the SCM product.
A total of 80 bits are used to define the state of the KCM. A total of 62
bits define the alarm state.
The alarm and process status bits are different than the SCM and are
defined in the KCM programming and operating manuals. The KCM
protocol also defines these values.

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Index

Index

A
Anybus Board 8
C
Comm Board 8
Config Channel 7
Config Port 7
D
DC Motor Field Supply 8
E
Expansion Channel 7
Expansion KSU II 6
H
Host Network 7
Host Port 7
I
Internal Channel 7
K
K10S Protocol 8
KCM 6
KCM CPU 8
KCM Drive 8
KCM/KD 6
KCM/SD 6
KMB Protocol 8
K-Net 7
K-Port 1 7
K-Port 2 7
K-Prom 7
KSU II 6
KSU II-Expansion Port 7
KSU II-Primary Port 6
M
Modbus Protocol 8
P
Primary KSU II 6
S
SmartConnex II 6
U
User Interface application for
Loader 8

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M912720 Item: 0000000388 Configured K-Cl-24-Kt20 Whs: 1 Rev:
Component Component description Position Std quantity Act quantity Offene Menge UM Required Last issue Whs
--------------- ------------------------------ -------- ------------ --------------- ------------ -- ---------- ---------- ---
0000000122 Lbl Id K-Tron 60x60mm 0040 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
0000000126 Term Acces Ground Screw 3001 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
0000000168 Plate Base W/ Cont Mtg Epl Kcl 3000 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
0000000310 Wshr Flat M5 D125 Sst 0646 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
0000000841 Mot Dc 95w 1:1 Flg 180v Sd 0501 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
0000003141 Wshr Flat M6 D125 Ss 0505 4.000 4.000 1.000 EA 11/22/2010 10/04/2010 1
0000003141 Wshr Flat M6 D125 Ss 0627 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
0000003141 Wshr Flat M6 D125 Ss 0642 2.000 2.000 1.000 EA 11/22/2010 10/04/2010 1
0000003141 Wshr Flat M6 D125 Ss 3006 4.000 4.000 1.000 EA 11/22/2010 10/04/2010 1
0000003142 Nut Hex M6x1 D934st Ss 0506 4.000 4.000 1.000 EA 11/22/2010 10/04/2010 1
0000003151 Nut Hex Domed M6x1 D1587 Ss 0038 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
0000003160 Ret Ring Bore 42mm Dia D472 Ss 0617 2.000 2.000 1.000 EA 11/22/2010 10/04/2010 1
0000003179 Wshr Lock M6 D127 Ss 0504 4.000 4.000 1.000 EA 11/22/2010 10/04/2010 1
0000003179 Wshr Lock M6 D127 Ss 0508 4.000 4.000 1.000 EA 11/22/2010 10/04/2010 1
0000003179 Wshr Lock M6 D127 Ss 3007 4.000 4.000 1.000 EA 11/22/2010 10/04/2010 1
0000004179 Kcm Sa W/O Cov 450w Mot 1101 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
0000005143 Kcl Fa Sc Sfs-24-6 W/O Damper 3005 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
0000008332 Plate Mtg Hd Ctd Kclkt20 0021 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
0000016645 Ftg Pg7 Gnd Strap Sfs-24 3015 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
0000025153 Kcm Sa Cover Lcd Dspl 1101 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
0000028258 Cover Hppr Rnd 2.2d 12l Mnl 1.000 0.000 1.000 EA 11/22/2010 1
0000028261 Hopper Fdr 12l 2.2d 1.000 0.000 1.000 EA 11/22/2010 1
0213000170 T20 Sa Grbx Red C 12.95:1 0022 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
5101500510 Mt Shock D20x25 Rbr Kcl 3002 4.000 4.000 1.000 EA 11/22/2010 11/18/2010 1
9101000060 ** Silicone Adhesive D-S-M 0803 0.000 0.000 1.000 EA 11/22/2010 10/04/2010 1
9107700150 Brg Ball 20/42 X 12 2-Seals 0618 2.000 2.000 1.000 EA 11/22/2010 10/04/2010 1
9198700570 Conn Cable 3pos +Gnd Female 0053 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9212000000 Stik-Clip 0071 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
9219700240 V-Clamp Hppr Fdr Sst K2m 0804 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9226401110 Cplg Shaft 10mm/11mm Kt20 0502 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9303700110 Scr Captive M8x20 Sst304 K2m 0042 2.000 2.000 1.000 EA 11/22/2010 10/04/2010 1
9303700310 Latch Draw Sst K2t6s1 / Kt20 0610 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9324000020 Gskt Rnd 42.5odx25idx6 T20 0619 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9324000030 Gskt Rnd Agit Brdg Hsg T20 0613 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9324000080 Seal Brg Housing Kt20 0614 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9324000110 T20 Seal 20x36x8 Bearing Hous. 0615 2.000 2.000 1.000 EA 11/22/2010 11/18/2010 1
9324000120 Spcr Rnd 36odx26idx3 T20 0616 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9324700440 Gskt Rnd Hppr K2 0802 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9324700510 O-Ring 34.59id X 2.62thk K2m20 0037 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9338000000 Gear Agit Screw Feeder T20 0622 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9338000030 T/20 Pinion Gear 0625 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9359001000 Scr Pan M3x.5x6 D85a Ss 0611 2.000 2.000 1.000 EA 11/22/2010 10/04/2010 1
9359001770 Scr Pan M4x.7x10 D85a Ss 0028 4.000 4.000 1.000 EA 11/22/2010 10/04/2010 1
9359002750 Scr Pan M5x.8x6 D85a Ss 0645 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
9359003770 Scr Hex M6x1x16 D933st Ss *D 0626 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
9359003800 Scr Hex M6x1x30 D933st 0503 4.000 4.000 1.000 EA 11/22/2010 10/04/2010 1
9359004010 Scr Pan M6x1x12 D85a Ss 0621 2.000 2.000 1.000 EA 11/22/2010 10/04/2010 1
9359004130 Scr Flt M6x1x10 D963st Ss 3003 4.000 4.000 1.000 EA 11/22/2010 10/04/2010 1
9359004140 Scr Flt M6x1x12 D963 Ss 0023 4.000 4.000 1.000 EA 11/22/2010 10/04/2010 1
9359004600 Scr Soc M6x1x90 D912 Stlzp 0507 4.000 4.000 1.000 EA 11/22/2010 10/04/2010 1
9359004690 Scr Soc M6x1x12 D912st Ss 0608 4.000 4.000 1.000 EA 11/22/2010 10/04/2010 1
9359005510 Scr Hex M8x1.25x160 D931stl 0036 2.000 2.000 1.000 EA 11/22/2010 10/04/2010 1
9359009260 Nut Hex M6-1 D439 Ss 0039 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
9359012860 Pin Dowel M3x10 D7st Ss 0609 2.000 2.000 1.000 EA 11/22/2010 10/04/2010 1
9359420680 Snap Ring As 20x1.2 St-Pvz 0655 2.000 2.000 1.000 EA 11/22/2010 11/18/2010 1
9359464800 Nut Knurl M8x1.25 Ss 0024 2.000 2.000 1.000 EA 11/22/2010 10/04/2010 1
9366010370 Wshr Flat 3/8 Ss 0628 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
9438000000 Key 5x5x16lg Din 6885 0623 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9459000350 Label Lockout Pwr To Rmv Gd 0630 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
9459000430 Lw Warning Label 0302 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
9459000440 Lbl Wrn Agit 3.50 X 2.75 0631 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9459001120 Lbl Blank 2.5x3 Metal Polyster 3014 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
9459700220 Lbl Wrn Finger 2.5x1.75 Vinyl 0041 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
9497302030 Adptr Motor Iec Kclkt20 0025 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9497701170 Tube Disch H Std Epl Kt20 0002 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9512000940 T20 Agitator Bolt Zinc Pltd. 0606 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9512711600 Plate Drive Agit Gry Kclkt20 0620 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9522000210 T20 Adapter Cover 0027 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9522000230 T20 Spacer 0624 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9522261510 Shaft Agit T20 0612 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9522272400 Nut Cap M6x20 Blk Andz 0632 2.000 2.000 1.000 EA 11/22/2010 11/18/2010 1
9522701350 Nut V-Clamp Hppr K2m 0807 1.000 1.000 1.000 EA 11/22/2010 10/04/2010 1
9528701960 Scr Set 18.5mm Cf Std Kt20 0001 1.000 1.000 1.000 PA 11/22/2010 11/18/2010 1
9532304580 Hsg Bearing Prg Kt20 0607 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9578263320 Cov Drive Agit Abs Kt20 0629 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9585001970 Plug Dome 3/8 Nylon Blk 0639 3.000 3.000 1.000 EA 11/22/2010 10/04/2010 1
9585002030 Caplug Tapered Plug #T-0 .173 0062 2.000 2.000 1.000 EA 11/22/2010 11/18/2010 1
9620000020 Conduit Plug Recessed 1/2''npt 2.000 2.000 1.000 EA 11/22/2010 10/04/2010 1
9620001840 Plug Lockg W/Oring M16x1.5 Bnp 0061 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9620700230 Pipe Plug Thd Pg9 Brass Np 0635 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9620700560 Adptr M16(M)-1/2''npt(F) Ss 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9620700570 Adapter M20(M)-1/2''npt(F) Sst 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9682400010 T20 Reducer 4:1 0509 1.000 0.000 1.000 EA 11/22/2010 1
9764400820 Bshg Strain M16 6-8 Id Npb 2.000 0.000 1.000 EA 11/22/2010 1
9764401600 Bshg Strain M20 8-11id Npb 2.000 2.000 1.000 EA 11/22/2010 11/18/2010 1
9778700060 Tool Aln Wrch 6mm Ball End K2m 0070 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9832000310 Cable 3cond 14awg Black Sj 0052 2.500 2.500 1.000 FT 11/22/2010 10/04/2010 1
9853302580 Cable Assy Spu Fem Qd 1.5m 0073 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9853302830 Conn Cable Spu/Motor Qx4 0072 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
9853303740 Ca Assy Gnd Strap Kcl 3014 1.000 1.000 1.000 EA 11/22/2010 11/18/2010 1
 Chapter 2:
Op Interface
Documentation
 OPERATING INSTRUCTION

KSU-II/KCM-KD Operation for LWB, WBB

and SFB Applications

Read this manual prior to operating or

servicing the equipment. This manual
contains all safety labels and warn-
ings.

0490020612-EN Rev. 1.2.0

 Service:
If you need assistance, please call your local service center or
K-Tron (Switzerland)
Industrie Lenzhard Tel. (062) 885 71 71
CH-5702 Niederlenz, Fax (062) 885 71 80
K-Tron (U.S.A.)
Rt. 55 and Rt. 553 Tel. (856) 589 -9083
Pitman, NJ 08071, Fax (856) 589 - 5664
Web: http://www.ktron.com

Before you call, gather the following information…

« Do you have alarm displays? What are they exactly?
« Are you able to eliminate the cause of the alarm displays?
« Have you modified part of the system, product or operating mode?
« Have you tried to remedy the fault in accordance with the operating and
service instructions?
« Record the six digit project or job number located on the machine and
in the project manual.
– Example: 403214

Use of the manual:

« This arrow is used for identifying one-step actions or actions that have
no specific order.
1. Numbers in a list identify tasks that have sequences you have to follow.
V This icon indicates a general cautionary note.

Reference to another manual section.

Marks helpful information.

Indicates that tools are needed for the task.

Specifies where information or a situation must be checked.

Order no.: 0490020612-EN “K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part of
operating personnel. Further, reference is made to the purchase order, acceptance or other document that contains
the express K-Tron disclaimer of warranties for a statement of the provisions limiting or disclaiming certain warranties
Date:2008/Feb/20 with respect to the Company's equipment. Except as otherwise expressly provided by K-Tron in any such document,
K-TRON MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NOR
Original: 0490020612-DE ANY OTHER WARRANTY, EXPRESS OR IMPLIED, WITH RESPECT TO THE EQUIPMENT.”
If an error or ommission is found, please contact: documentation@ktron.com.
 Table of Contents

1 Safety Notes ...................................................................................................................... 7

1.1 Safety symbol definitions .................................................................................................... 7
1.1.1 Electrical Hazard Icon ......................................................................................................... 8
1.1.2 Ground Icon ........................................................................................................................ 8
1.1.3 No Hands Icon .................................................................................................................... 8
1.1.4 Power Icon .......................................................................................................................... 8
1.2 Proper use .......................................................................................................................... 9
1.3 Organizational measures .................................................................................................... 9
1.4 Operator responsibilities ..................................................................................................... 9
1.5 Safety-conscious operation ................................................................................................ 9
1.6 Safety devices .................................................................................................................. 10
1.7 High voltage ...................................................................................................................... 10
1.8 Additional equipment ........................................................................................................ 10
1.9 Customer service and repairs ........................................................................................... 10
1.10 Removal from service ....................................................................................................... 11
1.11 Warranty ........................................................................................................................... 11

2 Application and Design .................................................................................................. 12

2.0.1 Document notation ............................................................................................................ 12
2.0.2 Additional programming information ................................................................................. 12
2.0.3 Abbreviations and terminology ......................................................................................... 12
2.1 Use in feeding systems ..................................................................................................... 14
2.1.1 Continuous feeding ........................................................................................................... 14
2.1.2 Batch feeding .................................................................................................................... 14
2.2 Batching Systems ............................................................................................................. 15
2.2.1 LWB Control mode ........................................................................................................... 16
2.2.2 LWB Refilling .................................................................................................................... 17
2.2.3 LWB with HCU Loader control .......................................................................................... 18
2.2.4 WBB Control mode ........................................................................................................... 19
2.2.5 WBB control with a dual weigh bridge .............................................................................. 20
2.2.6 SFB Control mode ............................................................................................................ 21

3 Operating and programming ......................................................................................... 22

3.1 Using KSU-II/KCM-KD operator interface ......................................................................... 22
3.1.1 LED display function ......................................................................................................... 23
3.1.2 KSU-II/KCM-KD Display ................................................................................................... 23
3.1.3 Keypad functions .............................................................................................................. 24
3.2 Operation and Programming level .................................................................................... 26
3.3 Operating level HOME menu ............................................................................................ 27
3.3.1 Entering a Batch size NEW SP ......................................................................................... 27
3.3.2 Totalizer key function ........................................................................................................ 27
3.3.3 Gravimetric and volumetric toggle control ........................................................................ 27
3.3.4 Alarm key functions .......................................................................................................... 28

Docu-No.: 0490020612-EN Rev. 1.2.0 Page 3

3.3.5 Setting display brightness ................................................................................................. 28
3.3.6 Screen saver ..................................................................................................................... 28
3.4 Programming level MAIN menu ........................................................................................ 29
3.4.1 Selecting a feeder to view ................................................................................................. 30
3.4.2 Security menu programming ............................................................................................. 30
3.4.3 Setting menu security ....................................................................................................... 30
3.4.4 Language selection ........................................................................................................... 31
3.5 Menu overview for all application types ............................................................................ 32

4 Switching the Feeding System ON and OFF ................................................................ 34

4.0.1 Checks prior to first operation ........................................................................................... 34
4.1 Switching to ‘ON’ ............................................................................................................... 34
4.2 Switching to “OFF” ............................................................................................................ 34

5 START/STOP the Feeder ................................................................................................ 35

5.1 Checking feeder parameters ............................................................................................. 35
5.2 Status line check ............................................................................................................... 35
5.2.1 Status line parameters ...................................................................................................... 36
5.3 Starting the feeder ............................................................................................................ 37
5.4 Stopping the feeder ........................................................................................................... 37
5.5 RUN/STOP LED status ..................................................................................................... 37
5.5.1 RUN/STOP LED action table ............................................................................................ 38
5.6 Feeder stopped by message ............................................................................................ 38

6 Operation - LWB Control ................................................................................................ 39

6.1 LWB <HOME> menu parameters ..................................................................................... 39
6.2 LWB Programming ............................................................................................................40
6.2.1 LWB Menu<PRODUCT CHANGE>, ................................................................................. 40
6.2.2 LWB Menu<CALIBRATION>, ........................................................................................... 43
6.3 LWB Emptying the feeder ................................................................................................. 47
6.4 LWB Scale friction test (repeatability) ............................................................................... 48
6.5 LWB Taring ....................................................................................................................... 49
6.6 LWB Scale calibration using static weight ....................................................................... 49
6.7 LWB Auto FF Calib function .............................................................................................. 50

7 Operation - WBB Control ............................................................................................... 52

7.1 WBB <HOME> menu parameters ..................................................................................... 52
7.2 WBB Programming ........................................................................................................... 53
7.2.1 WBB Menu <PRODUCT CHANGE> ................................................................................ 53
7.2.2 WBB menu <CALIBRATION> ........................................................................................... 57
7.3 WBB Emptying the feeder ................................................................................................. 58
7.4 WBB Taring ....................................................................................................................... 59
7.5 WBB Flow rate calibration using Auto FF Calib function .................................................. 59

8 Operation - SFB Control ................................................................................................. 61

Page 4 Docu-No.: 0490020612-EN Rev. 1.2.0

8.1 SFB <HOME> menu parameters ...................................................................................... 61
8.2 SFB Programming ............................................................................................................ 62
8.2.1 SFB <PRODUCT CHANGE> ............................................................................................ 62
8.2.2 SFB CALIBRATION menu ................................................................................................ 64
8.3 SFB Tarierung .................................................................................................................. 66
8.4 SFB Auto Calib function .................................................................................................... 66
8.4.1 SFB Flowrate calib. procedure with linearization .............................................................. 67

9 Calibration ....................................................................................................................... 69
9.0.1 Calibration tasks ............................................................................................................... 69
9.0.2 Span limits ........................................................................................................................ 69
9.0.3 Accuracy for reference equipment .................................................................................... 69
9.1 Flowrate accuracy check by sampling .............................................................................. 70

10 Alarms - What to Do ....................................................................................................... 71

10.1 KSU-II/KCM-KD alarm function ......................................................................................... 71
10.1.1 Stage 1- Pending alarm: ................................................................................................... 71
10.1.2 Stage 2 - Hard alarm: ....................................................................................................... 71
10.1.3 Possible responses to the error condition ......................................................................... 72
10.1.4 The error must be corrected. ............................................................................................ 72

11 Alarm Messages- Cause and Remedy .......................................................................... 73

11.1 System alarms .................................................................................................................. 73
11.2 Display messages ............................................................................................................. 78
11.3 Feeder won’t start - displayed messages ......................................................................... 78
11.4 Feeder won’t run in GRAV ................................................................................................ 78
11.5 LWB alarms ...................................................................................................................... 79
11.5.1 LWB Batch massflow variances ....................................................................................... 80
11.6 WBB Alarms ..................................................................................................................... 81
11.6.1 WBB Batch massflow variances ....................................................................................... 82
11.7 SFB Alarms ....................................................................................................................... 83
11.7.1 SFB Batch massflow variances ........................................................................................ 84

Docu-No.: 0490020612-EN Rev. 1.2.0 Page 5

Page 6 Docu-No.: 0490020612-EN Rev. 1.2.0
 Safety Notes 1
Safety symbol definitions 1.1

1 Safety Notes

Installation, commissioning and programming of the specified equip-

ment should only be undertaken by qualified personnel.

1.1 Safety symbol definitions

V This is the safety alert symbol. It is used to alert you to the potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

V CAUTION used without the safety alert symbol indicates a poten-

CAUTION tially hazardous situation which, if not avoided, may result in prop-
erty damage.

V CAUTION indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate personal injury.
! CAUTION

V WARNING indicates a potentially hazardous situation which, if not

! WARNING avoided, may result in death or serious personal injury.

V DANGER indicates an imminently hazardous situation, which if

! DANGER not avoided, will result in death or serious injury.

Docu-No.: 0490020612-EN Rev. 1.2.0 Page 7

1 Safety Notes
1.1 Safety symbol definitions

1.1.1 Electrical Hazard Icon

This sign indicates an electrical hazard. It is located on covers and
doors. Only qualified personnel are allowed to remove these covers or
open the doors.

1.1.2 Ground Icon

This sign indicates that a ground/PE connection is required.

1.1.3 No Hands Icon

Do not place hands or other body parts into moving parts or machine.

1.1.4 Power Icon

Power off and disconnect air supply before working on the equipment.

Page 8 Docu-No.: 0490020612-EN Rev. 1.2.0

 Safety Notes 1
Proper use 1.2

1.2 Proper use

V Only operate the KSU-II and KCM in conjunction with the feeder
equipment from K-Tron.
V Only operate the KSU-II and KCM in accordance with the specified
technical data.
V Do not use the equipment in a manner not intended by the manu-
facturer.

1.3 Organizational measures

V Observe the safety notes for the connected feeding devices.

V In addition to the operating instructions, always comply with gen-
erally prescribed safety regulations governing accident prevention
and environmental safety.
V Always keep the metering device operating instructions within
easy reach. Ensure that they are always complete and legible.

1.4 Operator responsibilities

V Ensure that only qualified and trained personnel work with the
KSU-II and KCM.
V Establish personnel responsibilities for operation and mainte-
nance.
V Ensure that personnel have read and understood the operating in-
structions to all installation components, particularly these safety
notes.
V The operator must have damaged or missing components re-
placed immediately.
V The operator of the KSU-II and KCM is responsible for compliance
with the legally prescribed accident and safety regulations.

1.5 Safety-conscious operation

V Any changes (including changes to operational behavior) which

affect safety must be immediately reported to the responsible
member of staff.
V Perform all operations with safety in mind.
V Do not make any internal adjustments to the KSU-II and KCM
while the feeder is in operation.

Docu-No.: 0490020612-EN Rev. 1.2.0 Page 9

1 Safety Notes
1.6 Safety devices

1.6 Safety devices

V The electrical safety devices must not be altered. This increases

the danger of accidents.
V Never operate the KSU-II or KCM with the housing open.
V Replace damaged cables and connections immediately.
V Only operate the feeding equipment if all safety devices are in-
stalled and fully functional.
V Check that the safety devices on the feeding equipment operate
properly daily.
V Never open or remove covers or hoods while the feeding equip-
ment is in operation.

1.7 High voltage

V High voltage of 230 Vac may be present on the line power cables
! DANGER of the KCM.
V Switch off the power to the KCM for 3 minutes before:
– any disassembly, maintenance and repair work
– replacing the motor.
V Only qualified electricians may work on the KSU-II and KCM.
V Protect the KSU-II and KCM against moisture entrance.

1.8 Additional equipment

V Modifications to the KSU-II or KCM are prohibited.

V The operator is responsible for complying with all safety regula-
tions related to operation with the feeding equipment.

1.9 Customer service and repairs

V The KSU-II and KCM may only be repaired by

– your authorized K-Tron customer service center
or
– qualified personnel, trained by K-Tron.
V Only use original K-Tron parts for repairs.

Page 10 Docu-No.: 0490020612-EN Rev. 1.2.0

 Safety Notes 1
Removal from service
1.10

1.10 Removal from service

V Disconnect the KSU-II and KCM from the power supply before re-
moval from service.
V The operator is responsible for the proper removal of the KSU-II
and KCM from service

1.11 Warranty

V See project specifications and sales agreements for warranty in-

formation.

Docu-No.: 0490020612-EN Rev. 1.2.0 Page 11

2 Application and Design
1.11Warranty

2 Application and Design

2.0.1 Document notation

The following is standard through out this document.

• Parameter name shown as <PARAM NAME> variable

• Parameter value shown as <Param Value> value
• Menu name as <MENU NAME> menu
• Alarm message as <Alarm Message> message
• Display indication or key action result as <INDICATION>.
• Dialog box indication as <Dialog>.
• Key or button as KEY

2.0.2 Additional programming information

See the following documents for more detailed programming informa-
tion.
WB-0590020606, WBB-0690020602, SFB-069002060

2.0.3 Abbreviations and terminology

• CPU = central processing unit, microprocessor
• HCU = Hurricane pneumatic loader control
• Host Channel = serial data connection to remote host computer
• HSU = Hurricane pneumatic loader control programming interface
• HMI = human, machine interface, usually a PC utilizing a commer-
cial SCADA software package
• Internal Channel = serial data connection to SFTs/HCU loader con-
trols and internal motor drives
• KCM = K-Tron control module, the SmartConnex II integrated feed-
er controller
• KCM-KD = 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-Net = KCM serial data connection to KSU-II, KSL or KSC
• K-Port 1 and K-Port 2 = data ports for a K-Tron specific interface
• KSU-II = K-Tron single unit user interface for the KCM
• LWB = Loss in weight batcher
• Drive-MDU = Common representation of all five types of drive pc
boards (450 watt DC drive, 1600 watt DC drive, AC drive interface,
stepper motor drive, vibratory drive)

Page 12 Docu-No.: 0490020612-EN Rev. 1.2.0

 Application and Design 2
Warranty
1.11

• pcb = printed circuit board

• SFT = Smart Force Transducer
• SFB = Smart Flow Batcher
• Smart Connex = KCM-System
• WBB = Weigh belt batch feeder

Docu-No.: 0490020612-EN Rev. 1.2.0 Page 13

2 Application and Design
2.1 Use in feeding systems

2.1 Use in feeding systems

The KSU-II/KCM-KD operating unit can be used in feeding systems
with K-Tron feeders for both continuous and batch feeding. The KSU-
II/KCM-KD is the single point operating unit of the SmartConnex II
control system. The KSU-II operates separately from the KCM. A
KCM local display can also be used. With regard to programming,
each behaves in the same way.
This manual describes the use of the KSU-II or the KCM-KD with local
display in the SmartConnex II environment. (Fig. 2.1)

KCM
Kontinuierlich Chargen

LWF WBF PID SFM LWB WBB SFB

M M

Fig. 2.1 Supported KCM control applications

2.1.1 Continuous feeding

In continuous feeding, bulk materials are continuously added to a pro-
cess without interruption.

2.1.2 Batch feeding

In batch feeding, a specified quantity of bulk material is added to a
process over a specific time.

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 Application and Design 2
Batching Systems 2.2

2.2 Batching Systems

The batch weight being delivered at a Fast Drive Command rate is

constantly being compared to the batch setpoint. When the batch
weight comes near the end of the batch, the unit will switch to dribble
mode. When the Actual Batch Weight reaches the Batch Size, the unit
will stop.
Two different control applications for batch feeding:
• Batch fast as possible - Volumetric
• Batch in defined time - Gravimetric

Fig. 2.2 LWB control mode

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2 Application and Design
2.2 Batching Systems

2.2.1 LWB Control mode

Fig. 2.3 LWB control strategy

The control signal called drive command is sent to the motor/vibratory

control unit. Two values of drive command are used. A Fast Drive
Command is used for the major portion of the batch while the Dribble
Drive Command is used near batch end to retain tight control of the
final delivery value. The motor/vibratory unit’s output voltage is pro-
portional to the control signal.
In volumetric mode, a specified batch time may not be met since the
feedfactor may not be correct and by definition is not updated. If time
control is critical, use gravimetric control. In volumetric control mode,
feedfactor does not update. Fast Drive Command and Batch Time are
the same batch to batch.
In gravimetric control, batch time and feedfactor are updated after
each batch is complete. To have the system deliver the desired quan-
tity of material in the Batch Time, it is necessary to first perform a
Feedfactor calibration so that a viable average Feedfactor (FF) is
available for use in the batch time calculations.

Note:
Command is changed, the Total Batch time changes. When the Batch
Time changes, the Fast Drive Command will change. When a Dribble
parameter changes, either the Fast Drive Command or Batch Time
will change depending upon what the operator last entered.

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 Application and Design 2
Batching Systems 2.2

2.2.2 LWB Refilling

In LWB-mode, the product is discharged and has to be periodically re-
filled. The refilling process is triggered automatically when the pro-
grammable minimum filling quantity has been reached.
The weight loss cannot be accurately measured during refilling. Three
refill possibilities exist:
• Refill: After Batch
• Refill: Pause Batch
• Refill: During Batch
To use <After Batch>, enough product must be in the batcher hopper
to reach the desired batch. If not select <Pause> so that refill can oc-
cur when the batcher is stopped. This gives the maximum accuracy.
If <During Batch> is selected, batching continues during the refill cy-
cle. The amount delivered during refill is an estimated value.
When the programmable maximum filling quantity has been reached,
the controller ends refilling and returns to normal batch weight mea-
surement.
• To prevent overfilling, the weight level has to be adapted to the refill
device in order to switch off the refill device properly.
• In order to guarantee a sufficient filling for the feeder feed screws,
the weight level entry that triggers refill must not be set too low. This
applies, in particular, to fluidizing or low density products.
• Changing hopper pressure conditions that occur during refill have
to be compensated.

Fig. 2.4 Refilling profile versus elapsed time

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2 Application and Design
2.2 Batching Systems

2.2.3 LWB with HCU Loader control

Fig. 2.5 is an example of an HCU loader control used with the KCM.

Start:
PowerPress Run
on HCU

Display awake in cycle

Start: Press Run Key

C2 timer active motor

Close C open D

level indicator

Start conveying C3

No
Load timer expired
or high level sensor refill signal
Stop motor
Yes

Yes

No Motor timer

No
Refill request active Start motor timer

Yes
Discharge delay C5
KCM

HCU
Start Discharge time C6

Refill request Off No

Yes Or Timer C6 expired

Fig. 2.5 Loader controls with KCM

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 Application and Design 2
Batching Systems 2.2

2.2.4 WBB Control mode

Fig. 2.6 WBB control mode with a single weigh bridge

The control signal called drive command is sent to the motor/vibratory

control unit. Two values of drive command are used. A Fast Drive
Command is used for the major portion of the batch while the Dribble
Drive Command is used near batch end to retain tight control of the
final delivery value. The motor/vibratory unit’s output voltage is pro-
portional to the control signal.
To maintain accurate velocity or displacement amplitude which repre-
sents the desired control value, speed or displacement feedback is re-
turned to the motor/vibratory control unit.
This control scheme is called cascade feedback control where one
feedback loop (motor/vibratory control) is nested inside the massflow
control loop.
Note:
Command is changed, the Total Batch time changes. When the Batch
Time changes, the Fast Drive Command will change. When a Dribble
parameter changes, either the Fast Drive Command or Batch Time
will change depending upon what the operator last entered.

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2 Application and Design
2.2 Batching Systems

2.2.5 WBB control with a dual weigh bridge

Weigh belt feeders with a dual weigh bridge increase the long term
stability, reduce cleaning intervals and increase accuracy at low
feedrates.
The tare weight of the belt is continuously measured by the second
weigh bridge that is outside the product zone on the weigh belt. Tare
values flow into a register where it is delayed by the shift clock signal.
The measured belt tare weight is subtracted from the material weight
exactly at the time when that segment is on the first weigh bridge
(Fig. 2.7).

Fig. 2.7 WBB dual weigh bridge function

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 Application and Design 2
Batching Systems 2.2

2.2.6 SFB Control mode

Fig. 2.8 Actuator SFB

The control signal called drive command is sent to the actuator. Two
values of drive command are used. A Fast Drive Command is used for
the major portion of the batch while the Dribble Drive Command is
used near batch end to retain tight control of the final delivery value.
In volumetric mode, a specified batch time may not be met . If time
control is critical, use gravimetric control.
In volumetric control mode, feedfactor does not update. Fast Drive
Command and Batch Time are the same batch to batch.
In gravimetric control, batch time and feedfactor are updated after
each batch is complete. To have the system deliver the desired quan-
tity of material in the Batch Time, it is necessary to first perform a
Feedfactor calibration so that a viable average Feedfactor (FF) is
available for use in the batch time calculations.
Note:
Command is changed, the Total Batch time changes. When the Batch
Time changes, the Fast Drive Command will change. When a Dribble
parameter changes, either the Fast Drive Command or Batch Time
will change depending upon what the operator last entered.
Possible Actuator:

Screwfeeder
Rotary Valve
Slide Valve

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3 Operating and programming
3.1 Using KSU-II/KCM-KD operator interface

3 Operating and programming

3.1 Using KSU-II/KCM-KD operator interface

The operator interface KSU-II and KCM-KD are using the same dis-
play and keyboard (Fig. 3.1).
GRAV LOCAL REF LWB01 • LED Display (Status)
BAT SIZE 23.5 kg
BATCHED 11.49 kg
BATCH % 48.00 %

• Alpha/numeric display with four lines displaying machine operating

values, status information and programming data.

• Keypad

Fig. 3.1 KSU-II_KD Faceplate

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 Operating and programming 3
Using KSU-II/KCM-KD operator interface 3.1

3.1.1 LED display function

LED LED name Function

RUN LED

Lights up when the feeder is in operation.

STOP LED
Power check. Lights up 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.
Illuminates when the KSU-II/KCM-KD is in
SETPOINT MODE the LOCAL setpoint mode. The feeder to
LED which it is connected is now being operated
as an independent device.

3.1.2 KSU-II/KCM-KD Display

LWF operating data is displayed as an eyample.

The operating level‘s display is structured as follows:

Line 1 status line
• Shows whether gravimetric or volumetrc mode is being used.
• Displays setpoint mode <Local>, <Line>, <Ratio> or <Direct>.
• Displays for refilling, calibrating, interlocks etc.
• Displays the feeder type and address
Line 2 to 4:
Displays the process‘s characteristic values such as setpoint, mass-
flow drive command etc..
• Press NEXT or C to scroll up and down on the screen.
Fig. 3.2 Operating Menu

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3 Operating and programming
3.1 Using KSU-II/KCM-KD operator interface

3.1.3 Keypad functions

Key layout Key name Function

GRAV/VOL
Grav Key for switching between gravimetric and
Vol
volumetric control mode.

NEW SP For entering the operating setpoint value for

New SP
LOCAL and RATIO setpoint modes.

TOT I000I For reading, erasing or pre-loading the total-

Tot|000| izer value (totaled feeding quantity).

Alarm display, acknowledge and clearing of

ALARM
Alarm
alarms.

HOME
For returning to the operating or user level.
HOME

For exiting a menu item or a programming

ESC ESC
level by one step.

For entering the programming level.

Operating level: display of the pro-
cess's characteristic
MENU operating values
MENU
Programming level: selection of a sub-
menu or a program-
ming parameter

NEXT Selects the next parameter in the menu or

NEXT
value list.

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 Operating and programming 3
Using KSU-II/KCM-KD operator interface 3.1

Key layout Key name Function

ENTER Entered values are stored or commands are

ENTER
carried out.

Starts the feeding process if all interlocks

RUN
RUN
and operating conditions are satisfied.

Stops the feeding process.

STOP • Press once to pause the running batch
STOP
• Press twice to discard the running batch

0 to 9 Numeric keypad.
Clears the last character entered. Also cy-
C cles the display in a direction opposite to the
NEXT key when pressed.

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3 Operating and programming
3.2 Operation and Programming level

3.2 Operation and Programming level

The KSU-II/KCM-KD interface operates at two levels:

TOTAL Operating level (HOME menu)

AVG FF C • Press HOME to access this menu. The process's characteristic val-
SCREW RPM
ues are displayed such as setpoint value, mass flow, drive com-
MOTOR RPM
NET WEIGHT
mand, speed etc. The setpoint is entered, the totalizer reset, alarm
DRIVE CMD
signals cancelled and the feeding process started and stopped at
BATCH % the operating level if these operations have not been blocked in the
BATCHED SECURITY menu.
BAT SIZE • Press NEXT or C to scroll up and down on the screen.
NEXT

Fig. 3.3 Operating Level

Programming level (MAIN menu)

• Press MENU to access this menu. All the feeder and system param-
eters are displayed for configuring the KSU-II/KCM-KD.
The main menu consists of 8 to12 sub-menus.
• Press NEXT or C to scroll up and down on the screen.
• Press ESC to exit menus and submenus or cancel and entry.

Fig. 3.4 Programming Level

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 Operating and programming 3
Operating level HOME menu 3.3

3.3 Operating level HOME menu

3.3.1 Entering a Batch size NEW SP

1. Press the NEW SP key for the prompt.
2. Enter the desired setpoint value and confirm with ENTER or ESC
BATCH SIZE 100.0
Kg to discard.
NEW = The setpoint can only be accessed when the <SECURITY> menu has
been programmed to allow it.
Fig. 3.5 Entering a new setpoint

Entry has been accepted.

ACCEPTED
The altered setpoint value will appear in the setpoint value line if it has
been accepted

Fig. 3.6 Entry accepted message

Entry has not been accepted

Check the parameter <MAX BAT SIZE> in the <PRODUCT
OUT OF RANGE CHANGE> menu, <BATCH SETUP> sub-menu. The <BATCH SIZE>
RANGE IS:
0 ....
value must be less than or equal to the <MAX BAT SIZE>. or the error
7200 kg/h ion Fig. 3.7 will be displayed.
Where the range limit is known, it will be displayed.
Fig. 3.7 Out of range message

3.3.2 Totalizer key function

« Press TOTAL for the <TOTALIZER> display. Read, clear or
change the totalizer value.
Totalizer access selections via the <SECURITY> menu.
• Hide: No access to TOTAL key.
• Clr Only: Use ENTER to clear totalizer
Tot|000|
• RD Only: Cannot clear totalizer
• Any Num: Enter any number into the totalizer, Input <0> to erase
the totalizer and then press ENTER to accept.
Fig. 3.8 Totalizer key usage

3.3.3 Gravimetric and volumetric toggle control

« Switch the controller to the desired mode with the GRAV/VOL key.
Grav The first field in the status line changes to the selected state.
Vol Works only on operator level <HOME> Menu

Fig. 3.9 Gravimetric/Volumetric mode

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3 Operating and programming
3.3 Operating level HOME menu

3.3.4 Alarm key functions

IWhen the alarm LED illuminates or flashes:
1. Press ALARM key
2. Read the alarm display.
3. Acknowledge the alarm signal by pressing ALARM.
Alarm
4. Clear the alarm signal by pressing ALARM again.
5. To return to the normal display press ESC or HOME.
Fig. 3.10 Alarm key usage

For alarm handling details see section 10.

3.3.5 Setting display brightness

Press ESC and 7 to decrease, ESC and 9 to increase the display
brightness.

3.3.6 Screen saver

The screen saver is enabled per default.
The value can be set in the <MACHINE> menu, <GENERAL> sub-Se-
curity menu programming

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 Operating and programming 3
Programming level MAIN menu 3.4

3.4 Programming level MAIN menu

Note:
• Press NEXT or C to scroll up and down on the display.
• The ‘>’ shows the active menu or variable to be selected

To switch to the programming mode:

MAIN MENU 1. Press MENU. The main menu is displayed.
> I-O SETUP 2. Select the desired sub-menu with NEXT or C.
SECURITY
3. Confirm the selection with ENTER.

Fig. 3.11 I-O SetUp menu selection

To select a specific parameter:

I/O SETUP
> DIGITAL INPUT 1. Select the program parameter.
DIGITAL OUTPUT
SETPOINT INPUT 2. Confirm the selection with ENTER.

Fig. 3.12 Selecting sub-menu

To change the program parameter value:

DIGITAL INPUT 1. Enter a new number for numeric values or select new entry with
> DIG IN CPUin1
FUNCTION Start
NEXT or C for pre-defined or text based parameters.
STATE Off 2. Confirm the entry with ENTER or discard with ESC.

Fig. 3.13 Selecting a parameter

ACCEPTED After the new value has been confirmed, the display will show for
about two seconds whether the new value has been accepted and will
then return to the sub-menu.

OUT OF RANGE
RANGE IS: If the entry is not accepted an <Out of Range> message will appear.
0 ....
7200 kg/h

Fig. 3.14 Entry messages

« Select the new program parameter with NEXT or

exit the selected sub-menu with ESC and select new sub-menu.
« Press ESC to exit out of programming one level at a time.
Press HOME to return to the operating/overview level.

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3 Operating and programming
3.4 Programming level MAIN menu

3.4.1 Selecting a feeder to view

Allowing this value to be accessed means that the Start/Stop function

CAUTION and other access may be assigned to another feeder.
To avoid risk of injury:
« Do not allow the operator, unless trained, to access this variable
« Set <FEEDER BEING VIEWED> to <Hide> after use for normal
operation.

If the KSU-II is connected by network to multiple KCM control units, it

is possible to view those units by selecting the feeder number in the
following manner. The KSU-II will then display the parameters for the
feeder selected. From the <SECURITY> menu, this function must be
set to <RD/WR> to be accessible.

To select a specific feeder to view, do the following:

1. Press MENU.
2. Select the <FDR BEING VIEWED> menu if not displayed.
DIGITAL INPUT 3. Press ENTER.
DIG IN CPUin1
> FUNCTION Start 4. Enter the feeder number to view.
STATE Off
5. Press ENTER to confirm.
The display will now display the desired feeder’s data.
Fig. 3.15 Selecting a feeder to view

3.4.2 Security menu programming

To set security, the KSU-II data lock-out function must be disabled.
For more information see KSU-II technical instructions 0490020604.
For the KCM built-in display, the default is for <Data Lock> = <Off>.
To program the lockout function see programming manuals.

3.4.3 Setting menu security

Selecting security access for programming menus is done as follows:
1. Press MENU.
2. Select the <SECURITY> menu.
3. Press ENTER.
4. For each access to menus, SP, <Feeder being viewed>, select
from one of the following actions:
– <Hide>
– <RD/WR> - read/write
– <Read>
5. Press ENTER after each selection.
6. Press ESC when done.
For totalizer key access refer to section 3.3.2

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 Operating and programming 3
Programming level MAIN menu 3.4

3.4.4 Language selection

To select the operating language of the KSU-II/KCM-KD:
1. Press MENU.
2. Press NEXT choise the <MACHINE> menu.
3. Press ENTER.
4. With NEXT select the <GENERAL> sub-menu.
5. Press ENTER.
6. With NEXT select the <LANGUAGE> parameter.
7. Press ENTER.
8. Select the language desired from the following list:
– <English>
– <Deutsch>
– <Francais>
– <Espanol>
– <Italian>
9. Press ENTER when the choice is selected.
10. Press HOME to exit.

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3 Operating and programming
3.5 Menu overview for all application types

3.5 Menu overview for all application types

Menu Titel LWB WBB SFB

Product Change Yes Yes Yes

- General YES YESYES YES
- Batch setup YES YES YES
Calibration YES YES YES
- Calibration YES No No
- Feedfactor YES No No
Alarm YES YES YES
- Alarm limits YES YES YES
- Alarm Setup YES YES YES
Tuning YES YES YES
Feedfactor YES No No
Refill YES No No
Scale YES YES YES
- General YES YES YES
- SFT YES YES YES
Machine YES YES YES
- General YES YES YES
- Machine No YES YES
- Motor YES YES YES
- Service Setup YES YES YES
- Performance YES YES YES
In- and Output YES YES YES
- Digital input YES YES YES
- Digital output YES YES YES
- Setpoint input YES YES YES
- Analog output YES YES YES
- Modbus I/O YES YES YES
Table page 1 of 2

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 Operating and programming 3
Menu overview for all application types 3.5

Menu Titel LWB WBB SFB

Calibriate YES YES YES

Loader YES No No
HCU Loader YES YES YES
System YES YES YES
- Communication YES YES YES
- SW Versions YES YES YES
- Parameter Backup YES YES YES
Security YES YES YES
Table page 2 of 2

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4 Switching the Feeding System ON and OFF
4.1 Switching to ‘ON’

4 Switching the Feeding System ON and

OFF

V Do not have any personnel in contact with moving portions of the

! WARNING feeding machinery as serious injury will occur when the machine
starts.

V Ensure that no uncontrolled refilling is being carried out when

CAUTION switching on and off the installation.
V Ensure that all visible connections and equipment are in order.

V Most programming will be done with the KCM in the stopped con-
dition. For certain tests, the feeder must be operating.

4.0.1 Checks prior to first operation

• Check to verify all machine safety guards are in place.
• Verify that material flow to each machine is OFF.
• Verify that all electrical connections are secure and correct.
• Verify that no person can come into contact with moving machine
parts when they are operational.
• Review all safety warnings prior to starting any machinery.
Provide all documentation and make it easily accessible prior to
starting equipment.

4.1 Switching to ‘ON’

« Use the main switch to turn the feeding system on.
On power-up, the user keypad and display shows data from the
connected KCM. (Fig. 4.1)
GRAV LOC CALIB LWB01
BATCH SIZE 100.00 kg
BATCHED 35.09 kg If alarms are present
BATCH % 35.09 %

Press ALARM ALARM

to query the alarm (see the alarm section 10).

Fig. 4.1 Home menu

4.2 Switching to “OFF”

« Switch the feeding system OFF with the main switch.
Ensure that the upstream equipment such as refilling device,
pre-feeder, receiver discharge etc. are also shut off.

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 START/STOP the Feeder 5
Checking feeder parameters 5.1

5 START/STOP the Feeder

V Before starting the feeding process, emptying, taring and

! WARNING calibrating the feeder make sure that no one is working on the
feeder and that there are no foreign objects in the feeder's hopper.
Be sure that all safety devices are operating correctly.

5.1 Checking feeder parameters

To operate the feeder safely the feeders programming parameters

CAUTION may only be altered by trained staff.

1. Enter machine parameters according to the machine data sheet

(see programming manuals).
2. Enter the parameters in the <PRODUCT CHANGE> menu in ac-
cordance to the process recipe and product feed.
« If alarms are present

Press ALARM ALARM

to query the alarm (see the alarm section 10).

3. Perform feeder calibration if necessary (see section 9).

4. Select the <HOME> menu and check the machine status.

5.2 Status line check

GRAV LOC LWF01

Verify that the Status line indicates the desired operation
(see chapter 5.2.1).

Fig. 5.1 Overview menu-status

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5 START/STOP the Feeder
5.2 Status line check

5.2.1 Status line parameters

Status Display Status Word Definition

GRAV Automatic control is ON.

VOL Automatic control is OFF.

LOC Feeder setpoint entry from feeder HOME menu in weight units per
hours or minutes. This entry can also be entered via the KSL or KSC
or can come from a host.

RAT Feeder setpoint entry from feeder HOME menu by percentage.

Feeder operating setpoint tracks an incoming analog signal as a
multiple of the entered ratio percentage value.

DIR Feeder setpoint is derived from an incoming analog value and can-
not be changed.

LN# Feeder setpoint is entered from a KSC or KSL. A KSL or KSC Line
screen is used for recipe control. The Line number is specified.

STOP Feeder is stopped.

RUN Feeder is running.

PERT(LWF) Scale disturbance.

REFIL(LWF) Feeder hopper is being refilled.

TARE(WBB) Feeder is being tared while the belt is running.

DISA The external Interlock or run enable input is not active. Feeder start
is disabled.

ALSH An alarm has occurred resulting in an automatic machine stoppage.

CALIB Feeder is running an automatic calibration cycle.

WAIT Feeder won’t run. Caused by the following:

• No setpoint is entered.
• Feedfactor is <0>:
• Feeder has a failed interlock.

EMPTY Feeder is running under the Empty Feeder function. Press the STOP
key to halt.

LOAD KCM built-in programmed loader is reloading.

PAUS Batch has been paused.

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 START/STOP the Feeder 5
Starting the feeder 5.3

5.3 Starting the feeder

1. Enter a batch size value.
2. Press GRAV/VOL to set the controller to GRAV.
3. Check and reset totalizer if necessary.
RUN 4. Press RUN.
Note: The RUN LED illuminates when the feeder motor is turning.
Fig. 5.2 Run button

5.4 Stopping the feeder

« Press STOP.
Note: The RUN LED blinks and the STOP LED goes on when the
feeder motor stops.
Note: For LWB equipment, if a refill has started during the batch, it will
STOP
continue filling the feeder until the programmed maximum refill value
is reached.
Fig. 5.3 Stop button

5.5 RUN/STOP LED status

The upper left green LED is on for machine running.
The lower left red LED is on for machine stopped.
The red LED on the upper right is used to indicate an alarm.
The yellow LED on the lower right is used to indicate LOCAL setpoint
mode.
For mor information see Chapter 5.5.1.
Fig. 5.4 LED Status window

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5 START/STOP the Feeder
5.6 Feeder stopped by message

5.5.1 RUN/STOP LED action table

Red LED Green LED Action

ON OFF Machine is stopped, not ready to run. Run Enable Input is disabled
or Alarm Shutdown is enabled. Machine will alarm if a Start com-
mand is issued.

ON BLINK Machine is stopped or Batch is paused but ready to run. Press RUN
to start.

ON ON Machine has been started but is missing an interlock or setpoint is

zero. Status indication is <WAIT>.

OFF ON Machine is running.

BLINK ON Machine Empty Function is active. Machine will run until empty. Ma-
chine shuts off when reaching empty level limits.

OFF BLINK Machine is in CALIB or AUTO TARE mode. Machine is running but
will stop when function is completed.

5.6 Feeder stopped by message

In the Alarm setup menu the parameter <STOP BY> shows the cause
that last stopped the feeder.

Parameter Cause

STOP BY Board Reset: e.g. after power on

Local Display: Stop key pressed on KCM, KSU-II
External Display: Stop key pressed on KSL, KSC
ALS Input: Programmable digital input activated
Run Disa: Programmable digital input or MDU Run enable input ac-
tivated
Stop Input: Programmable digital input activated
MDU DISA: Safety switch on drive board activated
Zero SP: Feeder start with Setpoint = 0
Emptying: Emptying cycle terminated
Interlock: Programmable digital input activated
Calib: Calibration cycle terminated
Tare: Tare cycle terminated on weigh belt feeder

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 Operation - LWB Control 6
LWB <HOME> menu parameters 6.1

6 Operation - LWB Control

For Start/Stop operation refer to section 5.

6.1 LWB <HOME> menu parameters

The following parameters can be viewed in the <HOME> menu to
check basic LWB operation.

Parameter Definition

BAT SIZE Current setpoint value in set weight units.

Input range: 0 to Max Batch Size.
RATIO SP Note:
• Units set by Units variable in the Machine menu.

BATCHED Display the current amount batched in weight units during the current
run.

BATCH% Display the current amount batched in percent of Batch Size during
the current run.

DRIVE CMD Current level of the drive-command output in percentage. It defines

the motor velocity or vibratory tray displacement.

NET WEIGHT Current net weight on the scale.

MOTOR RPM
or DISP Current speed of the motor in min-1.

SCREW RPM Shows the current screw speed in rpm, when the <GEAR REDUC-
TION> in the MACHINE Menu, MOTOR Submenu > 0.0.

TOTAL Discharged product quantity.

« Press key. Then enter <0>. See section 3.3.2.

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6 Operation - LWB Control
6.2 LWB Programming

6.2 LWB Programming

Note: The BOLD PARAMETERS are command actions in
the KSU-II/KCM-KD local display menu.

« Set up the <PRODUCT CHANGE> menu as required.

« Perform the <CALIBRATION> function if necessary
(see section 6.7).

To get the feeder to run initially, it may be necessary to enter a value

of <INIT FF> in the <PRODUCT CHANGE> menu.

6.2.1 LWB Menu<PRODUCT CHANGE>,

6.2.1.1 Sub-Menu<GENERAL>

Parameter Definition

REFILL ENABLED Setting for continuous feeding and automatic refill. The
net weight alarm limit is active.
DISABLED The feeder hopper can be emptied without refilling being
triggered. The net weight alarm limit is disabled.
IF RUNNING If Running is selected, Refill is enabled if the feeder
runs, otherwise it is disabled.
Default: DISABLED

REFILL MAX 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.
0.75*hopper volume* density or 0.75*(Scale range-tare) whichever is less. Adjust as
necessary

REFILL MIN Input of the lower refilling limit at which refilling is started.
Warning:
Feeding behavior can be affected if the refilling limit is set too low.
Do not uncover feeder horizontal agitator.
Initially set REFILL MIN = 0.4 x REFILL MAX.

Table page 1 of 2

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 Operation - LWB Control 6
LWB Programming 6.2

Parameter Definition

AUTO FF CALIB The starting feeding factor is calculated during calibration in volumet-
ric mode.

! CAUTION
This command will start the feeder. Ensure that no one is working at
the machine.
For more information see Capter 6.7

INIT FF Input of the starting feeding factor to determine the motor speed. The
Drive Command is calculated as follows:

Setpoint
------------------------------------------------- x100 = DriveCommand
InitialFeedfactor
The starting feed factor can also be calculated with the command
variable <AUTO FF CALIB>.

To Start enter a value equal to the <MAX SETPT> on the MACHINE menu.
Note:
Value of <0> will cause a Feedfactor Alarm and the feeder will not
run.

EMPTY FDR Empty feeder function. When started, the feeder runs at a drive com-
mand of 70%. The feeder stops automatically if no weight loss is de-
tected.
Note:
<Empty Drive Cmd> may be changed by the Service Variables.

! CAUTION
This command will start the feeder. Ensure that no one is working at
the machine.
Table page 2 of 2

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6 Operation - LWB Control
6.2 LWB Programming

6.2.1.2 LWB <PRODUCT CHANGE> <BATCH SETUP> menu

This menu sets batch specific parameters.

Parameter Definition

FAST DC Sets the drive command value to be used during the main portion of
the batch.
Input range: >0% to 100%, Default: 80%

DRIB DC Sets the drive command value to be used during the dribble portion
of the batch.
Input range: 0% to 100%, Default: 20%

BATCH TIME Sets the desired batch time in seconds. Includes the Dribble time.
When GRAV mode is used, batch time will be achieved for a given
batch assuming a FF Calibration was first completed.
Input range: 0 to 99999999 seconds Default: 0 seconds.
Note: the practical minimum batch time is 12 seconds.

DRIB TIME Sets the desired dribble time in seconds.

Input range: 0 to 99999999 seconds Default: 5 seconds

MAX BAT SIZE This value sets the maximum value for Batch Size setpoint in weight
units.
Input range: 0 to 9999999, Default: 0.

BATCH COUNT This is a running count of delivered batches. Enter a <0> to clear the
count.
Input range: 0 to 9999999 Default: 0

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 Operation - LWB Control 6
LWB Programming 6.2

6.2.2 LWB Menu<CALIBRATION>,

6.2.2.3 Sub-Menu<CALIBRATION>
Use the FF Calibration menu to perform batcher calibration.

Parameter Definition

INIT FF Input of the starting feeding factor to determine the motor speed. The
Drive Command is calculated as follows:

Setpoint
------------------------------------------------- x100 = DriveCommand
InitialFeedfactor
The starting feed factor can also be calculated with the command
variable <AUTO FF CALIB>.

To Start enter a value equal to the <MAX SETPT> on the MACHINE menu.
Note:
Value of <0> will cause a Feedfactor Alarm and the feeder will not
run.

AVG FF The value shows the estimated mass flow value expected at 100%
drive command and is calculated as:

Massflow
--------------------------------------------- x100 = AverageFeedfactor
DriveCommand

Average Feedfactor represents the massflow capacity of the feeder

and is affected by bulk material charchteristics and the current me-
chanical configuration.
Notes:
• The feeder will not run with a Feedfactor of <0>.

AUTO FF CALIB The starting feeding factor is calculated during calibration in volumet-
ric mode.

! CAUTION
This command will start the feeder. Ensure that no one is working at
the machine.
For more information see Capter 6.7

CAL PROD FED Shows the amount of material discharged during calibration.

ACT PROD FED After the calibrate cycle has been completed, enter the weight of the
actual delivered product into this variable. The <SPAN> will be auto-
matically calculated.
Table page 1 of 2

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6 Operation - LWB Control
6.2 LWB Programming

Parameter Definition

SPAN This is the weight span that corrects for massflow inaccuracy. This
value is automatically calculated when an entry is made to the <ACT.
PROD FED> variable.
The <SPAN> value can also be entered manually.

CAL CORRELA Automatically calculated during calibration. The value shows the re-
liability of the calibration data. A value of 100% means that the mass-
flow samples taken during calibration are extremely uniform indicat-
ing smooth product discharge.
Note:
• This value is not shown for vibratory feeders.

CAL CORR LIM If the <CAL CORREL> is below this limit value the calibration is
aborted.
Note:
• This value is not shown for vibratory feeders.

CAL DC Calibrating drive command.

Note:
• This value is not shown for vibratory feeders.

CALIB TIME Input of the duration of the automatic calibration cycle.

Note:
• This value is not shown for vibratory feeders.
Table page 2 of 2

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 Operation - LWB Control 6
LWB Programming 6.2

6.2.2.4 Sub-menu <FEEDFACTOR>

The following parameters are only displayed if a vibratory feeder is
connected.

Parameter Definition

INIT FF Input of the starting feeding factor to determine the motor speed. The
Drive Command is calculated as follows:

Setpoint
------------------------------------------------- x100 = DriveCommand
InitialFeedfactor
The starting feed factor can also be calculated with the command
variable <AUTO FF CALIB>.

To Start enter a value equal to the <MAX SETPT> on the MACHINE menu.
Note:
Value of <0> will cause a Feedfactor Alarm and the feeder will not
run.

AVG FF The value shows the estimated mass flow value expected at 100%
drive command and is calculated as:

Massflow
--------------------------------------------- x100 = AverageFeedfactor
DriveCommand

Average Feedfactor represents the massflow capacity of the feeder

and is affected by bulk material charchteristics and the current me-
chanical configuration.
Notes:
• The feeder will not run with a Feedfactor of <0>.
Table page 1 of 2

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6 Operation - LWB Control
6.2 LWB Programming

Parameter Definition

MF @ 8% DC

MF @ 12% DC

MF @ 17% DC
These individual values are calculated automatically by the function
<AUTO FF CALIB>.
MF @ 23% DC Note:
For setting the vibratory see KCM manual 0490020605
MF @ 33% DC

MF @ 50% DC

MF @ 70% DC
MF @ 100% DC Only display
The values are calculated automatically by the function
<AUTO FF CALIB>.
Table page 2 of 2

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 Operation - LWB Control 6
LWB Emptying the feeder 6.3

6.3 LWB Emptying the feeder

If the same product is to be used again later, record the operating pa-
rameters on the programming sheet. The <REFILL> will be automati-
cally <Disabled> when this procedure is run. Be careful not to allow
external means to reinstate the <REFILL> to <Enable>.

V This command will start the feeder. Ensure that no one is working
at the machine.
! CAUTION
LWB emptying process:
1. Select the <PRODUCT CHANGE>.
2. Select <GENERAL> sub-menu.
3. Select the <EMPTY FDR> function.

4. Press
ENTER

5. Press
RUN

Note:
– The feeder runs in volumetric control at the <EmptyDC> value
until the net weight stops changing and then the feeder stops au-
tomatically.

– The function <EMPTY FDR> can by stopet with

STOP

6. Switch the feeder system off with the main switch.

7. The feeder can now be cleaned.

V Only clean the feeder system when the main power switch is
! WARNING ‘OFF’.

Set the variable <REFILL> from <Disabled> to <Enable> in the

<PRODUCT CHANGE>, <GENERAL> menu when ready to proceed
with feeding a new product.

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6 Operation - LWB Control
6.4 LWB Scale friction test (repeatability)

6.4 LWB Scale friction test (repeatability)

This procedure is used to check the repeatability of the weighing sys-
tem using a small weight maximum 2% of scale range.
It is used before taring, linearity check and SPAN correction, after
working on the feeder e.g. cleaning, screw change, maintenance work
to ensure little mechanical friction on the weighing system.
Sources of scale friction are:
• Stretched, tensioned or twisted flexible connections (bellows).
• Tight or rigid cabling to the feeder.
• Plugged hopper ventilation.
• Over and under pressure in closed systems.
• Faulty scale or SFT.

Procedure
1. Stop flow to feed hopper by disabling the refill.
2. Record the current netweight for reference.
3. Place a small weight on to the scale.
4. After 5 seconds take off the weight.
5. Read the current netweight and compare with the previous one.
6. The repeatability should be within +/- 0.01% of the scale range.
7. On platform scales, the friction test has to be done with an empty
and with a full hopper. For more complete check test at 25, 50,
75% of the scale capacity.
8. If the netweight value is drifting more than +/- 0.01% of the scale
range over less than a period of 30 minutes, check for mechanical
friction or high vibration on the scale.
For more information see the weight test certificate in the project
manual (Form 12.23-0009) if provided.

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 Operation - LWB Control 6
LWB Taring 6.5

6.5 LWB Taring

1. Empty the feeder (see section 6.3)
2. Perform a friction test if necessary (see section 6.4)
3. Select <AUTO TARE> in the <SCALE> menu.
4. Press ENTER twice to tare. The feeder is tared now.
The current tare value is displayed in the <TARE > parameter.
5. Record the tare weight.
6. Check <Net Weight> value in the <SCALE> menu. The displayed
net weight must be near <0.00> (+/- 0.01% of the scale range).

6.6 LWB Scale calibration using static weight

The weighing system has to be linear within tolerances specified from
the factory. For more information see the weight test certificate
(Form 12.23-0009) in the project manual if provided or contact K-Tron.

This procedure is used to correct the weight reading of the weighing

system using reference weights or using pre-weighed product
samples. It is done after replacing components on the weighing sys-
tem.

Equipment
Test weight or product sample size of min. 10% of the scale capacity.
Scale Capacity = {Scale Range-Tare}

Procedure
1. Tare the scale (see section 6.5)
2. Apply test weight (as close to the hopper centerline as possible) or
fill the hopper with the product sample.
3. Read new <NET WEIGHT> value and calculate the correction
factor as:

ReferenceWeight
NewWtSpan = DisplayedWtSpan x -------------------------------------------------------
NetWeightReading

4. Enter new span value in <SPAN> in menu <SCALE>.

5. Remove the test weight and check that <NET WEIGHT>
returns to <0.000> (+/- 0.01% of the scale range).

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6 Operation - LWB Control
6.7 LWB Auto FF Calib function

6.7 LWB Auto FF Calib function

The LWB controller calculates the starting feeding factor during
calibration. The feedfactor indicates the estimated flowrate at 100%
drive command. The feedfactor in conjunction with the operating
massflow setpoint, provides the drive command reference for initial
operation upon start-up.
The optimal average feed factor is constantly recalculated in
gravimetric mode.
The feed factor calibration is necessary after changing product, feed-
ing tools, gear reduction or before flow rate accuracy tests to achieve
the best performance.
The feedfactor can be entered manually if known.
For more information see the weight test certificate or
feeder‘s maintenance and technical manual.

• If an error occurs or the <CAL CORRELA> value falls outside the

<CAL CORR LIM>, the feedfactor will be set to zero and the auto-
matic span update will not occur. Check the operation of the feeder
and redo the test.
• If the calculated <SPAN> value is outside the <AutoSpanLimit>, the
auto calibration test will fail. Have a qualified technician examine
the scale for defects.

V The calibration cannot be done during feeding into the process.

V Avoid accidental refilling and scale distrubances while calibrating,
otherwise the feedfactor may be erroneous.

Preparation
Reference scale and sample container size.
The feedfactor can be entered manually if known.

V This command will start the feeder. Ensure that no one is working
! CAUTION at the machine.

Note:

The calibration can by stopet with

STOP

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 Operation - LWB Control 6
LWB Auto FF Calib function 6.7

Procedure
1. Fill the hopper with product.
2. Enter 100 as <INIT FF> value in the <PRODUCT CHANGE>
menu, <GERERAL> sub-menu.
3. Enter <BAT SIZE>.

4. Press to start the feeder.

RUN

5. Allow the feeder to run until the metering device has filled and
feeding material is evenly discharging.

6. Press twice for stop the batch and stop the feeder.
STOP

7. Select AUTO FF CALIB in the <PRODUCT CHANGE> menu,

<GENEREL> sub-menu.

8. Press
ENTER

9. Press
RUN

10. Start AUTO FF CALIB in the <CALIBRATION> menu, <CALIBRA-

TION> sub-menu.
• For screw feeders the default calibration drive command is 10%
and the calibration time is 30sec.
• For vibratory feeders, drive commands beginning at 8% and ending
at 70%. The run time will be about 1 minute.

11. When the function stops, weight the contents of the container.
12. Enter the value in <ACT PROD FED>.
13. This value is automatically calculated when an entry is made to the
<ACT.PROD FED> variable. The <SPAN> value can also be en-
tered manualy.
Note:
• The drive command is set by the value <CAL DC>.
• The calibration time by <CALIB TIME>.
• The discharged amount of product is shown by <CAL PROD FED>.

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7 Operation - WBB Control
7.1 WBB <HOME> menu parameters

7 Operation - WBB Control

For Start/Stop operation refer to section 5

7.1 WBB <HOME> menu parameters

The following parameters can be viewed in the <HOME> menu to
check basic WBB operation.

Parameter Definitions

BAT SIZE
Current setpoint value in set weight units.
Input range: 0 to Max Batch Size.
or
Note:
• Units set by Units variable in the Machine menu.
RATIO SP
Display the current amount batched in weight units during the cur-
BATCHED rent run.
Display the current amount batched in percent of Batch Size during
BATCH% the current run.

DRIVE CMD Current level of the drive command output in percent.

Current value of belt loading in kg/meter or lb/ft on a tared weigh

BELT LOAD belt.

BELT SPD Speed of the weigh belt in meters/minute or feet/minute.

MOTOR RPM Current speed of the motor in min-1.

Discharged product quantity.

TOTAL Press to enter a new value.

See section 3.3.2.

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 Operation - WBB Control 7
WBB Programming 7.2

7.2 WBB Programming

Note: The BOLD PARAMETERS are command actions in
the KSU-II/KCM-KD local display menu.

« Set up the <PRODUCT CHANGE> menu as required.

« Execute the <CALIBRATION> function if necessary
(see section 7.5).

7.2.1 WBB Menu <PRODUCT CHANGE>

7.2.1.1 <GENERAL> submenu

Parameter Definition

BELT LOAD SP A value of BeltLoad Setpoint must be entered.

In volumetric control, the belt speed is a function of Belt Load set-
point and the operating setpoint. Belt Load Setpoint also defines the
HI and LO Belt Load alarms as the reference.
Note:
After the feeder is configured, calibrated and is operational, enter
the operating belt load into this variable.

BELT LOAD Displays the actual value of Belt Loading.

STATIC TARE This action performs a static tare of the belt. The belt does not run.
A static tare must be done prior to the <DYNAMIC TARE> so a ref-
erence value is found.
« Select <STATIC TARE>.

« Press twice.
ENTER

Notes:
• Weigh belt must be empty of product.
• A static tare action while the feeder is running will generate an
<Out of Range> message.
Table page 1 of 3

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7 Operation - WBB Control
7.2 WBB Programming

Parameter Definition

DYNAMIC TARE This command allows the dynamic belt tare function to start.
The belt runs at a set speed of 4 meter/min.
Note: An error message ‘Belt Tare Failed’ will occur if the dynamic
tare value falls outside a pre-defined value.

! CAUTION
This command will start the feeder. Ensure that no one is working at
the machine.
« Select Parameter <DYNAMIC TARE>.

« Press
ENTER

« Press to start the Dynamic Tare function.

RUN

Note:
• A static tare must be done prior.
• Weigh belt must be empty of product.

• Press to stop the <DYNAMIC TARE> function.

STOP

• A <Belt not empty> message will occur if a <STATIC TARE> is not

done prior to <DYNAMIC TARE>.
• If the feeder running and the Tare function is done, the message
<feerer run> is appear.
This is the weight span that corrects for massflow inaccuracy.
This value is automatically calculated when an entry is made to the
SPAN <ACT. PROD FED> variable.
The <SPAN> value can also be entered manually.
Table page 2 of 3

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 Operation - WBB Control 7
WBB Programming 7.2

Parameter Definition

EMPTY FDR Empty feeder function. When started, the feeder runs at a drive com-
mand of 75%. The feeder stops automatically if the beltload is less
than <Belt Empty Limit>.
Note:
<Empty Drive Cmd> may be changed by the Service Variables.

! CAUTION
This command will start the feeder. Ensure that no one is working at
the machine.
« Select parameter <EMPTY FDR>.

« Press then
ENTER

« Press to empty feeder.

RUN

Note:

Press to abort the <EMPTY FDR> function.

STOP

Table page 3 of 3

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7 Operation - WBB Control
7.2 WBB Programming

7.2.1.2 WBB <BATCH SETUP> Sub-menu

This menu sets batch specific parameters.

Parameter Definition

FAST DC-[%] Sets the drive command value to be used during the main portion of
the batch.
Input range: >0% to 100%, Default: 80%

DRIB DC- Sets the drive command value to be used during the dribble portion
of the batch.
Input range: 0% to 100%, Default: 20%

BATCH TIME Sets the desired batch time in seconds. Includes the Dribble time.
When GRAV mode is used, batch time will be achieved for a given
batch assuming a FF Calibration was first completed.
Input range: 0 to 99999999 seconds Default: 0 seconds.
Note: the practical minimum batch time is 12 seconds

DRIB TIME Sets the desired dribble time in seconds.

Input range: 0 to 99999999 seconds Default: 5 seconds

MAX BAT SIZE This value sets the maximum value for Batch Size setpoint in weight
units.
Input range: 0 to 9999999, Default: 0

BATCH COUNT This is a running count of delivered batches. Enter a <0> to clear the
count.
Input range: 0 to 9999999 Default: 0

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 Operation - WBB Control 7
WBB Programming 7.2

7.2.2 WBB menu <CALIBRATION>

This menu permits easy feeder calibration.

Parameter Definition

AUTO The discharged product is calculated during calibration in volumetric

mode (constant speed).
CALIBRATE
• The drive command is set by the value <CAL DC>.
• The calibration time by <CALIB TIME>.
• The discharged amount of product is shown by
<CAL PROD FED>.

! CAUTION
This command will start the feeder. Ensure that no one is working at
the machine.
For Calibrate see Chapter 7.5.

CAL PROD FED Shows the amount of material discharged during calibration.

ACT PROD FED After the calibrate cycle has been completed, enter the weight of the
actual delivered product into this variable. The <SPAN> will be au-
tomatically calculated.

SPAN This is the weight span that corrects for massflow inaccuracy. For
accurate feeding, the span must be nearly 1.000 or there is a prob-
lem with the weighing system. This value is automatically calculated
when an entry is made to the <ACT. PROD FED> variable.
The <SPAN> value can also be entered manually.

CAL CORRELA Automatically calculated during calibration. The value shows the re-
liability of the calibration data. A value of 100% means that the
massflow samples taken during calibration are extremely uniform in-
dicating smooth product discharge.

CAL CORR LIM If the <CAL CORREL> is below this limit value the calibration is
aborted.

CAL DC Calibrating drive command.

CALIB TIME Input of the duration of the automatic calibration cycle.

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7 Operation - WBB Control
7.3 WBB Emptying the feeder

7.3 WBB Emptying the feeder

If the same product is to be used again later, record the operating pa-
rameters on the programming sheet.

V This command will start the feeder. Ensure that no one is working
! CAUTION at the machine

WBB emptying process:

1. Select the <CHANGE PRODUCT>.
2. Select <GENERAl> menu.
3. Select the <EMPTY FDR> function.

4. Press .
ENTER

5. Press .
RUN

– The feeder runs in volumetric control at the <EmptyDC> value

(found in the Service Variable list) until the belt load reaches near
zero (net weight stops changing) and then stops automatically.

– The function <EMPTY FDR> can by stopet with

STOP

6. Switch the feeder system off with the main switch. The feeder can
now be cleaned.

! WARNING V Only clean the feeder system when the main switch is ‘OFF’.

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 Operation - WBB Control 7
WBB Taring 7.4

7.4 WBB Taring

1. Prevent flow onto the belt.
2. Empty the weight-belt feeder (see section 7.3)
3. After the feeder stops, disconnect motor power and clean the
weigh belt and feeder. Reconnect the motor power when done.
4. Perform a <STATIC TARE> (see chapter 7.2).
5. Perform a <DYNAMIC TARE> (see chapter 7.2).
– The weight-belt feeder will run for a time and then store the mean
tare weight in memory.
6. Open the <SCALE> menu, <GENERAL> sub-menu and record
the <TARE> and <TARE 2> if used.The displayed tare weights
must be between 300 and 1000g (0.14lb and 2.2lb). If not, check
alignment of the weighbridges.
7. Check <Net Weight> value in the <SCALE> menu. The displayed
net weight must be 0.000 kg +/- 2gr (0.004lb).

7.5 WBB Flow rate calibration using Auto FF

Calib function
It is done in general and on a regular basis during preventive
maintenance.
For more information see the weight test certificate or
feeder‘s maintenance and technical manual.

• If an error occurs or the <CAL CORRELA> value falls outside the

<CAL CORR LIM>, the feedfactor will be set to zero and the auto-
matic span update will not occur. Check the operation of the feeder
and redo the test.
• If the calculated <SPAN> value is outside the <AutoSpanLimit>, the
auto calibration test will fail. Have a qualified technician examine
the scale for defects.

Preparation
Reference scale and sample container size:
Minimum sample size = 22 x Beltloading

Set-up:
1. Empty the feeder (see section 7.3) if it necessary.
2. Retare the feder (see section 7.2) if it necessary.
3. Fill the belt with product.
4. Select calibration.
5. Product quantity of minimum two belt lengths with <CALIB TIME>
= 180 Sec at min. 1kg/m (2.2 lb./ft.) beltloading for one sample.
6. Enter calib drive command.

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7 Operation - WBB Control
7.5 WBB Flow rate calibration using Auto FF Calib function

For SWB 300/600 use following table to set the calibration drive
command:
– Gear reduction 80:1, <CALIB DC> = 100%
– Gear reduction 40:1, <CALIB DC> = 50%
– Gear reduction 20:1, <CALIB DC> = 25%
For WBF 300/600 use following table to set the calibration drive
command:
– Gear reduction 81:1 to 130:1, <CALIB DC> = 100%
– Gear reduction 41 to 80:1, <CALIB DC> = 50%
– Gear reduction 10:1 to 40:1, <CALIB DC> = 25%

V This command will start the feeder. Ensure that no one is working
! CAUTION at the machine.

7. Select <CALIBRATION>.

8. Press
ENTER

9. Press
RUN

10. Start CALIBRATION

11. When the function stops, weight the contents of the container.
12. Enter the value in <ACT PROD FED>.
13. This value is automatically calculated when an entry is made to the
<ACT.PROD FED> variable. The <SPAN> value can also be en-
tered manualy.
Note:
• The drive command is set by the value <CAL DC>.
• The calibration time by <CALIB TIME>.
• The discharged amount of product is shown by <CAL PROD FED>.

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 Operation - SFB Control 8
SFB <HOME> menu parameters 8.1

8 Operation - SFB Control

For Start/Stop operation refer to section 5.

8.1 SFB <HOME> menu parameters

The following parameters can be viewed in the <HOME> menu to
check basic SFB operation.

Parameter Definition

Current setpoint value in set weight units.

BAT SIZE
Input range: 0 to Max Batch Size.
Note:
RATIO SP
• Units set by Units variable in the Machine menu.
Display the current amount batched in weight units during the current
BATCHED run.
Display the current amount batched in percent of Batch Size during
BATCH% the current run.
Current level of the drive-command output in percentage. It defines
DRIVE CMD the motor velocity or vibratory tray displacement.

MF Current Massflow in weight/time .

MOTOR RPM
Current speed of the motor in min-1.
or DISP
Discharged product quantity.
TOTAL
« Press key. Then enter <0>. See section 3.3.2.

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8 Operation - SFB Control
8.2 SFB Programming

8.2 SFB Programming

Note: The BOLD PARAMETERS are command actions in
the KSU-II/KCM-KD local display menu.
« Set up the <PRODUCT CHANGE> menu as required.
« Execute the <CALIBRATION> function if necessary
(see section 8.4).

8.2.1 SFB <PRODUCT CHANGE>

8.2.1.1 Sub-menu <GENERAL>

Parameter Definition

AUTO RETARE If switched <On>, the weighing units are continuously tared if no
massflow is measured.
If switched <Off>, the auto tare function is disabled.
Auto Retare
Default: OFF

AUTO TARE The tare values for the Chute and Divert channel SFTs are stored in
the <Tare Chute> and <Tare Divert> values.
« Select <AUTO TARA>

« Press
ENTER

TARE Tare weigh of the Chute.

TARE 2 Tare weigh of the Divert.

THRESH CHUTE When the net weight on the Chute channel falls below this value, the
massflow is set to <0> and the LEDs indicate a ‘STOP’. Also engag-
es the Auto Tare function if enabled.

THRESH DIVERT When the net weight on the Divert channel falls below this value, the
massflow is set to <0> and the LEDs indicate a ‘RUN’. Also engages
the Auto Tare function if enabled.
<OFF>: Normal function.
Default: OFF

BYPASS VALVE <ON>: Programs the Bypass Valve to actuate at the time interval set
in the <PYPASS INT> variable.
<OFF>: Disables the Bypass Valve function.
Default: OFF

BYP. INTERVAL Time interval in seconds for the automatic taring function.

Table page 1 of 2

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 Operation - SFB Control 8
SFB Programming 8.2

Parameter Definition

SPAN This is the weight span that corrects for massflow inaccuracy. This
value is automatically calculated when an entry is made to the <ACT.
PROD FED> variable.
The <SPAN> value can also be entered manually.
Table page 2 of 2

8.2.1.2 BATCH SETUP sub-menu

This menu sets batch specific parameters.

Parameter Definition

FAST DC Sets the drive command value to be used during the main portion of
the batch.
Input range: >0% to 100%, Default: 80%

DRIB DC Sets the drive command value to be used during the dribble portion
of the batch.
Input range: 0% to 100%, Default: 20%

BATCH TIME Sets the desired batch time in seconds. Includes the Dribble time.
When GRAV mode is used, batch time will be achieved for a given
batch assuming a FF Calibration was first completed.
Input range: 0 to 99999999 seconds Default: 0 seconds.
Note: the practical minimum batch time is 12 seconds.

DRIB TIME Sets the desired dribble time in seconds.

Input range: 0 to 99999999 seconds Default: 5 seconds

MAX BAT SIZE This value sets the maximum value for Batch Size setpoint in weight
units.
Input range: 0 to 9999999, Default: 0

BATCH COUNT This is a running count of delivered batches. Enter a <0> to clear the
count.
Input range: 0 to 9999999 Default: 0

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8 Operation - SFB Control
8.2 SFB Programming

8.2.2 SFB CALIBRATION menu

Use the FF Calibration menu to perform SFB calibration.

Parameter Definition

CAL MODE <Lin P1-3> with linearize .

<Overall>without linearize
For mor information see chapter 8.4.

AUTO CALIBRATE The discharged product is calculated during calibration in volumetric

mode (constant speed).
• The drive command is set by the value <CAL DC>.
• The calibration time by <CALIB TIME>.
• The discharged amount of product is shown by
<CAL PROD FED>.

! CAUTION
This command will start the feeder. Ensure that no one is working at
the machine.
For more details see chapter 8.4.

CAL PROD FED Shows the amount of material discharged during calibration cycle as
calculated by the controller.

ACT PROD FED After the Feedfactor test has been completed, enter the weight of the
actual delivered product in this variable. The <SPAN> in the CALI-
BRATION Menu will be automatically calculated.

SPAN This is the weight span that corrects for massflow inaccuracy.
Note:
• This value is automatically calculated when an entry is made to the
<ACT. PROD FED> variable.
• The <SPAN> value can also be entered manually
For Calibrationdetail see chapter 8.4.

CAL CORRELA Will be automatically calculated during calibration. The value shows
the reliability of the calibration data. A value of 100% means that the
weight samples taken during calibration are extremely uniform indi-
cating smooth product discharge and no weight disturbances.

CAL CORR LIM If the <CALIB CORRELATION> is below this limit value the calibra-
tion test aborted.
Note:
This value self-adjusts after each completed calibration cycle.
Table page 1 of 2

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 Operation - SFB Control 8
SFB Programming 8.2

Parameter Definition

CAL DC Drive command used during the auto calibration cycle.

CAL TIME Input of the duration of the automatic calibration cycle.

A0, A1, A2 Linearization coefficients for the SFB (see Chapter 8.4).

Table page 2 of 2

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8 Operation - SFB Control
8.3 SFB Tarierung

8.3 SFB Tarierung

1. Prevent flow onto the belt.
2. Clean the chute and the divert.
3. Perform a <TARE>.
4. Open the <SCALE> menu, <GENERAL> sub-menu and record
the <TARE> and <TARE 2> if used.The displayed tare weights
must be between 0.000kg +/- 1gr. If not, check alignment of the
chute and the divert.
5. Check <TARE> and <TARA2> note for referenzdetails.

For the Flow Meter setting see maintenance instruction 0490016603.

8.4 SFB Auto Calib function

It is done in general and on a regular basis during preventive mainte-
nance.
For more information see the weight test certificate or
feeder‘s maintenance and technical manual.

• If an error occurs or the <CAL CORRELA> value falls outside the

<CAL CORR LIM>, the feedfactor will be set to zero and the auto-
matic span update will not occur. Check the operation of the feeder
and redo the test.
• If the calculated <SPAN> value is outside the <AutoSpanLimit>, the
auto calibration test will fail. Have a qualified technician examine
the scale for defects.

Preparation
Reference scale and sample container size:

V This command will start the feeder. Ensure that no one is working
! CAUTION at the machine.

Set-up:
1. Select calibration.
2. For MF calibration set <CAL MODE> to <OVERAL>.
3. Set calibrate time for enough material.
4. Set calibrate drive command <CAL DC> min. on 10% for enough
material.
5. Select >CALIBRATION> submenu CALIBRATION>.

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 Operation - SFB Control 8
SFB Auto Calib function 8.4

6. Press
ENTER

7. Press
RUN

8. Start CALIBRATION.
9. When the function stops, weight the contents of the container.
10. Enter the value in <ACT PROD FED>.
11. This value is automatically calculated when an entry is made to the
<ACT.PROD FED> variable. The <SPAN> value can also be en-
tered manualy.
Validation:
1. If the calibration was correctly done, the <SPAN> will be updated.

8.4.1 SFB Flowrate calib. procedure with linearization

This calibration mode is used when the SFB is used as feeder over a
wider range of flowrates.
Fig. 8.3 shows the typical error-curve (1) of a SFB.To improve the
accuracy over a certain feedrate range, take a minimum of one test
sample at three different feedrates which cover the desired feedrate
2 1
Deviation [%]

range.
1 2
0 Default calibration points:
-1
• Pt1 @20% drive command
-2
0 2 4 6 8 10 12 14 16 18 • Pt2 @40% drive command
Feedrate [t/h] • Pt3 @60% drive command
To linearize curve (2) within the desired feedrate range, adjust the
<Cal DC> values.
Fig. 8.3 SFB SPAN Linearization

V This command will start the feeder. Ensure that no one is working
! CAUTION at the machine

Set-up:
1. Place an empty, tared container under the flowmeter discharge.
2. Open the <CALIBRATION> menu.
3. Set the <CALIB MODE> to <Lin Pt1>.
4. Set the <CALIB TIME> to 120 seconds minimum.
5. Set the <CAL DC> to 20%.
6. In the <CALIBRATION> menu, select <AUTO FF CALIB>.

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8 Operation - SFB Control
8.4 SFB Auto Calib function

7. Press .
ENTER

8. Press Flow begins.

RUN

9. When the flowmeter stops, weight the contents of the container.

10. Enter the value of material delivered from the prior step into the
variable <ACT PROD FED>.
11. Set <CAL MODE> to <LinPt2>.
12. Set the <CAL DC> to 40%.
13. Redo steps 4-8.
14. Set <CAL MODE> to <LinPt3>.
15. Set the <CAL DC> to 60%.
16. Redo steps 4-8.

Validation:
1. If the calibration was correctly done, the <SPAN> and coefficients
A0, A1, A2 will be updated.
2. Record the <SPAN> and coefficients A0, A1 A2 values for future
reference.

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 Calibration 9
SFB Auto Calib function 8.4

9 Calibration

There are different calibration tasks and they are done on a regular
basis depending on the process or after maintenance work and espe-
cially after replacing components of the weighing system.
• All work should be done when the <SETPOINT MODE> = <Local>
and any interlocks from external equipment are deactivated.
• Record the tare, span and feedfactor values after calibration
for future use.

9.0.1 Calibration tasks

• Scale taring used for LWF,WBF, SFM
• Scale friction test (static weight reading, repeatability) used for
LWB.
• Feeding factor calibration used for LWB.
• Flowrate calibration (by SPAN correction)
– Comparing a static reference weight with the net-weight indica-
tion from the controller used only for LWB.
– Comparing a product sample weight with the computed weight
from the controller used for all feeders.

You can choose one of the following methods to validate flowrate:

– Auto Feedfactor Calibration.
– Totalizer
• Flowrate accuracy check (repeatability)

9.0.2 Span limits

Standard limits for <Span> for the different scales and feeder types:
• 3 point weighing system SFT, SFS platform scale: 0.99 to 1.01
• D/B/H4 platform scales, K2G/K4G scales: 0.95 to1.05
• SWB, WBF Belt feeder: 0.80 to 1.20
• WBF300/600 Belt feeder: 0.95 to 1.05
• SFB: 0.5 to 2.00 not linearized
For specific tolerances see the weight test certificate (12.23-0009) in
the project manual if provided.

9.0.3 Accuracy for reference equipment

• Calibrated test weights with accuracy class
M2, ANSI std. E617-class 4 (<0.02% 1- 50 kg).
• Reference scale error (<0.02% of reading).

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9 Calibration
9.1 Flowrate accuracy check by sampling

9.1 Flowrate accuracy check by sampling

This procedure is used to test the linearity and repeatability of the
feeder by comparing multiple product samples to the
massflow setpoint.
It is done after replacing components on the weighing system, during
commissioning and on a regular basis for validation depending on the
process requirements.
For more information see K-Tron Feeder Accuracy Definition
document I-060001.

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 Alarms - What to Do10
KSU-II/KCM-KD alarm function
10.1

10 Alarms - What to Do

When alarms occur, it is important to note them on the KSU-II or KCM-

KD local display.

10.1 KSU-II/KCM-KD alarm function

10.1.1 Stage 1- Pending alarm:

The red ALARM LED (upper right) illuminates when an alarm condi-
tion has been detected.
Soft-Alarms are programmed with an alarm delay time. If the alarm is
not active anymore before the alarm delay timer has elapsed, it will be
automatically cleared.
If the alarm delay timer has elapsed ant dthe alarm is still active, then
the Hard-Alarm will be activatet.

Fig. 10.1 Stage 1 alarm display

10.1.2 Stage 2 - Hard alarm:

The red ALARM LED (upper right) flashes when an alarm condition
has been detected.
Hard alarm have to be achnowledged or cleared.

If more than one alarm condition is present, they will be displayed in

ALARM order of the alarm number.
STOP BY Board Reset
06 WT PROC FAILURE
07 INCORRECT NUM SFT

Fig. 10.2 Stage 2 alarm display

The alarm relay is configured for failsafe operation. It is not energized

for an alarm.

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10 Alarms - What to Do
10.1KSU-II/KCM-KD alarm function

10.1.3 Possible responses to the error condition

1. Press ALARM key ALARM

, to display the alarm.

2. Press ALARM key to acknowledge the alarm.

3. Press ALARM to clear the alarm signal.

10.1.4 The error must be corrected.

1. To query the alarm see chapter 11.
2. Press STOP to stop feeding and correct the error.
3. Press ALARM to clear the alarm signal.
4. Press RUN to start the feeder.

V If this requires work on the feeder, switch off the feeding system.
Power the feeder when repairs are complete.

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 Alarm Messages- Cause and Remedy11
System alarms
11.1

11 Alarm Messages- Cause and Remedy

11.1 System alarms

.
– The associated number is the alarm number used for configura-
tion and data communications.
– The HCU is the control unit for the Hurricane vacuum material
loader for the feeder. It is programmed via the KSU-II/KCM-KD
and its alarms are reported there.
– The first number is the KCM alarm, the second the HSU alarm.
(KCM#/HSU#). This code begins at KCM alarm (21) and ends at
KCM alarm (29).

Alarm Num- Alarm Cause Remedy

• KCM Hardware error. Datea check- « Check KCM.

00 HARDWARE ERROR
sum error. « Clear alarm and try unit.
• The K-PROM cannot be accessed. « Correctly insert K-PROM.
01 KPROM MEM FAIL
« Replace K-PROM.
• Checksum error in kgr file area. « Verify K-PROM is properly in-
02 KPROM*KGR*FAIL stalled.
« Replace K-PROM.
• Power dip detected. CPU did not re- « Verify AC mains are within specifi-
03 POWER GLITCH set. cation.
« Replace drive pcb (power supply).
• Internal channel, used by CPU, « Check connections.
05 INT CHAN FAIL
drive board ans SFT,has failed. « Replace either CPU or Drive pcb.
• SFT(s) failed. « Locate which SFT has failed on the
• Serial communication to the load cell <SFTs> line in the <SCALE>
interrupted. Menu, <SFT> sub-menu.
• f = SFT internal failure. communica-
06 WT PROC FAILURE
tion OK.
• t = No communication from the SFT
to the controller board.
• ?= Not valid answer from SFT.

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11 Alarm Messages- Cause and Remedy
11.1System alarms

Alarm Num- Alarm Cause Remedy

• Number of SFTs found during poll- « Check <SFT REQUIRED>.

ing does not equal that required. « Check nummer of SFTs.
07
INCORRECTNUM.SFT « Replace SFT.
« Check SFT operating.
• SFT is showing an incorrect status. « Ckeck SFT.
08 BAD SFT STATUS
« Replace SFT if problem persists.
• The CPU did not find a motor drive « Check drive pcb LEDs for correct
09 NO MDU FOUND on the internal channel on power-up. function.
« Replace drive or CPU pcb.
• The KCM CPU lost the motor drive « Check drive pcb LEDs for correct
on the internal channel while in oper- function.
10 MOTOR ALARM ation. « Check Internal channel connec-
tions.
« Replace drive or CPU pcb.
• Motor drive has lost communication « Check Internal channel connec-
11 with the KCM CPU and then turns off tions.
MDU SERIAL TIMEOUT all digital outputs and shuts of drive « Replace drive or CPU pcb.
power.
12 MDU THERMAL OVL • Drive temperature has been ex- « Reduce operating temperature.
ceeded > 75 deg C. Drive stops.
13 MDU SPEED DEV • No speed feedback signal is present « Check speed pick-up and power
when motor is asked to run. connections.
• Speed deviation from target > ± 5 « Check programming and motor
rpm. date.
• Wrong motor voltage programmed. « Check motor.
14 « Check motor power limit.
MOTOR OVERLOAD
Motor current too high. « Check programming and motor
date.
15 • Safety relay failed. « Replace Drive pcb.
MDU SAFETY RELAY

16 • Dual tach signals connected, one « Check tachometer-replace.

MOTOR/ENCDR FAIL failed. « Check motor brushes.
• Over-voltage on drive power supply. « Replace motor if required.
• Motor voltage applied but no speed « Replace KCM drive board.
feedback.
« Check for excessive line voltage.
• Drive temperature > 85 deg. C.
« Reduce operating temperature.
17 • Speed feedback but no motor volt- « Replace drive board.
MDU UNCONTROLLED age applied.

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 Alarm Messages- Cause and Remedy11
System alarms
11.1

Alarm Num- Alarm Cause Remedy

18 • EEPROM checksum failed. « Cycle power. If error persists, re-
MDU EEPROM FAILED place drive pcb.
19 MDU DRIVE FAILED • MDU drive pcb has failed. « Check drive coil for proper imped-
ance.
20 MDU POLARITY • Coil polarity is incorrect on the vibra- « Change the feedback coil polarity
tory drive (Vibratory feeder only). by swapping leads at KCM.
21 HCU REMOVED • HCU was removed. « Connect HCU at the KCM and
switch KCM On.
« Repoll SFT channel to re-connect
HCU.
« Clear NOVRAM if necessary.
22 HCU ALARM • HCU has an alarm. « See following alarms for trouble
shooting 23 to 29.
23/01 • EEPROM failed. « Clear alarm.
HCU EEPROM FAILED Change EEPROM or HCU.
« Cycle power to the HCU.
24/02 • The controller's digital output driver « Change HCU.
HCU DRIVER FAILED has detected a fault. « Latched.
25/03 • Supply hopper level sensor not co- « Refill or change supply hopper.
HCU SUPP.HOPP.LOW nered or failed. « Check P17.
« Check sensor or P23.
Note: Alarm will automatically clear
when material is above sensor.
26/04 • The differential pressure across the « Clean or replace filter.
HCU D.P.ALARM filter is too high indicating a clogged « Check P24 and P16.
filter.
« Check P17.
• Sensor failed or not installed.

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11 Alarm Messages- Cause and Remedy
11.1System alarms

Alarm Num- Alarm Cause Remedy

27/05 If P20 Discharge Mode =01“Fill” mode « Check Parameter P25 Number of
HCU CYC.COUNT AL then: load cycles.
• Max. numbers of load cycle exceed- « Check conveying rate.
ed, because Buffer Hopper Low in- « Check Buffer hopper sensor.
put has been active (on) for more
than the allowed load cycles. The
Buffer Hopper Low signal going in-
active clears the load cycle counter.
If P20 Discharge Mode =02 (LWF)
mode then:
• Discharge Request input has been « Check Parameter P25 Number of
on for more than the allowed load load cycles.
cycles. The Discharge Request sig- « Check conveying rate.
nal going inactive clears the load cy-
cle counter. « Check discharge request signal.

28/06 • Discharge valve has failed to either « Check sensor on the discharge
HCU DISCH VALVE open or close properly. This alarm is valve.
automatically disabled in P18 Oper- « Check P26.
ating Modes 03 and 04.
29/07 • Receiver is still full after discharge. « Check receiver. Material bridging in
HCU REV.FULL AL. the receiver. Clean receiver.
• Receiver proximity switch too sensi-
tive adjusted or failed. « Check Receiver proximity switch or
P17.
30 • Protocol of KGR file does not match « Make corrections as necessary.
KLINK WRONG KGR that required by the installed com-
munication circuit card.
31 KLINK NO KGR • No KGR file loaded. « Load KGR file with SmartConfig or
switch to <Built-IN> KGR file.
32 HPORT FAIL • Host communication pcb error. « Check communications and set-
tings.
« Exchange communications pcb as
necessary.
« Replace anybus.
33 HPORT FAIL INIT • Host communication pcb could not « Check host communications pcb
be initialized. connections.
« Replace anybus.
34 • Improper pcb installed in the host « Install correct host communications
HPORT ILLEGAL BD port location. pcb.
« Replace anybus.
35 KPORT FAIL • K-Port has failed. « Replace K-Port comm pc card.

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 Alarm Messages- Cause and Remedy11
System alarms
11.1

Alarm Num- Alarm Cause Remedy

36 KPORT FAIL INIT • K-Port communication pcb could not « Check communications and set-
be initialized. tings.
« Check host communications pcb.
« Replace K-Port comm pc card.
37 • Wrong communication board in- « Check host communications pcb.
KPORT ILLEGAL BD stalled. « Replace K-Port comm pc card.
38 • One or more feeder parameters are « Correct KGR file.
KGR PARAM ERROR not correct for the specified feeder. « Use <Built-IN> KGR file.
39 EXT IO FAIL • The MODBUS I-O connection has « Check I-O module and connec-
failed. tions.
40 • Digital input on KCM selected for Ex- « Check input and connections.
EXT ALR ACTIVATED ternal Alarm is active.
41 INTERLOCK FAIL • Drive pcb Run Enable digital input is « Check input and connections.
open during operation.
42 START IGNORED • Start conditions not fulfilled. « Check machine status.
« Check for setpoint and re-enter if
necessary.
« Check all KCM digital inputs for
correct operation.
45 DRIVE CMD CEILING • Drive command has reached the « Reduce drive command.
limit <DC CEILING>. « Increase <Drive Command Ceil-
ing>.
48 • DC motor brushes may be wearing « Motor brushes need inspection and
CHECK_MOTOR_BRUS out and ready to fail. replacement if worn.
HES
« If brushes are OK, re-enter a rele-
vant brush life number in the Per-
formance sub-menu.

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11 Alarm Messages- Cause and Remedy
11.2Display messages

11.2 Display messages

Message Cause Remedy

Out of Range • Input value is outside of allowed « Enter a value within the permitted
Tare Failed range. limits of the parameter. See the
specific programming manual for
more information.
Nak’d Feeder Run- • Command can not be executed « Stop the feeder before making the
ning when the feeder is running. entry.

11.3 Feeder won’t start - displayed messages

Message Cause Remedy

Wait • No setpoint is entered. « Enter an operating <SP>.

• Feedfactor, if required, is <0>. « Enter an <Initial Feedfactor> if re-
• Interlock has failed. quired.
« Check interlocks.
Alsh • Automatic alarm shutdown because « Check alarm message and correct
of an alarm. problem.
PAUS • Batch has been paused through « With RUN continue the batch.
pressing STOP.
Disa • Start via bit input disabled (Interlock « Check interlocks to the KCM.
or Run enable).

11.4 Feeder won’t run in GRAV

Message Cause Remedy

Feeder remains in • Conditions for gravimetric control « Check input for forced VOL func-
VOL control not fulfilled. tion.

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 Alarm Messages- Cause and Remedy11
LWB alarms
11.5

11.5 LWB alarms

Process alarms Cause Remedy
52 FEEDFACT. BAD • Feedfactor = 0 « Enter new feedfactor.
• Feedfactor outside <FF DEV LIMIT> « Check feedfactor limit in <ALARM>
limits. menu <FF DEV LIMIT>.
« Check feeding condition.
53 • The weight on the scale is above the « Check functions of the scale.
SCALE OVERRANGE scale gross range permitted. « If LWB, reduce level of refilling -
<REFILL MAX> parameter.
54 • The weight on the scale is below the « Check the scale and re-tare.
SCALE UNDERRANGE zero or gross weight < 0.
55 NETWT > LIMIT • The material weigh in the hopper is « Check for proper hopper filling.
above the limit set in the <ALARM> « Check the tare value.
menu. <NW HI LIMIT>.
« Check the scale.
56 NETWT < LIMIT • The material weigh in the hopper is « Check for proper hopper filling.
below the limit set in the <ALARM> « Check the tare value.
menu.<NW LO LIMIT>.
« Check the scale.
57 REFILL EXPIRED • The programmed refilling time (pro- « Check refilling system.
gram parameter <ALARM> menu, « Increase <Refill Time Maximum>.
<MAX REFILL TIME> was exceed-
ed without refilling being completed. « Increase refilling rate.

58 LOADER TIMEOUT • Loader time of loader has elapsed « Check material pickup.
• Refill requested during a loading cy- « Check loader funktion.
cle.
59 • Batch is out of tolerance. « Increase <BATCH TOL>.
BATCH TOLERANCES
« Ckeck Batch parameter.
« Check feeder material configura-
tion.
60 BATCH TIME • Batch time is higher as <TIME Lim. « Batch time limit enlarge
CHARGE>. « Check Batch parameter
« Check feeder material configura-
tion.

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11 Alarm Messages- Cause and Remedy
11.5LWB alarms

11.5.1 LWB Batch massflow variances

Alarms Cause Remedy

General batch mass- • High Vibrations. « Check sales for friction.

flow fluctuations « Check feeder/materialconfigura-
LWB tion.
« Increase feeder building.
« Protect the feeder from drafts and
air currents.
« Batch Limit enlarge.
« Increase the tolerance limit of pa-
rameters <MF ERR+/MF ERR-> in
the <ALARM> menu.
• Irregular motor speed. « Check the motor speed and the
tacho meter.
« verify the discharge feeder screws
are not bound.
« Seals, air purge defective; Material
jammed in leakage sheaf.
• Pressure fluctuations in the storage « Improve ventilation, install a pres-
container caused by pressure, suc- sure compensator on the ventila-
tion or insufficient ventilation. tion connection during the suction
process.

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 Alarm Messages- Cause and Remedy11
WBB Alarms
11.6

11.6 WBB Alarms

Process alarms Cause Remedy

52 BELT SLIP • Belt slip is above the <BELT SLIP « Check belt tension.
LIM> in the <ALARM> menu. « Check feeder and re-tare.
« Check <Belt slip>.
53 SCALE OVERRANGE • The weight on the weigh bridge is « Check the weigh bridge.
above the scale gross range permit- « Verify that the side skirts do not
ted. touch the weigh belt.
54 SCALE UNDER- • The weight on the weigh bridge is « Check the weigh bridge.
RANGE below the zero or tare value. « Check weigh bridge alignment.
55 BELTLOAD HIGH • The belt load is higher than the limit « Increase the limit value - <HI BELT
entered on the <ALARM> menu. LOAD>.
« Check for side skirts touching the
belt.
« Check for proper weigh bridge
alignment.
56 BELTLOAD LOW • The belt load is lower than the limit « Increase the depth of material on
entered in the <ALARM> menu. the weigh belt.
« Lower the <LO BELT LOAD> val-
ue.
57 BELT DRIFT • Belt is drifting off the machine. « Check belt tracking.
« Clean the belt.
« Set the belt tracking.
« Re-tare the weight belt.

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11 Alarm Messages- Cause and Remedy
11.6WBB Alarms

Process alarms Cause Remedy

58 BELT BUILDUP • Material is accumulating on the « Clean weigh belt.
weigh belt such that the belt loading « Re-tare weight belt.
on the secondary weigh bridge is
greater than the Belt Empty Lim-
it*BeltLoadSP.
59 BATCH TOLERANCE • Batch is out of tolerance. « Increase INTERGRAL TIME.
« Check batch parameter.
« Check material.
60 BATCH TIME FOULT • Batch time is higher as <TIME Lim. « Enlarge <BATCH TIME LIM>.
CHARGE> « Check batch parameter.
« Set GRAV setpoint.
« Adjust BELT SP to BELT MF.
61 BELT INDEX FAIL • Belt index function has failed, if « Check belt index sensor and re-
used. place if failed.

11.6.1 WBB Batch massflow variances

Alarms Cause Remedy

General batch mass- • Vibrations and shock at feeder. « Improve feeder mounting structure.
flow « Increase the <INTEGRAL TIME> in
fluctuations-WBB the <TUNING> menu.
« Increase the tolerance limit of pa-
rameters <MF ERR+/MF ERR-> in
the <ALARM> menu.
• Irregular material discharge. « Adjust inlet gate to smooth material
profile on the belt.
« Reduce belt loading to increase
belt speed.
« Change inlet section to provide for
better flow.
« Change inlet to a pre-feeder.
• Irregular motor speed in VOL. « Check the motor speed and the ta-
cho meter.

Page 82 Docu-No.: 0490020612-EN Rev. 1.2.0

 Alarm Messages- Cause and Remedy11
SFB Alarms
11.7

11.7 SFB Alarms

Process alarms Cause Remedy
53 D-RANGE ERROR • The weight on the divert channel is « Check divert channel.
below the zero point. Net weight is « Re-tare divert channel.
negative.
54 C-RANGE ERROR • The weight on the chute channel is « Check chute channel.
below the zero point. Net weight is « Re-tare chute channel.
negative.
55 OVER FLOW • The flow through is too high as a val- « Correct the problem of excessive
ue above the <MAX FLOWRATE> flow.
in the <ALARM> menu. « Adjust the flowrate limit.
56 NO FLOW • A no flow condition has been detect- « Correct the condition of no flow to
ed as a value below the <MIN the SFB.
FLOWRATE> in the <ALARM> « Adjust the flowrate limit.
menu.
57 VALVE ERROR • Bypass not in right position. « Check Bypass valve function.
• Bypass valve blocked.
• Position switch defective or not con- « Bypass relays incorrectly adjusted
nected. or are defective.
• Pressure solenoid defective. « Bit Input incorrectly programmed.
• No air supply at the pressure valve. « Check pressure valve.
« Check DC supply and pressure.
59 BATCHTOLERANCE • Batch is out of tolerance. « Reduce the <DRIBBLE CMD> val-
ue.
« Increase <DRIBBLE TIME>.
« Check feeder for flushing.
60 BATCHTIME2HIGH • The actual batch time has exceeded « Increase the <FAST DRIVE
the desired batch time plus the batch COMD>. Increase the <GRACE>
time grace period. or <BATCH TIME>.
« Increase feeder capacity.

Docu-No.: 0490020612-EN Rev. 1.2.0 Page 83

11 Alarm Messages- Cause and Remedy
11.7SFB Alarms

11.7.1 SFB Batch massflow variances

Alarms Cause Remedy

General batch mass- • Vibrations and shock at feeder. « Improve feeder mounting structure.
flow « Increase the tolerance limit of pa-
fluctuations-SFB rameters <MF ERR+/MF ERR-> in
the <ALARM> menu.
• Inlet gate to the chute or divert « Friction between chute or divert
chanel not free. chanel.
• Irregular material discharge. « Ckeck for material bridging.
• Distance to heigh. « Reduce prefeeder distance.
• Irregular material discharge. « Check chute and divert chanel.

Page 84 Docu-No.: 0490020612-EN Rev. 1.2.0

 PROGRAMMING INSTRUCTION

KCM LWB Programming

text

Read this manual prior to operating or

servicing the equipment. This manual
contains all safety labels and warn-
ings.

0590020606-EN Rev. 1.5.0

 Service:
If you need assistance, please call your local service center or
K-Tron (Switzerland)
Industrie Lenzhard Tel. (062) 885 71 71
CH-5702 Niederlenz, Fax (062) 885 71 80
K-Tron (U.S.A.)
Rt. 55 and Rt. 553 Tel. (856) 589 -9083
Pitman, NJ 08071, Fax (856) 589 - 5664
Web: http://www.ktron.com

Before you call, gather the following information…

« Do you have alarm displays? What are they exactly?
« Are you able to eliminate the cause of the alarm displays?
« Have you modified part of the system, product or operating mode?
« Have you tried to remedy the fault in accordance with the operating and
service instructions?
« Record the six digit project or job number located on the machine and
in the project manual.
– Example: 403214

Use of the manual:

« This arrow is used for identifying one-step actions or actions that have
no specific order.
1. Numbers in a list identify tasks that have sequences you have to follow.
V This icon indicates a general cautionary note.

Indicates an electrical hazard.

Reference to another manual section.

Marks helpful information.

Indicates that tools are needed for the task.

Specifies where information or a situation must be checked.

Indicates where power is applied or removed.

Don’t place hands or other body parts into machine.

Order no.: 0590020606-EN “K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part of
operating personnel. Further, reference is made to the purchase order, acceptance or other document that contains
the express K-Tron disclaimer of warranties for a statement of the provisions limiting or disclaiming certain warranties
Date:2007/06/06 with respect to the Company's equipment. Except as otherwise expressly provided by K-Tron in any such document,
K-TRON MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NOR
Document Change Notice: 799 ANY OTHER WARRANTY, EXPRESS OR IMPLIED, WITH RESPECT TO THE EQUIPMENT.”
If an error or ommission is found, please contact: documentation@ktron.com.
KIT Project No: 228, SW ver. 1.5
 Table of Contents

1 Safety Notes ...................................................................................................................... 1

1.1 Safety symbol definitions .................................................................................................... 1
1.1.1 Related safety/electrical icons ............................................................................................ 1
1.2 Proper use .......................................................................................................................... 2
1.3 Organizational measures .................................................................................................... 2
1.4 Operator responsibilities ..................................................................................................... 2
1.5 Safety-conscious operation ................................................................................................ 3
1.6 Safety devices .................................................................................................................... 3
1.7 High voltage ........................................................................................................................ 3
1.8 Additional equipment .......................................................................................................... 4
1.9 Removal from service ......................................................................................................... 4
1.10 Customer service and repairs ............................................................................................. 4
1.11 Warranty ............................................................................................................................. 4
1.12 Applied safety signs and placards ...................................................................................... 4
1.12.1 Selected safety signs on machines .................................................................................... 4

2 Loss in Weight Batcher (LWB) ........................................................................................ 5

2.0.1 Abbreviations and terminology ........................................................................................... 5
2.0.2 Document notation .............................................................................................................. 6
2.0.3 Additional programming information ................................................................................... 6
2.1 KSU-II/KCM-KD menu structure ......................................................................................... 6
2.2 KSL menu structure ............................................................................................................ 8
2.2.1 KSL Operator overview ....................................................................................................... 8
2.2.2 KSC operator interface ....................................................................................................... 9
2.3 K-Vision ............................................................................................................................ 11

3 Technical Data-Simplified .............................................................................................. 12

4 Switching the System ON and OFF ............................................................................... 13

4.0.1 Checks prior to first operation ........................................................................................... 13
4.1 Switching to ‘ON’ .............................................................................................................. 13
4.2 Switching to “OFF” ............................................................................................................ 14

5 START/STOP the Batching Process ............................................................................. 15

5.0.1 Starting the batcher .......................................................................................................... 15
5.0.2 Stopping the batcher ......................................................................................................... 15

6 Programming Reference ................................................................................................ 16

6.0.1 Menu and sub-menu listing ............................................................................................... 16
6.1 Operator’s overview .......................................................................................................... 17
6.1.1 General notation on programming menus ........................................................................ 18
6.2 Product Change menu ...................................................................................................... 19

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 1

6.2.1 Product Change sub-menu ............................................................................................... 19
6.2.2 Batch Set-up sub-menu ....................................................................................................21
6.3 Calibration ......................................................................................................................... 23
6.3.1 Calibration sub-menu ........................................................................................................ 23
6.3.2 Feedfactors sub-menu for motor driven feeders ............................................................... 26
6.3.3 Feedfactors sub-menu for vibratory feeders ..................................................................... 27
6.4 Alarm menu ....................................................................................................................... 28
6.4.1 Limits sub-menu ................................................................................................................ 28
6.4.2 Alarm setup sub-menu ...................................................................................................... 29
6.4.3 Alarm mode actions .......................................................................................................... 31
6.5 Tuning menu ..................................................................................................................... 32
6.5.1 Tuning parameters ............................................................................................................ 32
6.6 Feedfactor menu ............................................................................................................... 33
6.6.1 Feedfactor menu for motors .............................................................................................. 33
6.6.2 Feedfactor menu for vibratory feeders .............................................................................. 34
6.7 Refill Menu ........................................................................................................................ 35
6.7.1 Refill menu parameters ..................................................................................................... 35
6.8 Scale menu ....................................................................................................................... 37
6.8.1 General scale setup sub-menu ......................................................................................... 37
6.8.2 SFT Setup sub-menu ........................................................................................................ 38
6.8.3 Manual addressing of SFTs .............................................................................................. 39
6.9 Machine menu .................................................................................................................. 41
6.9.1 General Setup sub-menu .................................................................................................. 41
6.9.2 Changing feeder control application type .......................................................................... 42
6.9.3 KSU-II/KCM-KD screen saver description ........................................................................ 42
6.9.4 Motor sub-menu ................................................................................................................ 44
6.9.5 DC motor interface setup sub-menu ................................................................................. 44
6.9.6 AC motor interface setup sub-menu ................................................................................. 46
6.9.7 Vibratory drive motor setup sub-menu .............................................................................. 47
6.9.8 Universal stepper motor interface setup sub-menu .......................................................... 48
6.9.9 HiPo, LoPo Stepper motor interface setup sub-menu ...................................................... 49
6.9.10 Stepper motor programming table .................................................................................... 50
6.9.11 Service sub-menu ............................................................................................................. 51
6.9.12 Performance sub-menu ....................................................................................................52
6.10 I/O Menu ........................................................................................................................... 53
6.10.1 Digital input sub-menu ...................................................................................................... 53
6.10.2 Digital output sub-menu .................................................................................................... 55
6.10.3 Setpoint input sub-menu ................................................................................................... 56
6.10.4 Analog output sub-menu ................................................................................................... 57
6.10.5 Modbus I-O sub-menu ...................................................................................................... 59
6.10.6 Adding External Modbus I-O, an example ........................................................................ 60
6.11 Loader menu ..................................................................................................................... 61
6.11.1 Loader parameters ............................................................................................................ 61
6.12 HCU loader set-up ............................................................................................................ 62
6.13 System setup (only KSU-II/KCM). ..................................................................................... 64
6.13.1 Communication sub-menu ................................................................................................ 64
6.13.2 SW Version ....................................................................................................................... 65
6.13.3 Drive type by displayed MDU# .......................................................................................... 65

Page 2 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

6.13.4 Parameter Backup sub-menu ........................................................................................... 66
6.13.5 Changing the K-PROM password. .................................................................................... 66
6.14 Security menu (only KSU-II/KCM-KD) .............................................................................. 67
6.14.1 Security parameters .......................................................................................................... 67

7 Calibration ....................................................................................................................... 69

8 Other Programming ........................................................................................................ 70

8.1 Setting refill parameters .................................................................................................... 70
8.1.1 Setting the Refill Max value .............................................................................................. 70
8.1.2 Setting the Refill Min value ............................................................................................... 70
8.1.3 Setting the Post Refill Delay ............................................................................................. 70
8.1.4 Setting the Refill Timer ..................................................................................................... 71
8.2 Calibrating analog I-O ....................................................................................................... 71
8.3 Using an external motor drive ........................................................................................... 72
8.4 HP to watts conversion chart ............................................................................................ 72

9 Alarm Messages- Cause and Remedy .......................................................................... 73

9.1 System alarms .................................................................................................................. 73
9.2 LWB alarms ...................................................................................................................... 80
9.3 Display messages ............................................................................................................. 81
9.4 Batcher won’t start - displayed messages ........................................................................ 81
9.5 Batcher won’t run in GRAV ............................................................................................... 81
9.5.1 Batch fluctuations-LWB .................................................................................................... 82

10 Appendix ......................................................................................................................... 84
10.1 Special KCM LWF features .............................................................................................. 84
10.1.1 SFT Addressing ................................................................................................................ 84
10.1.2 Refill Algorithms for the KCM ............................................................................................ 85
10.1.3 Refill using the integrated loader function ......................................................................... 88
10.2 Programming the loader function ...................................................................................... 94
10.3 Programming parameters for HCU ................................................................................... 95
10.4 Drive status tables ............................................................................................................ 96
10.4.1 DC Drive hex status codes ............................................................................................... 96
10.4.2 Vibratory drive hex status codes ....................................................................................... 97
10.4.3 Stepper drive hex status codes ........................................................................................ 98
10.4.4 AC drive interface hex status codes ................................................................................. 99
10.5 SFT status table .............................................................................................................. 100
10.6 Service variables ............................................................................................................ 101
10.7 LWB PSR Map ................................................................................................................ 102
10.8 LWB ASR Map ................................................................................................................ 103
10.9 Parameter listing-LWB .................................................................................................... 109

11 INDEX ............................................................................................................................. 119

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 3

Page 4 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0
 Safety Notes 1
Safety symbol definitions 1.1

1 Safety Notes

Installation, commissioning and programming of the specified

equipment should only be undertaken by qualified personnel.

1.1 Safety symbol definitions

V This is the safety alert symbol. It is used to alert you to the potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

V CAUTION used without the safety alert symbol indicates a poten-

CAUTION tially hazardous situation which, if not avoided, may result in prop-
erty damage.

V CAUTION indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate personal injury.
! CAUTION

V WARNING indicates a potentially hazardous situation which, if not

! WARNING avoided, may result in death or serious personal injury.

V DANGER indicates an imminently hazardous situation, which if

! DANGER not avoided, will result in death or serious injury.

1.1.1 Related safety/electrical icons

This icon is used to indicate an electrical hazard. It is located on cov-

ers and doors. Only qualified personnel are allowed to remove these
covers or open the doors.

This symbol shows where an electrical ground or PE is to be placed.

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 1

1 Safety Notes
1.2 Proper use

1.2 Proper use

V Only operate the KCM in conjunction with the batcher equipment

from K-Tron.
V Only operate the KCM in accordance with the specified technical
data.
V Do not operate where there is a risk of explosion.
V Do not use the equipment in a manner not intended by the manu-
facturer.

1.3 Organizational measures

V Observe the safety notes for the connected feeding devices.

V In addition to the operating instructions, always comply with gen-
erally prescribed safety regulations governing accident prevention
and environmental safety.
V Always keep the metering device operating instructions within
easy reach. Ensure that they are always complete and legible.

1.4 Operator responsibilities

V Ensure that only qualified and trained personnel work with the
KCM.
V Establish personnel responsibilities for operation and mainte-
nance.
V Ensure that personnel have read and understood the operating in-
structions to all installation components, particularly these safety
notes.
V The operator must have damaged or missing components re-
placed immediately.
V The operator of the KCM is responsible for compliance with the le-
gally prescribed accident and safety regulations.

Page 2 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Safety Notes 1
Safety-conscious operation 1.5

1.5 Safety-conscious operation

V Any changes (including changes to operational behavior) which

affect safety must be immediately reported to the responsible
member of staff.
V Perform all operations with safety in mind.
V Do not make any internal adjustments to the KCM while the batch-
er is in operation.

1.6 Safety devices

V The electrical safety devices must not be altered. This increases

the danger of accidents.
V Never operate the KCM with the housing open.
V Replace damaged cables and connections immediately.
V Only operate the feeding equipment if all safety devices are in-
stalled and fully functional.
V Check that the safety devices on the KCM and on the feeding
equipment operate properly daily.
V Never open or remove covers or hoods while the feeding equip-
ment is in operation.
V If accessing KCM internal components, allow 3 minutes to lapse
prior to opening the enclosure. This ensures safe discharge of high
voltage components.

1.7 High voltage

Warning! Danger!
! DANGER V High voltage of 230 Vac may be present on the line power cables
of the KCM.
V Switch off the power to the KCM for 3 minutes before:
– any disassembly, maintenance and repair work
– replacing the motor.
V Only qualified technicians may work on the KCM.
V Protect the KCM against moisture entrance.

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 3

1 Safety Notes
1.8 Additional equipment

1.8 Additional equipment

V Modifications to the KCM are prohibited.

V The operator is responsible for complying with all safety regula-
tions related to operation with the feeding equipment.

1.9 Removal from service

V Disconnect the KCM from the power supply before removal from
service.
! CAUTION V The operator is responsible for the proper removal of the KCM
from service.

1.10 Customer service and repairs

V The KCM may only be repaired by

– your authorized K-Tron customer service center
or
– qualified personnel, trained by K-Tron.
V Only use original K-Tron parts for repairs.

1.11 Warranty

V See project specifications and sales agreements for warranty in-

formation.

1.12 Applied safety signs and placards

1.12.1 Selected safety signs on machines

Fig. 1.1 Power applied sign

Page 4 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Loss in Weight Batcher (LWB) 2
Applied safety signs and placards 1.12

2 Loss in Weight Batcher (LWB)

For operator instruction with safety notes, see separate operations

manual.
The following programming instructions covers LWB application pro-
gramming for the displays KSU-II/KCM-KD, KSL, 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-KD display. (Fig.2.1)

2.0.1 Abbreviations and terminology

• Config port = diagnostic serial data port from KCM
• CPU = central processing unit, microprocessor
• Drive-MDU = Common representation of all five types of drive pc
boards (450 watt DC drive, 1600 watt DC drive, AC drive interface,
stepper motor drive, vibratory drive)
• HCU = Hurricane pneumatic loader control
• Host Channel = serial data connection to remote host computer
• HSU = Hurricane pneumatic loader control programming interface
• HMI = human, machine interface, usually a PC utilizing a commer-
cial SCADA software package
• Internal Channel = serial data connection to SFTs/HCU loader con-
trols and internal motor drives
• KCM = K-Tron control module, the SmartConnex II integrated feed-
er controller
• KCM-KD = 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-Net = KCM serial data connection to KSU-II, KSL or KSC
• K-Port 1 and K-Port 2 = data ports for a K-Tron specific interface
• KSU-II = K-Tron single unit user interface for the KCM
• LWB = loss-in-weight batcher
• pcb = printed circuit board
• SCADA = supervisory, control and data acquisition system
• Smart Connex II = second version of SmartConnex architecture
• SFT = Smart Force Transducer

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 5

2 Loss in Weight Batcher (LWB)
2.1 KSU-II/KCM-KD menu structure

2.0.2 Document notation

The following is standard through out this document.

• Parameter name shown as <PARAM NAME> variable

• Parameter value shown as <Param Value> value
• Menu name as <MENU NAME> menu
• Alarm message as <Alarm Message> message
• Display indication or key action result as <INDICATION>.
• Dialog box indication as <Dialog>.
• Key or button as KEY

2.0.3 Additional programming information

0490020605 = KCM Electronics

0490020612 = KSU-II or KCM-KD LWB operation with calibration pro-
cedures
0590020614 = KSL LWB operation with calibration procedures
0490020612 = KSC LWB operation with calibration procedures
0490020614 = Smart Connex II Overview
0690020601 = KCM General PC Utilities
0690020607 = K-Vision LWB operation with calibration procedures

2.1 KSU-II/KCM-KD menu structure

SECURITY

SYSTEM

HCU LOADER

LOADER

NEXT I/O SET-UP

MACHINE SET-UP

C SCALE

REFILL

FEEDFACTOR

TUNING

ALARM

PRODUCT CHANGE

FDR BEING VIEWED

Fig. 2.1 KSU-II/KCM-KD LWB menu structure

The figure above shows the LWB menu structure that is used for con-
troller programming.

Page 6 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Loss in Weight Batcher (LWB) 2
KSU-II/KCM-KD menu structure 2.1

The operator overview home page shows the most important process
data.(Fig. 2.2)

TOTAL
AVG FF C
SCREW RPM
GRAV LOC LWB01 MOTOR RPM
BATCH SIZE 100.00 kg NET WEIGHT
BATCHED 89.99 kg DRIVE CMD
BATCHED % 89.99 % BATCHED %
BATCHED
BATCH SIZE

NEXT

Fig. 2.2 KSU-II/KCM-KD operator overview loop

Note:
Screw speed is shown only under certain conditions.

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 7

2 Loss in Weight Batcher (LWB)
2.2 KSL menu structure

2.2 KSL menu structure

For specific KSL programming instructions e.g. Line and System pro-
gramming see relevant instructions. (Fig.2.3)

HCU Loader
Loader
I-O
.10
Machine
.9
Scale Set-Up
.8
Refill
.7
Tuning
.6
Alarm Log
.11
Alarms
Feedfactor .5
.4
Product Change
.3
Overview
.2
.1
Menu X.0
F1

Machine
Main Menu
Overview
+
Product change MENU NR. E.g 1.1
Feedfactor
.. +
Selection

Fig. 2.3 KSL LWB programming menu structure

2.2.1 KSL Operator overview

With the Machine button, the application specific programming can be

accessed. (fig.2.4)
Note:
Machine To have Read/Write access to all KSL screens, set the KSL security
to level <3>.

Fig. 2.4 KSL batcher selection button

The overview screen for a typical application with the KSL is next.
(Fig.2.5)

Page 8 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Loss in Weight Batcher (LWB) 2
KSL menu structure 2.2

1 2 3 4 5
1 12/09/02 10:53:00 7 8 9
A N B O C P System
----------------- Overview KCMLWB M 5.0
Net weight: 120.000 kg 4
D Q
5
E R F S
6
Massflow 50.00 kg/hr
Batch Size: 50.000 kg
1
G T
2
H U
3
I V
Line

M
Delivered Weight : 40.000 kg
Motor Speed: 200 rpm
Totalizer:40.000 kg Batch %: 80%
0 .
K X
+/- C Machine
J W L Y M C
Ave. Feedf: 500 kg/hr
Drive Command: 10.000 %
A-M N-Z
VOL LOCAL DRIB
Menu Next Prev Next
More
page page feeder

F1 F2 F3 F4 F5 ESC

Fig. 2.5 KSL overview page for LWB

2.2.2 KSC operator interface

Using the KSC, K-Tron Smart Commander HMI PC based user inter-
face permits complex configurations to be implemented. Up to 30
batchers may be configured. For KCM applications, at least Version 4
KSC must be used.

Click on the Feeder icon button to call up the specific batcher.

(Fig.2.6)

Fig. 2.6 KSC batcher selection

For specific KSC programming instructions e.g. Line and System pro-
gramming see relevant instructions.

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 9

2 Loss in Weight Batcher (LWB)
2.2 KSL menu structure

Fig. 2.7 KSC LWB overview screen

The easy to use KSC interface allows simple batcher operation and
with trending and alarm reporting capabilities, permit historical sur-
veys. The menu layout is as shown using folder tabs as the menu rep-
resentation. (Fig.2.7)

Notes:
For information on the following: See section 2.0.3
• User interface operation; keypad and display function
• For feeder calibration
• LWF general operation
• Technical specifications for controllers and user interfaces

Page 10 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Loss in Weight Batcher (LWB) 2
K-Vision 2.3

2.3 K-Vision
Please review the operating manuals for K-Vision as screen layouts
are not necessarily the same as presented in this document, however
all KCM LWB programming parameters used in K-Vision are present-
ed in this manual.

Fig. 2.8 K-Vision

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 11

3 Technical Data-Simplified
2.3 K-Vision

3 Technical Data-Simplified

V See document 0490020605 for more detail on KCM electronics.

Specification Limitations Notations

Manufacturer K-Tron
Device name KCM batcher controller
Service application KCM must only be installed in an in-
dustrial or manufacturing power en-
vironment. Connection in a residen-
tial power system is not permitted.
Programming require- Either a KSU-II, a KCM-KD, a KSL- It is also possible to program the
ments V4 with BIOS version 2 or KSC-V4 controller via a PC connected to the
is required for programming the KCM config port. See document
KCM controller. 0490020605.

Page 12 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Switching the System ON and OFF 4
Switching to ‘ON’ 4.1

4 Switching the System ON and OFF

V Most programming will be done with the KCM in the stopped con-
dition. For certain tests, the batcher must be operating.

V Before switching the KCM on, ensure that no automatic refilling is

CAUTION being carried out and that all visible connections and equipment
are in order.

V Do not have any personnel in contact with moving portions of the

! WARNING feeding machinery as serious injury will occur when the machine
starts.

4.0.1 Checks prior to first operation

• Check to verify all machine safety guards are in place.
• Verify that material flow to each machine is OFF.
• Verify that all electrical connections are secure and correct.
• Verify that no person can come into contact with moving machine
parts when they are operational.
• Review all safety warnings prior to starting any machinery
• Provide all documentation and make it easily accessible prior to
starting equipment.

V For detailed operating instructions, use manual 0490020612 for

KSU-II or KCM-KD.

V For KSL operation, use manual 0590020614

4.1 Switching to ‘ON’

« Use the main switch to turn the system on.
On power-up, the user keypad and display shows data from the con-
nected KCM.
If alarms are present after powering the system, see Alarm section 9.
Check the status line:
– Setpoint mode: local, ratio, direct or line
– Operating mode - <GRAV/VOL>

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 13

4 Switching the System ON and OFF
4.2 Switching to “OFF”

1. Verify whether all the parameters of the selected operating mode

are displayed (refer to factory settings).

4.2 Switching to “OFF”

« Switch the batcher system OFF with the main switch.
« Verify all required programming is present.
Note:
Entered data will automatically be saved during power off time.

V Ensure that the refill system does not perform an unauthorized re-
fill.
! CAUTION

Page 14 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 START/STOP the Batching Process 5
Switching to “OFF” 4.2

5 START/STOP the Batching Process

V For detailed operating instructions, use manual 0490020612 for

KSU-II or KCM-KD.

V For KSL operation, use manual 0590020614.

V Before starting the batching process, make sure that no one is

! WARNING working on the batcher and that there are no foreign objects in the
batcher's hopper.
V Be sure that all safety devices are operating correctly.

V To run a batcher in Gravimetric control, bulk material must be in

the batcher.

5.0.1 Starting the batcher

1. Select the desired batcher to view.
2. Enter a setpoint value.
3. Press the GRAV/VOL key to set the controller to GRAV or VOL re-
spectively. Select GRAV to permit the batch to be completed with-
in the batch time.
4. Check and reset totalizer if necessary.
5. Press the RUN key.
Note:
• The RUN LED illuminates when the batcher motor is turning.

5.0.2 Stopping the batcher

1. Select the desired batcher to view.
2. Press the STOP key for the desired batcher.
Notes:
• The RUN LED blinks and the STOP LED goes on when the batcher
motor stops.
• If a refill has started, it will continue filling the batcher until the pro-
grammed maximum refill value is reached.

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6 Programming Reference
4.2 Switching to “OFF”

6 Programming Reference

The first parameter name (in CAPs) is for KSU-II/KCM-KD 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-KD. For KSL and KSC functions keys are used instead of com-
mand functions.
MF= massflow rate in kg/hr. or lb./min. or other units.

6.0.1 Menu and sub-menu listing

• Product Change menu

– Product Change sub-menu
– Batch Set-Up sub-menu
• Calibration menu
– Calibration sub-menu
– Feedfactor sub-menu
• Alarm menu
– Alarm limits sub-menu
– Alarm setup sub-menu
• Tuning menu
• Feedfactor menu
• Refill menu
• Scale menu
– General scale sub-menu
– SFT setup sub-menu
• Machine
– General sub-menu
– Motor sub-menu
– Service sub-menu
– Performance sub-menu
• 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 is connected
• HCU Loader menu-appears when HCU is connected to KCM

Page 16 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Programming Reference 6
Operator’s overview 6.1

• System menu
– Communications sub-menu
– SW Versions sub-menu
– Parameter Backup sub-menu
• Security menu

6.1 Operator’s overview

The overview loop for KSU-II/KCM-KD or page for KSL or KSC shows
the most important process data.

Parameter Definition

BAT SIZE Current setpoint value in set units or percentage of an incoming sig-
nal. Ratio SP is only displayed if parameter Setpoint Mode is set to
Ratio.
Batch Size Input range: 0 to MaxBatchSize. Note: units set by Units variable in
the Machine menu.

BATCHED Display the current amount batched in weight units during the current
run.
Input range: Display only.
Delivered Weight
BATCH% Display the current amount batched in percent of Batch Size during
the current run.Input range: Display only.

Batch%
DRIVE CMD-[%] Current level of the drive-command output in percentage. It defines
the motor velocity or vibratory tray displacement.
Drive Command
Input range: Display only, 0-125%

NET WEIGHT Current net weight on the scale.

Net Weight Input range: Display only

MOTOR RPM Current speed of the motor.

Motor Speed Input range: Display only

DISPLACE Displacement of the vibratory batcher tray in µM.

Input range: Display only for vibratory batchers
Displacement
SCREW RPM Shows the current screw speed in rpm, when the <GEAR REDUC-
TION> in the MACHINE Menu, MOTOR Submenu > 1.0.

Screw Speed
Table page 1 of 2

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6 Programming Reference
6.1 Operator’s overview

Parameter Definition

AVG FF This value, by definition, is the estimated mass flow rate expected at
100% drive command. In conjunction with setpoint, this value deter-
Average Feedf or Aver- mines the motor speed/vibratory displacement when in volumetric
age Feedfactor control mode.
Input range: Display only

TOTAL Discharged product quantity.

Totalizer This value can be reset to zero by pressing function key or entering
Zero.

« Press key for KSU-II/KCM-KD.Then enter <0>. If locked

see section 6.14.

« Press for KSL.

« Press for KSC.

Input range: 0 to 999999 weight units. Overflow will be displayed as

#### on the KSU-II/KCM or ????? on the KSC.
Table page 2 of 2

6.1.1 General notation on programming menus

KSL and KSC menu parameters are shown as <Post Refill Delay>.
KSU-II/KCM-KD menu parameters are shown as <MASSFLOW>.
KSU-II/KCM-KD key commands are shown as RUN.

Page 18 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Programming Reference 6
Product Change menu 6.2

6.2 Product Change menu

The Product Change sub-menu allows easy product changeover.
The Batch Set-Up sub-menu configures the batching program.

6.2.1 Product Change sub-menu

Parameter Definition

REFILL ENABLED Setting for continuous feeding and automatic refill. The
net weight alarm limit is active.
DISABLED The batcher hopper can be emptied without refilling be-
Refill Enable
ing triggered. The net weight alarm limit is disabled.
IF RUNNING If Running is selected, Refill is enabled if the batcher
runs, otherwise it is disabled.
Default: DISABLED

REFILL MAX. Input of the upper refilling limit at which refilling is stopped.
Warning:
Refill Level Maximum Do not exceed the hopper capacity or scale capacity when entering
the top refilling limit. See section 8.1.1.
Input range: <0.95 x Gross scale range
Default: 0.06 kg

REFILL MIN Input of the lower refilling limit at which refilling is started.
Warning:
Refill Level Minimum Feeding behavior can be affected if the refilling limit is set too low.
Do not uncover batcher’s horizontal agitator. See section 8.1.2.
Input range: < Refill Maximum
Default: 0.05 kg
Table page 1 of 3

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6 Programming Reference
6.2 Product Change menu

Parameter Definition

AUTO FF CALIB This action permits easy batcher calibration. For this the program pa-
rameter <CAL DC> and <CAL TIME> have to be entered. Material is
discharged for the value of <CAL TIME> and the starting feeding fac-
tor is calculated.
Notes:
• Calibration can be canceled with STOP.
• Pressing ENTER instead of RUN as noted above will abort the
AUTOFFCALIB routine and return the user to the HOME menu.
• Performing an AUTOFFCALIB function on an already running
batcher will have no effect upon operation.

! WARNING V This command will start the batcher. Make sure that nobody is
working on the machine.

« For KSU-II/KCM-KD select this parameter, press ENTER

twice and then RUN

« For KSL press MORE-F5 then then START key.

« For KSC press

Attention:
Refilling and feeding errors during calibration reset the program pa-
rameter FF INIT to <0> and activate the <FEEDFACTOR ERR>
alarm.

INIT FF Input of the starting feeding factor to determine the motor speed. The
Drive Command is calculated as follows:

Initial Feedfactor
DriveCommand(%) = 100 x (Setpoint/Initial Feedfactor)

The starting feed factor can also be calculated with the command
variable <AUTO FF CALIB>. Value of <0> will cause a Feedfactor
Alarm.
The batcher will not run with a Feedfactor of <0>.
Input range: 0 to 99999 Default: 100 kg/hr
Table page 2 of 3

Page 20 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Programming Reference 6
Product Change menu 6.2

Parameter Definition

EMPTY FDR Empty batcher function. When started, the batcher runs at a drive
command of 75%. The batcher stops automatically if no weight loss
is detected.
Note:
<Empty Drive Cmd> may be changed by the Service Variables.

V This command will start the batcher. Make sure that nobody is
! CAUTION working on the machine.

« Select EMPTY FDR, then press ENTER twice then RUN

key.

« For KSL press MORE-F5- then then press RUN.

« For KSC, press the key then the RUN.

Notes:
• The <EMPTY FDR> action can be halted with the STOP key.
• The Net Weight Low alarm is also generated when the Empty Fdr
cycle finishes.
Table page 3 of 3

6.2.2 Batch Set-up sub-menu

This menu sets batch specific parameters.

Parameter Definition

FAST DC-[%] Sets the drive command value to be used during the main portion of
the batch.
Fast Drive Command
Input range: >0% to 100%, Default: 80%

DRIB DC-[%] Sets the drive command value to be used during the dribble portion
of the batch.
Dribble Drive Command
Input range: 0% to 100%, Default: 20%

Table page 1 of 2

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6 Programming Reference
6.2 Product Change menu

Parameter Definition

BATCH TIME-[sec] Sets the desired batch time in seconds. Includes the Dribble time.
When GRAV mode is used, batch time will be achieved for a given
Batch Time batch assuming a FF Calibration was first completed.
Input range: 0 to 99999999 seconds Default: 0 seconds.
Note: the practical minimum batch time is 10 seconds.

DRIB TIME-[sec] Sets the desired dribble time in seconds.

Dribble Time Input range: 0 to 99999999 seconds Default: 5 seconds

MAX BAT SIZE This value sets the maximum value for Batch Size setpoint in weight
units.
Maximum Batch Size
Input range: 0 to 9999999, Default: 0.

BATCH COUNT This is a running count of delivered batches. Enter a <0> to clear the
count.
Batch Count
Input range: 0 to 9999999 Default: 0
Table page 2 of 2

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 Programming Reference 6
Calibration 6.3

6.3 Calibration
Use the FF Calibration menu to perform feeder calibration. See sec-
tion 2.0.3 for documents to be used specifically when calibrating the
feeder.
Notes:
• Section 6.3.1 is for motor driven feeders
• Section 6.3.2 is for vibratory feeders

6.3.1 Calibration sub-menu

Parameter Definition

INIT FF Input of the starting feeding factor to determine the motor speed. The
Drive Command is calculated as follows: (not for vibratory feeders).
Initial Feedfactor
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 28. The batcher will not run with a Feedfactor of <0>.
<INIT FF> not shown for vibratory control.
Input range: 0 to 99999
Default: 100 kg/hr

AVG FF The value shows the estimated mass flow value expected at 100%
drive command and is calculated as:

Average Feedfactor
AverageFeedfactor = 100 x (Massflow/DriveCommand(%)

Average Feedfactor represents the massflow capacity of the feeder

and is affected by bulk material characteristics and the current feed-
er mechanical configuration.
Notes:
• The batcher will not run with a Feedfactor of <0>.
• This value is not calculated for vibratory feeders.
Input range: Display only
Table page 1 of 3

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6 Programming Reference
6.3 Calibration

Parameter Definition

AUTO FF CALIB This action permits easy feeder calibration. For this the program pa-
rameter <CAL DC> and <CAL TIME> have to be entered. Material is
discharged for the value of <CAL TIME> and the starting feeding fac-
tor is calculated.
Notes:
• Calibration can be canceled with STOP.
• Pressing ENTER instead of RUN as noted above will abort the
AUTOFFCALIB routine and return the user to the HOME menu.
• Performing an AUTOFFCALIB function on an already running
feeder will have no effect upon operation.
V This command will start the feeder. Make sure that nobody is
working on the machine.

! CAUTION « For KSU-II/KCM-KD 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 Shows the amount of material discharged during calibration cycle as
calculated by the controller.
Calibrate Product Fed
Input range: Display only in set units

ACT PROD FED After the Feedfactor test has been completed, enter the weight of the
actual delivered product in this variable. The <SPAN> in the CALI-
BRATION Menu will be automatically calculated.
Actual Product Fed
If you wish to calculate the <SPAN> manually, just ignore this entry
and proceed to the SCALE Menu, GENERAL SCALE Sub-menu and
enter the computed span there.
Table page 2 of 3

Page 24 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Programming Reference 6
Calibration 6.3

Parameter Definition

SPAN This is the weight span and it is automatically calculated when an en-
try is made to the <ACT. PROD FED> variable. This is the value that
corrects for massflow inaccuracy. For feeding, the span must be
Weight Span nearly 1.000 or there is a problem with the weighing system. This val-
ue is ‘read only’.
If you wish to calculate the <SPAN> manually, just ignore this entry
and proceed to the SCALE Menu, GENERAL SCALE Sub-menu and
enter the computed span there.
Default: 1.000

CAL CORRELA-[%] Will be automatically calculated during calibration. The value shows
the reliability of the calibration data. A value of 100% means that the
Calibrate Correlation
weight samples taken during calibration are extremely uniform indi-
Note: cating smooth product discharge and no weight disturbances.
Not used for vibratory feeders Input range: Display only [%]

CAL CORR LIM-[%] If the <CALIB CORRELATION> is below this limit value the feedfac-
tor will be set to <0>, the calibration test aborted and a Feedfactor
Calibrate Corr Limit Alarm will be generated.
Note: Note:
Not used for vibratory feeders This value self-adjusts after each completed calibration cycle.
Input range: 0 to 100% Default: 80%

CAL DC-[%] Drive command used during the auto calibration cycle.
Calibrate Drive Cmd
Input range: 0 to 100% Default: 10%
Note:
Not used for vibratory feeders

CALIB TIME-[sec] Input of the duration of the automatic calibration cycle.

Calibrate Time
Input range: 15-999 seconds Default: 30 seconds
Note:
Not used for vibratory feeders
Table page 3 of 3

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6 Programming Reference
6.3 Calibration

6.3.2 Feedfactors sub-menu for motor driven feeders

Parameter Definition

INIT FF Input of the starting feeding factor to determine the motor speed. The
Drive Command is calculated as follows: (not for vibratory batchers).
Initial Feedfactor
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 28. The batcher will not run with a Feedfactor of <0>.
<INIT FF> not shown for vibratory control.
Input range: 0 to 99999
Default: 100 kg/hr

AVG FF The value shows the estimated mass flow value expected at 100%
drive command and is calculated as:

Average Feedfactor
AverageFeedfactor = 100 x (Massflow/DriveCommand(%)

Average Feedfactor represents the massflow capacity of the batcher

and is affected by bulk material characteristics and the current feed-
er mechanical configuration.
Notes:
• The batcher will not run with a Feedfactor of <0>.
• This value is not calculated for vibratory batchers.
Input range: Display only

Page 26 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Programming Reference 6
Calibration 6.3

6.3.3 Feedfactors sub-menu for vibratory feeders

Parameter Definition

MF @ 8% DC These individual values are calculated automatically by the function

<AUTO FF CALIB>.
When the setpoint change exceeds the <SEPT CHG LIM>, the con-
Vibratory FF 8%
troller switches to using the appropriate MF value at the Drive Com-
mand expected.
MF @ 12% DC

Vibratory 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%

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6 Programming Reference
6.4 Alarm menu

6.4 Alarm menu

This menu sets the alarm parameters and limits.
Note:
Any alarm that is set in percent, is disabled when the entry is <0>.

6.4.1 Limits sub-menu

Parameter Definition

BATCH TOL-[%] The batch tolerance alarm is triggered when the final batch delivery
value is greater or less than the Batch Size Setpoint by the entered
Batch Tolerance
value - in percent.
Enter <0> to turn the alarm off.
Input range:.0 to 100%Default:0%

FF DEV LIMIT-[%] Maximum permissible difference between the AVG FF (Average

Feedfactor) and the INIT FF (Initial Feedfactor). Not for vibratory
Feedfactor Deviation
feeders.
Limit
Enter <0> to turn the alarm off.
Input range:0 to 100% Default:0%

MAX REFILL TIME-[sec] Input of the maximum refilling time.

Refill Time Max. If the top refilling limit is not reached when this time has passed, an
alarm will be triggered.
See also Variable TIMER OPTION page.
Input range:5 to 9999 seconds.Default: 30 seconds.

NW LO LIMIT Min. product level at which an alarm is immediately triggered. This

parameter is only active if Refill is Enabled.
Net Weight Low Limit
Input range:0 to < REFILL MIN. Default: 0.1 kg

NW HI LIMIT Max. product level at which an alarm is immediately triggered.

Net Weight High Limit Input range:0 to scale range. Default: 0 kg = no alarm.

BAT TIME GRACE-[sec] The Batch Time Grace interval in seconds plus the entered Batch
Time if exceeded while running a batch, will generate an alarm for
Batch Time Grace
exceeding the batch time.
Input range:0 to 9999999 Default: =0

Page 28 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Programming Reference 6
Alarm menu 6.4

6.4.2 Alarm setup sub-menu

Parameter Definition

ALARM DELAY-[sec] Time between the alarm detection and activation of the alarm relay
output when the alarm is of the type <Timed> or <Timed-Stop>. The
Alarm Delay alarm output will not be activated and the alarm will be cancelled if
the fault is corrected within this time period.
Input range: 0 to 999 seconds Default: 30 seconds.

STARTUP DELAY-[sec] Time during which process related alarm signals are suppressed
when the machine is being started up. See section 6.4.1.
Startup Delay
e.g. Massflow High error is suppressed.
Input range: 0 to 999 seconds Default: 60 seconds.

STOP CLRS ALARM Select <Yes> if alarms are to be cleared when a stop occurs. Select
<No> if alarms are not to be cleared during a Stop action.

Clear Alarm on Stops

Default: No

ALR Input of the alarm number, which can be selected from the list in the
appendix. With the programming variable ALARM MODE the select-
Number of Selected
ed alarm number can be influenced.
Alarm Input range: See section 9.2.

ALR Shows the alarm function for the selected alarm number.

Name of Selected Alarm

ALARM MODE The selected alarm at the variable Alarm number can be influenced
as follows:
Selected Alarm Mode
Setting Definition
IGNORE Alarm will be ignored.
IMMED Alarm will be activated immediately but ALS output
will not change.
IMMED-STOP Alarm will be activated immediately and ALS out-
put switches ON.
TIMED Alarm will be activated after entered startup up-
and alarm delays but ALS output will not change.
TIMED-STOP Alarm will be activated after entered startup and
alarm delays and ALS output switches ON.

Selection will depend upon the action desired. See section 6.4.3 for
additional information.

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6 Programming Reference
6.4 Alarm menu

Parameter Definition

STOP BY This message displays what caused the KCM to last stop.
Note:
Feeder Stopped By The KSL will display this data on the Alarm Log screen.

• Board reset: KCM CPU was shutdown

• Local display: KSU-II/KCM-KD stop key pressed
• External display: KSL or KSC stop key pressed
• ALS Input: Alarm shutdown input caused the stop
• Run Disable: Run Enable input caused the stop
• Stop input: External bit input stop function
• MDU DISA: Drive disabled stopping the output
• Zero SP: The setpoint went to zero while the machine was running
• Emptying: The emptying function, when complete, causes the
KCM drive to stop
• Interlock: The interlock input prevents the KCM from running
• Calib: Machine has stopped after completing a calibration cycle
• Tare: Machine has stopped after completing a tare cycle
• Batch Complete: Machine has stopped after completing a batch
• Batch Pause: Machine has been paused during a batch but the
batch is not yet complete

Page 30 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Programming Reference 6
Alarm menu 6.4

6.4.3 Alarm mode actions

V The following chart is important in that it describes the functions of

controller outputs and display LEDs under differing alarm condi-
tions. These actions are different than other K-Tron controllers.

Notes:
• Alarm Relay is On for no alarm (fail-safe).
• For Alarm Stop to actually stop the machine, the Alarm shutdown
output must be wired to the Alarm Shutdown input. See document
0490020605 for details.

Alarm Mode Alarm Alarm LED ALS Digital Alarm Relay ASR Bit
Display Output

Ignore Off Off Off On On

Alarm - On On-blinking Off Off On
Immediate
Alarm - Timed On On-steady during Off Off after On
time-out time-out
On-blinking after
time-out
Alarm Stop - On On-blinking On Off On
Immediate
Alarm Stop - On On-steady during On after Off after On
Timed time-out time-out time-out
On-blinking after
time-out

Table: 1 Alarm
mode
function

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6 Programming Reference
6.5 Tuning menu

6.5 Tuning menu

This menu programs the tuning and control parameters for the appli-
cation.

6.5.1 Tuning parameters

Parameter Definition

CTRL GAIN The motor amplification factor determines the control signal for the
motor controller. A value of 5% is ideal for most batching applica-
Motor Control Gain
tions.
Setting Reaction Consequence
Large value 30 Control aggressive Risk of oscillations great.
Small value 5 Control less active Risk of oscillations low.
Input range: 0 to 100% Default: 5%

ADAPTIVE TUNE Switches automatic parameter setting of SAMPLE TIME and ADAPT
GAIN <ON> or <OFF>.
Adaptive Tuning ON is recommended!
Input range:.ON or OFF Default:ON

STOP PERT This threshold value is in grams of weight. When the batcher is
stopped, and when the net weight deviation is greater than the Pert
Pert Thresh Fdr Stopped
Stop Threshold, a perturbation will be detected. This is helpful when
unannounced refills occur.
Input range: Read only: in grams. Default: 1.9

STABLE WT CNT Number of stable weight readings after dribble that are required for
batch complete. This value is related to PERT STOP variable.
Stable Weight Counts
Input range:0 to 999999 Default: = 4

PREACT WGT Preact weight is the amount of expected batch overshoot whereby
the controller can stop the batch by this amount prior to batch com-
plete to minimize batch overshoot. Normally this number is small.
Preact Weight
Input range:0 to scale range Default: = 0

SAMPLE TIME [ms]) Setting of the SFTs' measuring cycle in milliseconds. The weight loss
is measured using this time interval during batching. When the
Weight Sample Time [ms] <ADAPTIVE TUNE> is <On>, this value is automatically set. This
value can only be manually set when <ADAPTIVE TUNE> is <Off>.
Input range:80 to 5040 msec. Default: 160 msec.

POST BAT JOGS If enabled, the batcher will jog to bring the batched weight up to the
batch size setpoint if the batch stopped below the low tolerance limit.
Enable/Disable Jogs
Input range:ON or OFF Default: OFF

Page 32 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Programming Reference 6
Feedfactor menu 6.6

6.6 Feedfactor menu

Use the FF Calibration menu to perform batcher calibration.
Notes:
• Section 6.3.1 is for motor driven batchers
• Section 6.3.2 is for vibratory batchers

6.6.1 Feedfactor menu for motors

Parameter Definition

INIT FF Input of the starting feeding factor to determine the motor speed. The
Drive Command is calculated as follows: (not for vibratory batchers).
Initial Feedfactor
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 28. The batcher will not run with a Feedfactor of <0>.
<INIT FF> not shown for vibratory control.
Input range: 0 to 99999
Default: 100 kg/hr

AVG FF The value shows the estimated mass flow value expected at 100%
drive command and is calculated as:

Average Feedfactor
AverageFeedfactor = 100 x (Massflow/DriveCommand(%)

Average Feedfactor represents the massflow capacity of the batcher

and is affected by bulk material characteristics and the current feed-
er mechanical configuration.
Notes:
• The batcher will not run with a Feedfactor of <0>.
• This value is not calculated for vibratory batchers.
Input range: Display only

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 33

6 Programming Reference
6.6 Feedfactor menu

6.6.2 Feedfactor menu for vibratory feeders

Parameter Definition

MF @ 8% DC These individual values are calculated automatically by the function

<AUTO FF CALIB>.
When the setpoint change exceeds the <SEPT CHG LIM>, the con-
Vibratory FF 8%
troller switches to using the appropriate MF value at the Drive Com-
mand expected.
MF @ 12% DC

Vibratory 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%

Page 34 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Programming Reference 6
Refill Menu 6.7

6.7 Refill Menu

This menu allows easy refill set-up.

6.7.1 Refill menu parameters

Parameter Definition

REFILL Enabled Setting for continuous feeding and automatic refill. The
net weight alarm limit is active.
Disabled The batcher hopper can be emptied without refilling be-
Refill or Refill Enable
ing triggered. The net weight alarm limit is disabled.
If Running If <Running> is selected, refill is only enabled when the
batcher runs, otherwise it is disabled.
Default: Disabled

REFILL MAX. Input of the upper refilling limit at which refilling is stopped.
Warning:
Refill Level Maximum Do not exceed the hopper capacity or scale capacity when entering
the top refilling limit. See section 8.1.1.
Input range: < 0.95 x Gross scale Default: 0.06 kg

REFILL MIN Input of the lower refilling limit at which refilling is started.
Warning:
Refill Level Minimum Feeding behavior can be affected if the refilling limit is set too low.
Do not uncover batcher horizontal agitator. See section 8.1.2.
Input range: < Refill Maximum Default: 0.05 kg

POST REFILL DELAY Delay time before the batcher switches back to gravimetric mode af-
ter refilling. See section 8.1.3.
Input range: 0 to 60 seconds Default: 10 sec.
Post Refill Vol/Grav Delay
REFILL Select when to allow a refill. Options are:
Undefined, After Batch, Pause Batch, During Batch.
Batch Refill Control Default: After Batch

REFILLMODE Selections: Auto, Man, AutoTerm

This entry controls how the refill is executed and particularly what oc-
curs if a refill failure happens.
Refill Mode
Use <Auto> for automatic refill systems else use <Man> for LWB
hoppers that are refilled by hand.
AutoTerminate allows the refill device to shut off if a refill fails.
See section 10.1 for more information.
Default: Auto_Terminate
Table page 1 of 2

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6 Programming Reference
6.7 Refill Menu

Parameter Definition

FLT CLEAR TIM 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 Loaders.
Filter Clear Time
Input range: 100-9999 msec. Default: 1000 msec.
Table page 2 of 2

Page 36 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Programming Reference 6
Scale menu 6.8

6.8 Scale menu

This menu programs the scale parameters and SFT operation in two
separate menus/screens.

6.8.1 General scale setup sub-menu

Parameter Definition

TARE Weight of the batcher and hopper with no material. This value will set
automatically when Auto Tare function is executed.
Tare Weight
Input range: 0 to scale range [kg]

AUTO TARE This command allows the current weight value to be entered into the
TARE memory when the product hopper is empty.

« For KSU-II/KCM select parameter then press

« For KSL press F5-MORE then

« For KSC press

SPAN Input of the span correction factor for fine compensation of mechan-
ical scale weighing errors. This value may automatically change if
the Auto Span feature is used in the CALIBRATION menu.
Weight Span
Input range: 0.4 to 2.5 Default: 1.000

NET WEIGHT Display of the current weight of the feeding material on the scale.
Net Weight Net weight = Gross Weight - Tare
Range: Display only 0 to scale range [kg]

GROSS WEIGHT Display of the current total weight of the batcher and feeding material
on the scale.
Gross Weight
Range: Display only, 0 to scale range [kg]

SCALE RANGE Input of the scale's nominal capacity.This value will be read automat-
ically from the connected load cell (s). If an mechanical reduction is
Scale Range
used (e.g. B3 weighing bridges) enter the new weighing range.
Note:
To change this value, units must be <kg/hr> or <kg/min>.
Input range: Normal Display only [kg] or 1 to 999999 kg

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6 Programming Reference
6.8 Scale menu

6.8.2 SFT Setup sub-menu

SFT REQUIRED Input of the number of connected SFTs.

Number of SFTs Re- Input <1> for single point weighing system e.g. SFS 24 or D5 scale
or <3> for a three SFT weighing system.
quired
Input range: 0 to 6

REPOLL This command will cause the controller to execute a poll on the
weight channel to locate connected and operational SFTs by ad-
dress.

« For KSU-II/KCM-KD select this parameter and press twice.

« For KSL press

« For KSC press

AUTO READDRESS This parameter allows SFTs to be auto-readdressed automatically.

See section 10.1.1 for more information.

« For KSU-II/KCM, press key for KSU-II/KCM.

SFTs The addresses and error signals of the connected weighing cells are
displayed.Typically the parameter will appear as:
<-1-------D> or <-123-----D>.
SFT Configuration
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 address
t =SFT no longer responds. Weight channel data communication fail-
ure
f =Internal failure in the SFT, replace SFT
For a new initialization of the display press ENTER twice at the vari-
able <REPOLL>.
Address <D> that is shown in the SFT configuration is the KCM drive
address.
If an HCU is present, in KCM SW version 1.3 and later, address <E>
will be displayed.
Input range: Display only
Table page 1 of 2

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 Programming Reference 6
Scale menu 6.8

SFT SELECTED Selects the SFT to query parameters:

Node # Of Selected SFT SFT #, SFT SN#, SFT ADDRESSED, SFT WEIGHT, SFT TYPE,
SFT STATUS.
Input range: 0 to 11

SFT ADDRESSED Switching <Off> will address the selected SFT to <0>.
SFT Addressed Switching <On> sets the SFT address selected in the SFT SELECT-
ED program parameter if there is an available spare SFT.
Input range: On or Off

SFT WEIGHT Displays the current gross weight on the selected SFT.
SFT Weight Input range: Display only

SFT TYPE Displays the type of the selected SFT.

SFT Type Input range: Display only

SFT STATUS SFT error display. The <Process Status Word> of the selected
weighing module is displayed. Any status word except 00000183 or
SFT Status
00000181 indicate SFT failures.
Input range: Display only see chapter (10.5)

SFT # Display of the software version of the selected SFT.

SFT Software or SFT Input range: Display only
Board SW Rev
SFT SN # Reports the serial number of the selected SFT.

SFT Serial # (Number)

SFT TEMPERATURE Indicates the SFT’s internal temperature, in degrees Celsius, of the
selected SFT, if the SFT software supports this display parameter.

SFT Temperature
Table page 2 of 2

6.8.3 Manual addressing of SFTs

To set the address of a newly installed SFT to a prescribed address,
follow the next procedure.
1. Select SCALE menu, SFT sub-menu.
2. View SFTs variable to verify the SFT in question is at address <0>.
3. Select <SFT SELECTED>.
4. Enter the new SFT address.
5. Select <SFT ADDRESSED>.

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6 Programming Reference
6.8 Scale menu

6. Select <On>.
7. View SFTs variable to verify the SFT is now at the desired ad-
dress.
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 variable to verify the SFT address is now <0>.
8. Select <SFT SELECTED>.
9. Enter new SFT address.
10. Select <SFT ADDRESSED>.
11. Select <On>.
12. View SFTs variable to verify the SFT is now at the desired ad-
dress.

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 Programming Reference 6
Machine menu 6.9

6.9 Machine menu

This menu programs the batcher specific information. The data is ar-
ranged in three separate screens or menus.

6.9.1 General Setup sub-menu

SETPOINT MODE Setting Meaning

Setpoint Mode LOCAL Batcher is operated as an individual unit.
RATIO Percentage of an external analog setpoint input =
operating setpoint.
DIRECT External analog setpoint input = operating setpoint.
LINE1-8 Batcher Setpoint is entered from the Line overview
Page. In this mode the batcher is assigned to a
line. It's called recipe mode. Use Line1 for KSL.
Input range: See list Default Local

UNITS Selection of the desired units.

Units Selection Note:
This selection change automatically all weight specific units.
Setup:
kg/h, kg/min, lb/h, lb/min, T/h (metr. Ton), ET/h (engl. Ton), gr/h, gr/
min.
Input range: See list Default kg/h

RUN TIME-[hours] Display of the total run time in hours. A value may be entered as a
baseline.
Feeder Run Time
Input range: Normal Display only

FDR ADDR Address of the selected KCM.

Note:
Feeder Number • If the KCM CPU DIP switch, positions <1> to <5> are all set to <0>,
then the feeder address is set by this entry, else it is from the DIP
switch and then this parameter is ‘read only’.

APPLICATION Input of the connected batcher type:

Selection:
KCM_LWF, KCM_WBF, KCM_SFM, KCM_LWB, KCM_PID,
Control Type KCM_VOL
Input range: See list Default KCM_LWB for LWB

LANGUAGE Selects the desired language for the KSU. Choices are English, Ger-
man, French, Spanish and Italian.
Table page 1 of 2

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6 Programming Reference
6.9 Machine menu

SCREEN SAVER When set to <On> activates the KSU-II and KCM/KD screen saver
function.
Input range: On or Off Default: On
Only in KSU-II/KCM-KD

Feeder Name Enter batcher name at KSL only.

Only for KSL

Table page 2 of 2

Note:
• Other control application types may be displayed, but are not yet
active and selectable.

6.9.2 Changing feeder control application type

To change the feeder from one application type to another, perform
the following procedure.
1. Select <APPLICATION>
2. With NEXT, select the desired new application like <WBF>.
3. Press ENTER.
4. Press ENTER again or wait for the parameter <APPLICATION> to
again appear.
5. Select <Confirm>
6. Press ENTER to load new application.

6.9.3 KSU-II/KCM-KD screen saver description

The screen saver is used to protect the screen from burning out when
always the same data is shown. The screen saver is based on the pa-
rameter <MACHINE SETUP> menu, <GENERAL> sub-menu,
<SCREEN SAVER> parameter to <On/Off>. The value On or Off is
held in the KSU-II EEPROM. This allows to program each KSU-II in-
dividually to have the screen saver on or off. The default value is On.
The screen saver functions as follows:
1. After setting 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 saver char-
acter (all pixels on) moves smoothly through each character posi-
tion line by line. When it reaches the last character position it re-
starts on the first top left position.

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 Programming Reference 6
Machine menu 6.9

4. When the screen saver is in state 2 or 3 above, any key entered in

the keypad will restore the screen to the normal brightness and
screen data. The 12 hour timer restarts.

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6 Programming Reference
6.9 Machine menu

6.9.4 Motor sub-menu

The motor sub-menu is shown for four types of drives.
• DC drives for 450 and 1600 watts
• AC interface drive
• Vibratory drive
• Stepper motor drive in three versions
All DC drives are identified in this section by ‘MDU’ 450W and 1600W
DC motor setup sub-menu

6.9.5 DC motor interface setup sub-menu

Some parameters will not be displayed for every drive case. This sec-
tion is used for DC motor driven feeders when the 450W or 1600 W
DC motor drive is installed.

Parameter Definition

GEAR REDUC This entry must be the total reduction value between the drive motor
and the feed screw. When the entry is equal to the specified reduc-
tion, screw speed is shown in the variable <SCREW RPM>.
Gear Reduction or Total
Input range: 0 to 999 Default: 0
Gear Reduction
PICK UP TEETH Input of the number of teeth on the pick up gear.
Speed Pickup Teeth This gear is used for measuring the speed.
Input range: 0 to 9999
Default: 120 for DC drive, 400 for stepper drive

ACTUAL POWER-[watts] Displays the actual consumed motor power.

Actual Motor Power Input range: Display only [W]

MAX. MOT POWER- This entry sets the maximum output power to the motor when using
the internal KCM DC motor drive.(See nameplate on DC motor for
[watts]
value)
Max Motor Power Input range: 25 to 1600 W Default: Depends upon installed drive

MAX MOT VOLTAGE This entry sets the maximum output voltage to the motor when using
the internal KCM DC motor drive. (See nameplate on DC motor for
value)
Motor Voltage
Input range: 90 to 220 Vdc Default: 180 Vdc

MAX MOT SPEED-[rpm] Input of the maximum motor rpm for 100% drive command.
Input range: Drive specific. Default: drive specific
Maximum Motor Speed (See nameplate on DC motor for value)

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 Programming Reference 6
Machine menu 6.9

Parameter Definition

MDU STATUS The MDU status codes reveal operational condition of the Drive. See
listing of MDU status codes in document 0490020605. Also listed in
the Appendix. See section 10.4.1.
MDU Status

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6 Programming Reference
6.9 Machine menu

6.9.6 AC motor interface setup sub-menu

Some parameters will not be displayed for every drive case. This sec-
tion is used for AC motor driven feeders when the AC Drive Interface
is installed.

Parameter Definition

GEAR REDUC This entry must be the total reduction value between the drive motor
and the feed screw. When the entry is equal to the specified reduc-
tion, screw speed is shown in the variable <SCREW RPM>.
Gear Reduction or Total
Input range: 0 to 999 Default: 0
Gear Reduction
PICK UP TEETH Input of the number of teeth on the pick up gear.
Speed Pickup Teeth This gear is used for measuring the speed.
Input range: 0 to 9999
Default: 120 for DC drive, 400 for stepper drive

MAX MOT SPEED-[rpm] Input of the maximum motor rpm for 100% drive command.
Input range: Drive specific. Default: drive specific
Maximum Motor Speed (See nameplate on DC motor for value)

MDU STATUS The MDU status codes reveal operational condition of the Drive. See
listing of MDU status codes in document 0490020605. Also listed in
the Appendix. See section 10.4.1.
MDU Status

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 Programming Reference 6
Machine menu 6.9

6.9.7 Vibratory drive motor setup sub-menu

The following parameter are only displayed if a vibratory feeder drive

is installed.

Parameter Definition

KV DEVICE Selection of the used Vibratory type.

KV1=1, KV2=2, KV3=3.
Input range: 1,2,3 Default: KV2=2
Vibratory Type
VIB SPAN Span adjustment for vibratory tray displacement.
Vibratory Displacement The displacement must be measured at the vibratory and the SPAN
calculated according following formula:
Span
NewSpan = OldSpan x ((Expected_Displacement)/(Measured_Displacement))

Input range: 0.5 to 2.0 Default= 1.000

MDU STATUS The MDU status codes reveal operational condition of the Drive. See
listing of MDU status codes in document 0490020605. Also listed in
the Appendix. See section 10.4.2.
MDU Status

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6 Programming Reference
6.9 Machine menu

6.9.8 Universal stepper motor interface setup sub-menu

Some parameters will not be displayed for every drive case. This sec-
tion is used for stepper motor driven feeders including Bulk Solids
pumps. A chart of stepper motor sizes will be provided to aid in proper
programming.

V The following chart is provided to program the universal stepper

drive 0000005987 only.

Parameter Definition

GEAR REDUC This parameter, if entered as the gear reduction value between the
stepper motor and the disk/screw, results in the disk/screw speed
being displayed in the parameter <SCREW RPM>.
Gear Reduction or Total
Input range: 0 to 999 Default: 0
Gear Reduction
PICK UP TEETH Input of the number of pulses per revolution of the optical encoder.
Speed Pickup Teeth This encoder is used for measuring the speed.
Input range: 0 to 9999
Default: 400 for stepper drive is standard

ACTUAL POWER-[watts] Displays the actual consumed stepper motor power.

Actual Motor Power Input range: Display only [W]

MAX. MOT POWER- This entry sets the maximum output power to the stepper motor
when using the internal KCM Stepper motor drive. (See nameplate
[watts]
on Stepper motor for this value, then use table 6.9.10 to set power.)
Max Motor Power Input range: 25 to 194 W Default: Depends upon installed drive

MAX MOT SPEED-[rpm] Input of the maximum motor rpm for 100% drive command.
Input range: Drive specific. Default: drive specific
Maximum Motor Speed (See table 6.9.10 for values)

MDU STATUS The MDU status codes reveal operational condition of the Drive. See
listing of MDU status codes in document 0490020605. Also listed in
the Appendix. See section 10.4.1.
MDU Status

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 Programming Reference 6
Machine menu 6.9

6.9.9 HiPo, LoPo Stepper motor interface setup sub-menu

V This chart is used to program the HiPo and LoPo stepper drives,
part numbers 0000004568 and 0000001430 respectively.

Parameter Definition

GEAR REDUC This parameter if entered as the gear reduction value between the
stepper motor and the disk/screw, results in the disk/screw speed
being displayed in the parameter <SCREW SPEED>.
Gear Reduction or Total Input range: 0 to 999 Default: 0
Gear Reduction
PICK UP TEETH Input of the number of pulses per revolution of the optical encoder.
Speed Pickup Teeth This encoder is used for measuring the speed.
Input range: 0 to 9999
Default: 400 for stepper drive

MAX MOT SPEED-[rpm] Input of the maximum motor rpm for 100% drive command.
Input range: Drive specific. Default: 60
Maximum Motor Speed (See table 6.9.10 for values)

MDU STATUS The MDU status codes reveal operational condition of the Drive. See
listing of MDU status codes in document 0490020605. Also listed in
the Appendix. See section 10.4.1.
MDU Status

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6 Programming Reference
6.9 Machine menu

6.9.10 Stepper motor programming table

Feeder Type Max Maximum Required Stepper Drive

Motor Power
RPM Setting-W
BSP100 60 49 0000001430
0000005987
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

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 programming.

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 Programming Reference 6
Machine menu 6.9

6.9.11 Service sub-menu

Parameter Definition

S.VAR Display of the service variable name. See list in the appendix.

Service Variable Function

S.VAR VALUE Display and change of the service program value as selected with S.
VAR.
Service Variable Value

TRACETICK This parameter sets the time interval for recording operating data to
memory so that it can be viewed on a PC for analysis.
The data stored includes the following:
Tracetick
Batch Size, Massflow, Drive Command, Net Weight.
The following operational states include: Pert Condition, Refill, Grav,
Drive Enable, Any alarms present are also recorded.
Selections:
Stop: The trace recording is stopped and the data can be read from
the Configuration serial data port 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 second of data
1 second: 1 sample per second of data
5 seconds: 1 sample of data very 5 seconds
15 seconds: 1 sample of data very 15 seconds
60 seconds: 1 sample of data very 60 seconds
Default: 1 second
Notes:
• The default value of 1 second will return after a KCM power inter-
ruption. Any other value of <Trace Tick> is not stored during a
power interruption.
• There are 3600 individual samples of data in storage. So for a 1
second time-tick, 1 hour of data is preserved. For a 60 second
time-tick, 60 hours of data are stored.
• Please see document 0690020601 for operational details on using
this resource.

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6 Programming Reference
6.9 Machine menu

6.9.12 Performance sub-menu

Parameter Definition

INT 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
Internal Channel-% square as follows:
IntChanPrf% = 100 * 1 - [(Load² + (0.1*Err/min)²) /2]
Example: 5 errors/min and 50% load = 75% performance.
Expect normal values of 75% to 99%.

KCM TEMPURATUR- Displays the actual temperature in the KCM in °C.

[deg C] Input range: Display only.

KCM Temperature
TORQUE-% The motor torque is derived from the power indication according to
the following formula:
Only for DC motor and stepper Torque = 100*(actual power * nominal speed) / (nominal power * ac-
motor drives tual speed).
Notes:
Torque-% • On low speeds, this indication might be inaccurate.
• 100% torque is the maximum allowed.
• Not for vibratory feeders or for AC Drive Interface.
• At low speeds, torque will reach a maximum of 100% before <Ac-
tual Power> reaches <Maximum Motor Power>. At high speeds,
the opposite will occur.

BRUSH REMAIN-% The DC motor brush life is estimated according to the following for-
mula:
Estimated_Life = Expected_Life * Nominal_Power / Current_Power
Brush Remain-%
To indicate the remaining life, the following formula is calculated
once per second:
Brush_Remain = Brush_Remain - [(100/(3600*5000))*(MotorPower
Only for DC motors / 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 basic of current brush life.

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 Programming Reference 6
I/O Menu 6.10

6.10 I/O Menu

These menus program the digital and analog I-O functions. The KSL
shows these variables over four pages; Digital Output, Digital Input,
Analog Input, Analog Output. The KSC uses 3 screens.
Notes:
• DENA = drive enable
• ALS = alarm shutdown
• See KCM Electronics 0490020605 manual for wiring details
• Inputs with an * are activated by an edge transition. All other 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 relay outputs on
the MDU (Drive) pcb, terminal block J5
• External_In1...External_In8 and External_Out1...External_Out8
are used for remote MODBUS I-O.

6.10.1 Digital input sub-menu

Parameter Definition

DIG IN Selection of the desired bit input of the KCM for programming. Select
any of the following inputs: CPU1-CPU4, MDU_IN1, MDU_IN2,
Digital Input
Spare 1, Spare 2, Ext _In1 - Ext _In8.
Note:
For Ext In function to work, Modbus I-O must be configured first and
the external I-O module (e.g.WAGO) connected via K-Port 2.
Input Range: See list

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6 Programming Reference
6.10 I/O Menu

Parameter Definition

FUNCTION Input function of the selected output no. [1-24].

Digital Input Function Selection: None, Start*, Stop*, Interlock, Run Enable, ALS Input, Ack
Alarm*, Clr Alarm*, Start/Stop, Vol Mode, Loc/Ext, Rat/Dir, Ext
Alarm, Total Clr*, Data Lock, Batch_Pause, Empty*, Ref Bypass, Ref
Cmd*, Calib*, Loader Lvl, Loader Ena
Input Range: See list
Default: CPU_In_1 = Start, CPU_In_2 = Stop, CPU_In_3 = ALS In-
put.
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 En-
abled.
• If refill is active and running, initiating a Refill Command input will
terminate the refill. If the refill is not active, initiating the Refill Com-
mand input will cause the Refill cycle to begin as stated under the
prior conditions.
Note; If batcher is running then:
• Interlock requires no Start command upon release of Interlock for
the batcher to re-start
• Run Enable requires a Start command upon release of Run En-
able to re-start the batcher

STATE Displaying the actual status of the selected digital input.

Input range: Display only (Off = non active, On = active)
Digital Input State
POLARITY The selected digital input changes the function from e.g NO to NC.
Selections are:
Polarity
Input range: Normal or Inverse
Default: Normal

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 Programming Reference 6
I/O Menu 6.10

6.10.2 Digital output sub-menu

Parameter Definition

DIG OUT Selection of the desired bit output of the KCM for programming. Se-
lect CPU_Out1 to CPU_Out4, MDU Relay 1, MDU Relay 2, MDU Re-
Digital Output
lay 3, Spare, Ext_Out1 to Ext_Out8.
Input Range: See list
Note:
For Ext Out function to work, Modbus I-O must be configured first
and the external I-O module (e.g.WAGO) connected via K-Port 2.

FUNCTION Input function of the selected output no. [1-16]

Digital Output Function Selections:
None, Feeder Run, Any Alarm, Alarm Relay, ALS Out, Drive Ena,
Grav Mode, PSR-MAP^, ASR MAP^, Totalizer Pulse, Refill, Refill
Expired, Loader, Blow-off, Dribble, Batch Complete
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 Displaying the actual status of the selected digital output.

Input range: Display only (Off = non active, On = active)
Digital Output State
POLARITY The selected digital output changes the function from e.g. NO to NC.
Selections are:
Polarity
Input range: Normal or Inverse
Default: Normal

EXT TOT PULS Input of the resolution of an external Totalizer

External Totalizer Pulse Input range: 0* to 999999 Default: 0 kg/pulse
The maximum pulse rate is 3 pulses/second.
The calculation of the increment is as follows:

Ext Tot Increment(min) = Massflow[kg/hr]/1000

DIGOUT MAP^ If at the variable <FUNCTION> the selection PSR-MAP or ASR MAP
was made, it is possible to program any output function listed in the
Digital Output Map table in the appendix. See sections 10.7 and 10.8.

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6 Programming Reference
6.10 I/O Menu

6.10.3 Setpoint input sub-menu

Refer to document 0490020605 for more information.

V For calibration, see section 8.2.

Parameter Definition

SOURCE Selection of the desired remote setpoint input for the KCM. Select
CPU_0-10kHz, CPU_Analog, Extern
Notes:
Analog Input Source
• See document 0490020605 for wiring details when selecting CPU
source inputs.
• For Extern function to work, Modbus I-O must be configured first
and the external I-O module (e.g.WAGO) connected via K-Port 2.
• Check the jumper on the KCM CPU for the following possible
choices: 0-5 Vdc, 0-10 Vdc, 4-20 Ma if CPU_Analog is the input
selection.

AIN VALUE-[%] Display of the actual input value in percentage of the maximum val-
ue, AinMax as defined below.
Analog Input Value%
Input range: Display only

AIN MIN-[%] Scaling of the analog output for the minimum value. (Offset adjust-
ment e.g. 20% for 4 mA).
Analog In Value Min
This value can be used also to invert the analog input.
Input range: 0 to *100%
*Inverted 100%

AIN MAX-[%] Scaling of the analog output for the maximum value.
Analog In Value Max This value can be used also to invert the analog input.
Input range: 100 to *0% Default: 100%
*Inverted 0%

DEADBAND-[%] Input of the deadband in percentage of the maximum value. Chang-

es at the input below this value will have no change to the setpoint
Deadband
value.
Input range: 0 to 100% Default: 0%

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 Programming Reference 6
I/O Menu 6.10

6.10.4 Analog output sub-menu

V The KCM CPU only outputs a 0-20 mA current value. Use appro-
priate resistors to convert to the desired voltage.
V Maximum source voltage is 12 Vdc for the current output.
V Refer to document 0490020605 for more information on electrical
connections and operational limitations.
V For calibration, see section 8.2.

Parameter Definition

AOUT NUM Selection of the desired analog output for the KCM.
Select: CPU, EXT1 - EXT3.
Analog Output Input range: See list
Note:
For Ext1-Ext3 functions to work, Modbus I-O must be configured first
and the external I-O module (e.g.WAGO) connected via K-Port 2.

FUNCTION The analog output can be assign with the following function:
Analog Output Function NETWEIGHT (20mA/Scale range) x netweight
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)
BATCH SIZE (20mA/Max. Batch Size) x Batch Size
BATCH PERC 20mA*BatchMass/BatchSize
BATCH MASS 20mA*BatchCompleteMass/MaxBatchSize
Input range: See list Default: None

AOUT VALUE-[%] Display of the actual output value in percentage of the maximum val-
ue.
Analog Output Value%
Input range: Display only

AOUT MIN Scaling of the analog output for the minimum value. (Offset adjust-
ment e.g. 20% for 4 mA)
Analog Output Minimum
This value can be used also to invert the analog output.
Input range: 0 to *100%
*Inverted 100%

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6 Programming Reference
6.10 I/O Menu

Parameter Definition

AOUT MAX. Scaling of the analog output for the maximum value.
Analog Output Maximum This value can be used also to invert the analog output.
Input range: 100 to *0% Default: 100%
*Inverted 0%

DEABAND-[%] Input of the deadband in percentage of the maximum value. Chang-

es at the output below this value will have no change to the process
Analog Output Deadband value.
Input range: 0 to 100% Default: 0%

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 Programming Reference 6
I/O Menu 6.10

6.10.5 Modbus I-O sub-menu

This menu is not available in the KSL or KSC.

Parameter Definition

ADDR 80 - 83 These are the read only I-O addresses for any external Modbus I-O
that has been connected to K-Port 2. For each address, the module
type (if connected) or problem will be indicated. Possibilities at each
address are:
WAGO, MISSING, CONFLICT, NONE

WAGO = the Wago system of Modbus I-O modules is connected.

CONFLICT = Addresses of connected modules are in conflict after
powering the system. Select <REBIND NOW>. Press ENT twice to
clear the fault.
MISSING or CHANGED = Module that was present is no longer
found. Select <REBIND NOW>. Press ENT twice to clear the fault.
Input range: 80 to 83 Default: 80

DETAILS This read only parameter presents information about the operation
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 (Ext_IO_Fail), the Rebind Now function can clear
the alarm. However, this action will remove all external I-O function.
It is best to examine why the external module failed before executing
Rebind Now.

The Rebind Now function assigns <None> to any previously pro-

grammed external I-O point and then performs a new binding based
upon the rule as follows:
Lowest module by address with lowest I-O point is assigned the low-
est I-O number
e.g. Four digital input module at address 80 is automatically bound
with EXTIN1 at module input 0 to EXTIN 4 at module input 3.
After the Rebind Now action, each I-O point requires reassignment
of its function. e.g. <Start>.

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6 Programming Reference
6.10 I/O Menu

6.10.6 Adding External Modbus I-O, an example

Follow this procedure to configure remote I-O.

« Preset the Modbus I-O module to an address of 80, 81, 82 or 83.
« Program the Modbus I-O module to follow the K-Port 2 communi-
cation specifications
– 19,200 baud, 8E1
« Program K-Port 2 for Modbus I-O
« Make all wiring connection between the KCM and the external
modules
Then do the following:
1. Power the KCM and the external I-O modules together.
2. Use the Modbus I-O menu to perform the following set-up.
Note:
If it is not possible to power the KCM and modules together, 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 input or output point.
e.g. If the module was a digital 4 input module at address 80, the
screen would look like this:
I/O POINT 1 -> EXTIN1
I/O POINT 2 -> EXTIN2
I/O POINT 3 -> EXTIN3
I/O POINT 4 -> EXTIN4
I/O POINT 5 -> None
I/O POINT 6 -> None
I/O POINT 7 -> None
I/O POINT 8 -> None
8. Go to the specific I-O menu and set the function for each active I/
O point. e.g. set the digital input function for <Clr Tot>.
9. Test the function of each module I-O point.

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 Programming Reference 6
Loader menu 6.11

6.11 Loader menu

This menu programs the vacuum loader function. No HCU is required.
See section 10.2 for more information on loader applications.
Notes:
• In later KCM S/W versions 1.3 and later, this menu will be hidden if
an HCU is connected to the KCM.
• Be sure the parameter <LOADER FUNCTION> in this menu is
<Disabled> if a loader with HCU control is to be used.

6.11.1 Loader parameters

Parameter Definition

LOADER FUNCTION Selects whether loader runs or not. Select <ON> to run, <OFF> to
stop.

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
Max Load Time
SHUTDOWN TIME Time, in seconds, for the motor to wind down at the end of the load
cycle.
Default: 5 seconds
Shutdown Time
DISCHARGE TIME Time, in seconds, it takes to discharge the loader contents.
Default: 10 seconds
Discharge Time
VALVE CLOSE TIME Time, in seconds, it takes for the discharge valve to close at the end
of a discharge.
Default: 5 seconds
Valve Close Time

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6 Programming Reference
6.12 HCU loader set-up

6.12 HCU loader set-up

This menu programs the Hurricane loader function. This menu is used
in place of the HSU. Also see manual 0290023601 for more loader op-
erational information.

V This menu is only displayed, if a HCU (Hurricane Control Unit) is

connected.
V The HCU Loader controller is connected to the KCM via the Inter-
nal Channel. See document 0490020605 for more information
V Be sure that the LOADER parameter is <disabled> in the LOADER
menu. Hide the LOADER menu.

Parameter Definition

COMMAND The following commands can be selected and be executed with the
ENTER key:
Loader Command
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

V Conveying starts if you press ENTER at the selection <RUN>.

! WARNING The process can be stopped only by selection of the command stop.
The start/stop key on the control unit does not have a function for the
loader.

HCU CYCLE Displays the current active cycle.

Active Cycle Motor Motor Timer active. After the timer expired the mo-
tor will stop.
LoadDly Delay until the valve is closing and a new convey-
ing cycle is starting.
Load Hurricane is conveying material.
Line Clr Conveying pipe emptying cycle is active.
DischDly Discharge delay time. Delay = Time until the motor
stops.
Disch Discharge cycle: Display only.
Input range: Display only

HCU TIME -[sec] Remaining time in the current active cycle.

Active Time Input range: Display only

Table page 1 of 2

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 Programming Reference 6
HCU loader set-up 6.12

Parameter Definition

HCU STATUS Display of the current status of the HCU. Normal OK.
Loader Status ALARM HCU has an alarm.
PROG HCU in programming mode.
REC FULL Receiver is full.
BUFFER FULL Buffer hopper is full.
HCU COM FAIL Serial communication between KCM and HCU in-
teruppted.
Input range: Display only

PARAM NUM Input of the parameter number. The name and value represented by
the parameter number will be displayed under the variables PARAM
Not on KSL DESC and PARAM VALUE respectively.
Input range: see section 10.3 and document 0290023601.

PARAM VALUE Input of the desired value for the selected PARAM NUM.
Parameter Value input range: see section 10.3 and document 0290023601.

PARAM NAME Display of the parameter name selected with PARAM NUM.
Parameter Name Input range: Display only
See section 10.3 and document 0290023601.
Table page 2 of 2

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6 Programming Reference
6.13 System setup (only KSU-II/KCM).

6.13 System setup (only KSU-II/KCM).

This menu is only used with the KSU-II/KCM display and not available
for KSL or KSC.

This menu programs the key communication functions for the KCM.
Note:
Siemens 3694R protocol is not supported.

6.13.1 Communication sub-menu

Parameter Definition

HOST PROT Input of the desired communication protocol

Input range: Modbus, ALLEN BRAD AB-CIF, Siemens 3694R, Profi-
busDP, Modbus/TCP, ModbusPlus, DeviceNet, Ethernet/IP.
Default: None

HOST FILE Select either a custom downloaded *.kgr file for data communica-
tions or select the pre-loaded file (built-in). See document
0590020611 for details.
Input range: Built-in, Kgr File.
Default: Kgr File

K-PORT1 PROT Selects the function for K-Port #1, Choices are: None, KSU, KSL,
KSC/KMB. For K-Vision, use KSC/KMB protocol.
Default: KSU

BAUD RATE Displays baud rate selections when K-Port #1 is set to KSC/KMB or
if set to KSL and the service variable K10S_KCDR is <1>.
Choices are: 9600, 19,200, 38,400, 57,600, 115,200

K-PORT 2 PROT Selects the function for K-Port #2, Choices are: None, KSU, Modbus
I-O, KSC/KMB

CONF MODE Input 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.
• Selection <Diag> is used for diagnostic trace functions.

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 Programming Reference 6
System setup (only KSU-II/KCM). 6.13

6.13.2 SW Version

Parameter Definition

SW# The KCM CPU controller application software part number and revi-
sion.

HW# The KCM CPU hardware number and revision.

MDU# The Drive CPU application software part number.

Note:
• Before calling K-Tron service, have the SW version numbers avail-
able for your system.

6.13.3 Drive type by displayed MDU#

MDU # Software from Display MDU Drive Type PCB Part Number

04900-20211 1600 Watt DC motor drive 0000002610

02900-20200 450 Watt DC motor drive 0000007405

04900-20202 AC drive interface 0000003413

03900-20202 Vibratory drive 0000000684

04900-20212 Universal stepper drive 0000005987

02900-26200 LoPo stepper drive 0000001430

02900-26200 HiPo stepper drive 0000004568

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6 Programming Reference
6.13 System setup (only KSU-II/KCM).

6.13.4 Parameter Backup sub-menu

This menu provides a method for parameter back-up in the KCM K-
Prom.

V It is important to save your programming to the K-Prom using the

steps below, once your programming is verified and complete.

Parameter Definition

PASSWORD Password to access the <ACTION> function of saving and recalling

data from a K-Prom.
Default: <1234>
Entered Password
See section 6.13.5 on how to change this entry.

ACTION Action functions are: Save, Recall.

<SAVE> stores active operational data to the back-up storage area
of the K-PROM.
Backup Action
<RECALL> places into active operational memory the saved K-
PROM data.

6.13.5 Changing the K-PROM password.

See document 0690020601 for detailed information on changing the
K-PROM password with your PC.

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 Programming Reference 6
Security menu (only KSU-II/KCM-KD) 6.14

6.14 Security menu (only KSU-II/KCM-KD)

This menu sets access for all menus in the KSU-II/KCM-KD.

The access to the security menu can be de-activated by the data lock-
out input of the KSU-II/KCM-KD display.
All programmed security selections (e.g RD/WR) will be de/activated
immediately by programming the ACCESS TYPE.

V Menus marked with * are hidden by default.

6.14.1 Security parameters

Parameter Definition

PRODUCT CHANGE AccessType Permission

RD/WR Reading and writing possible.
ALARM*
READ Read only possible.
TUNING* HIDE No access menu. Menu is not visible.

FEEDFACTOR
REFILL*
SCALE*
MACHINE SETUP*
I-O SETUP*
LOADER*
HCU LOADER*
SYSTEM*
FDR BEING VIEWED*
TOT KEY Select: <Clear Only>, <Rd Onl>y, <Any Num> as entries.

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6 Programming Reference
6.14 Security menu (only KSU-II/KCM-KD)

Parameter Definition

SP ACCESS Select: RD/WR, Read. Hide.

VOL/ALARM CLR Select: Enable, Disable.

Vol/Alarm when enabled, allows use of the Grav/Vol key and permits
alarms to be acknowledged or cleared.

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 Calibration 7
Security menu (only KSU-II/KCM-KD) 6.14

7 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.

V For detailed operating instructions, use manual 0490020612 for

KSU-II or KCM-KD.

V For KSL operation, use manual 0590020614

V For KSC operation, use manual -490020607

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 69

8 Other Programming
8.1 Setting refill parameters

8 Other Programming

8.1 Setting refill parameters

8.1.1 Setting the Refill Max value

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

8.1.2 Setting the Refill Min value

1. Select the REFILL menu.
2. Select <REFILL MIN> parameter.
3. Enter a value that is = 0.4*REFILL MAX value.
4. Execute a refill to verify that the horizontal agitator if the batcher is
so equipped, is not uncovered at any time. Adjust the value if nec-
essary.

V If is important that the horizontal agitator does not become uncov-

ered during normal operation as it may affect batcher perfor-
mance.

8.1.3 Setting the Post Refill Delay

Note:
Only adjust this value if the batcher is unstable (noted by highly vary-
ing 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 to verify that motor speed is now quite stable im-
mediately after a refill. If not, repeat step 3 until a stable exit from
refill is achieved.
Note:
Don’t exceed 30 seconds for <POST REFILL DELAY> unless other-
wise advised.

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 Other Programming 8
Calibrating analog I-O 8.2

8.1.4 Setting the Refill Timer

Refill timer set-up equipment required:

• Stop watch

Refill timer set-up procedure:

1. Execute a refill
2. Start a stop watch when the refill begins
3. Stop the stop watch when the refill is compete and the discharge
device stops discharging product.
4. Select the ALARM menu.
5. Select <MAX REFILL TIME> parameter.
6. Enter a value =1.25* the stop watch value.

8.2 Calibrating analog I-O

The formula for an analog value output can be demonstrated by the
following formula as an example. Setpoint will be used as the value
and 20 ma is the full scale representation.

Val = 20 × ⎛⎝ --------------------------------⎞⎠ × ( AoutMax – AoutMin ) + AoutMin

BatchSP
( MaxBatch )

Deadband works as indicated in the following equations.

Val ≤ Deadband ( Val → 0 )

∆Val ≤ Deadband ( Val → PreviousVal )

∆Val > Deadband ( Val → NewVal )

To calibrate an analog output, do the following. In this example, set-

point 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 an-
alog output is exactly correct.

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8 Other Programming
8.3 Using an external motor drive

4. Double check with Setpoint = 0, but no adjustment is normally re-

quired.

8.3 Using an external motor drive

To use an external motor drive rather than the internal KCM motor
drive, do the following:
1. The AC Interface drive board is installed.
2. In the ANALOG OUTPUT sub-menu, set the following:
– <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 given val-
ue of drive command.

8.4 HP to watts conversion chart

Use this chart to figure the power in watts for motors listed in hp.

HP Watts

0.125 93
0.25 187
0.5 373
0.75 560
1.0 746
1.5 1119
2.0 1492

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 Alarm Messages- Cause and Remedy 9
System alarms 9.1

9 Alarm Messages- Cause and Remedy

9.1 System alarms

Note:
The associated number is the alarm number used for configuration
and data communication.

– The HCU is the control unit for the Hurricane vacuum material
loader for the feeder. It is programmed via the KSU-II/KCM-KD
and its alarms are reported there.
– The first number is the KCM alarm, the second the HSU alarm.
(KCM#/HSU#). This code begins at KCM alarm (21) and ends at
KCM alarm (29).

Alarm Num- Alarm Cause Remedy

00 HARDWARE ERROR • KCM Hardware error. EEPROM da- « Check KCM CPU.
ta is corrupt. For example, this mes- « Clear alarm and try unit.
sage will occur after updating or
changing firmware on the KCM.
01 KPROM MEM FAIL • The K-PROM cannot be accessed « Correctly insert K-PROM.
by the KCM CPU. « Replace with known good K-
PROM.
02 KPROM*KGR*FAIL • Checksum error in kgr file area. « Verify K-PROM is properly in-
stalled.
« Replace K-PROM.
03 POWER GLITCH • Power dip detected. CPU did not re- « Verify AC mains are within specifi-
set. cation,
« Replace drive pcb. (power supply)
05 INT CHAN FAIL • Internal channel has failed to com- « Check Internal Channel connec-
municate between the CPU and tions.
drive boards. (also SFTs and HCU) « Replace either CPU or Drive pcb.
(also check SFTs and HCU if used)

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9 Alarm Messages- Cause and Remedy
9.1 System alarms

Alarm Num- Alarm Cause Remedy

06 WT PROC FAILURE • SFT(s) failed. « Locate which SFT has failed on the
• Serial communication to the load cell <SFTs> line in the <SCALE>
interrupted. Menu, <SFT> sub-menu.
• f = SFT internal failure. communica-
tion OK.
• t = No communication from the SFT
to the controller board.
• ?= Not valid answer from SFT.
07 • Number of SFTs found during poll- « Check <SFT REQUIRED> number
INCORRECTNUM.SFT ing does not equal that required. is valid. See <SCALE> menu,
<SFT> sub-menu.
« Check for all SFTs being operation-
al.
08 BAD SFT STATUS • SFT is showing an incorrect status. « Replace SFT if problem persists.
09 NO MDU FOUND • The KCM CPU did not find a motor « Check drive pcb LEDs for correct
drive on the internal channel on function.
power-up. « Check Internal channel connec-
tions.
« Replace drive or CPU pcb.
10 MOTOR ALARM • The KCM CPU lost the motor drive « Check drive pcb LEDs for correct
on the internal channel while in oper- function.
ation. « Check Internal channel connec-
tions.
« Replace drive or CPU pcb.
11 • Motor drive has lost communication « Check Internal channel connec-
MDU SERIAL TIMEOUT with the KCM CPU and then turns off tions.
all digital outputs and shuts of drive « Replace drive or CPU pcb.
power.
12 MDU THERMAL OVL • Drive temperature has been ex- « Reduce operating temperature
ceeded > 75 deg C. Drive stops.
13 MDU SPEED DEV • No speed feedback signal is present « Check speed pick-up for operation
when motor is asked to run. and replace if necessary.
• Speed deviation from target > ± 5 « Check speed pick-up wiring and
rpm power connections.
• Wrong motor voltage programmed. « Check programming.
« Replace drive.
« Check motor.

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 Alarm Messages- Cause and Remedy 9
System alarms 9.1

Alarm Num- Alarm Cause Remedy

14 • Motor current limit is exceeded. « Reduce motor load.
MOTOR OVERLOAD
Note: « Check motor power limit in the
The Safety switch is not designed to be <MECHANICAL> menu, <MO-
used as a normal way of interlocking TOR> sub-menu.
the KCM. It is used for safety control « Review material/feeder selection.
only.
15 • Safety relay failed to close contacts « Replace Drive pcb.
MDU SAFETY RELAY on power up and contacts remained
closed after power down.
16 • Dual tach signals connected, one « Check tachometer-replace.
MOTOR/ENCDR FAIL failed. « Check motor brushes.
• Over-voltage on drive power supply. « Replace motor if required.
• Motor voltage applied but no speed « Replace KCM drive board.
feedback.
« Check for excessive line voltage.
• Drive temperature > 85 deg. C.
« Reduce operating temperature.
17 • Speed feedback but no motor volt- « Replace drive board.
MDU UNCONTROLLED age applied.
18 • EEPROM checksum failed. « Cycle power. If error persists, re-
MDU EEPROM FAILED place drive pcb.
19 MDU DRIVE FAILED • MDU drive pcb has failed. (vibratory « Exchange vibratory drive pcb.
drive only. Drive coil current too « Check drive coil for proper imped-
high) ance.
20 MDU POLARITY • Coil polarity is incorrect on the vibra- « Change the feedback coil polarity
tory drive. (Vibratory feeder only) by swapping leads at KCM.
• Displacement frequency out of
range.
21 HCU REMOVED • HCU was removed. « Connect HCU at the KCM and
switch KCM On.
« Repoll SFT channel to re-connect
HCU.
« Clear NOVRAM if necessary.
22 HCU ALARM • HCU has an alarm. « See following alarms for trouble
shooting.
23/01 • EEPROM failed. « Clear alarm.
HCU EEPROM FAILED Change EEPROM or HCU.
« Cycle power to the HCU.

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9 Alarm Messages- Cause and Remedy
9.1 System alarms

Alarm Num- Alarm Cause Remedy

24/02 • The controller's digital output driver « Change HCU.
HCU DRIVER FAILED has detected a fault. « Latched.
25/03 • Material is below the level of the « Refill or change supply hopper.
HCU SUPP.HOPP.LOW supply hopper proximity sensor. « Check P17.
• Sensor failed. « Check sensor or P23.
Note: Alarm will automatically clear
when material is above sensor.
26/04 • The differential pressure across the « Clean or replace filter.
HCU D.P.ALARM filter is too high indicating a clogged « Check P24 and P16.
filter.
« Check P17
27/05 If P20 Discharge Mode =01“Fill” mode « Check Parameter P25 Number of
HCU CYC.COUNT AL then: load cycles.
• Max. numbers of load cycle exceed- « Check conveying rate.
ed, because Buffer Hopper Low in- « Check Buffer hopper sensor.
put has been active (on) for more
than the allowed load cycles. The
Buffer Hopper Low signal going in-
active clears the load cycle counter.
If P20 Discharge Mode =02 (LWF)
mode then:
• Discharge Request input has been « Check Parameter P25 Number of
on for more than the allowed load load cycles.
cycles. The Discharge Request sig- « Check conveying rate.
nal going inactive clears the load cy-
cle counter. « Check discharge request signal.

28/06 • Discharge valve has failed to either « Check sensor on the discharge
HCU DISCH VALVE open or close properly. This alarm is valve.
automatically disabled in P18 Oper- « Check P26.
ating Modes 03 and 04.

29/07 • Receiver is still full after discharge. « Check receiver. Material bridging in
HCU REV.FULL AL. the receiver. Clean receiver.
• Receiver proximity switch too sensi-
tive adjusted or failed. « Check Receiver proximity switch or
P17.
30 • Protocol of KGR file does not match « Make corrections as necessary.
KLINK WRONG KGR that required by the installed com-
munication circuit card.
31 KLINK NO KGR • No KGR file loaded « Load KGR file with SmartConfig or
switch to <Built-IN> KGR file.

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 Alarm Messages- Cause and Remedy 9
System alarms 9.1

Alarm Num- Alarm Cause Remedy

32 HPORT FAIL • Host communication pcb error. « Check communications pcb for
proper LED operation.
« Exchange communications pcb as
necessary.
33 HPORT FAIL INIT • Host communication pcb could not « No host communications pcb is in-
be initialized. stalled.
« Check host communications pcb
connections.
« Replace host communications pcb.
34 • Improper pcb installed in the host « Install correct host communications
HPORT ILLEGAL BD port location. pcb.
35 KPORT FAIL • K-Port has failed « Replace K-Port comm pc card.
36 KPORT FAIL INIT • K-Port communication pcb could not « Replace K-Port comm pc card.
be initialized.
37 • Host communication pcb is installed « Check host communications pcb
KPORT ILLEGAL BD on the wrong port location-(K-Port). for proper mounting location.
38 • One or more feeder parameters are « Correct KGR file.
KGR PARAM ERROR not correct for the specified feeder. « Use <Built-IN> KGR file.
39 EXT IO FAIL • The MODBUS I-O connection has « Check connections to remote I-O
failed. device.
« Check remote I-O device wiring.
40 • Digital input on KCM selected for Ex- « Investigate the cause of this input
EXT ALR ACTIVATED ternal Alarm is active. being active and correct.
41 INTERLOCK FAIL • Drive pcb Run Enable digital input is « Check the Drive pcb Run Enable
open during operation. digital input for proper function.
42 START IGNORED • Start conditions not fulfilled. « Check status line.
« Check for setpoint and re-enter if
necessary.
« Check all KCM digital inputs for
correct operation.

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9 Alarm Messages- Cause and Remedy
9.1 System alarms

Alarm Num- Alarm Cause Remedy

43 MASSFLOW HIGH • The current massflow is above the « Increase the alarm start delay time
tolerance entered in <ALARM> in the <ALARM> menu.
menu parameter <MF ERR+>. « Increase the tolerance <MF
ERR+> value.
« Check for proper feeding of materi-
al.
« See if another alarm <DRIVE CMD
LO> is present.
44 MASSFLOW LOW • The current massflow is below the « Increase the alarm start delay time
tolerance entered in <ALARM> in the <ALARM> menu.
menu parameter <MF ERR->. « Increase the tolerance <MF ERR->
value.
« Check for proper feeding of materi-
al.
« Re-range the feeder to achieve the
desired feedrate.
« Lower the operating setpoint <SP>.
« See if another alarm <DRIVE CMD
HI> is present.

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 Alarm Messages- Cause and Remedy 9
System alarms 9.1

Alarm Num- Alarm Cause Remedy

45 DRIVE CMD CEILING • Drive command has reached the « Reduce drive command.
limit <DC CEILING> « Increase Drive Command Ceiling.
See <MECHANICAL SETUP>,
<MOTOR> sub-menu.
46 DRIVE CMD HIGH • The drive command has exceed the « Check for proper feeding of materi-
value <DRV CMD HI> Limit in the al.
<ALARM> menu. – Check for bridging in hopper
– Check for adequate product in
hopper
« Lower the operating setpoint <SP>.
« Increase the <DRV CMD HI> value
in the <ALARM> menu.
« Check for motor rotation.
– Replace KCM if drive has failed.
– Check motor.
– Check speed sensor.
47 DRIVE CMD LOW • The drive command has dropped « Raise the operating setpoint <SP>.
below the value <DRV CMD LO> « Increase the <DRV CMD LO> val-
Limit in the <ALARM> menu. ue in the <ALARM> menu.
48 • DC motor brushes may be wearing « Motor brushes need inspection and
CHECK_MOTOR_BRUS out and ready to fail. replacement if worn.
HES
« If brushes are OK, re-enter a rele-
vant brush life number in the Per-
formance sub-menu.

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9 Alarm Messages- Cause and Remedy
9.2 LWB alarms

9.2 LWB alarms

Process alarms Cause Remedy

52 FF ALARM • Feedfactor is zero or feeding condi- « Enter new feedfactor.
tion changed so that the feedfactor « Check feedfactor limit in <ALARM>
exceed the set limit in the <ALARM> menu <FF DEV LIMIT>.
menu <FF DEV LIMIT>.
« Check feeding condition.
53 SCALE OVER • The weight on the scale is above the « Check the scale for proper opera-
scale gross range permitted. tion.
« If LWB, reduce level of refilling -
<REFILL MAX> parameter.
54 SCALE UNDER • The weight on the scale is below the « Check the scale and re-tare.
zero or gross weight < o.
55 WEIGHT HIGH • The material weigh in the hopper is « Check for proper hopper filling.
above the limit set in the <ALARM> « Check the tare value.
menu. <NW HI LIMIT>.
« Check for scale or weigh bridge
measurement errors.
56 WEIGHT LOW • The material weigh in the hopper is « Check for proper hopper filling.
below the limit set in the <ALARM> « Check the tare value.
menu.<NW LO LIMIT>.
« Check for scale or weigh bridge
measurement errors.
57 REFILL TIME • The programmed refilling time (pro- « Check refilling device, increase the
gram parameter <ALARM> menu, time in program parameter
<MAX REFILL TIME> was exceed- <ALARM> menu, <ALARM
ed without refilling being completed. LIMTS> sub-menu, <MAX REF
TIME> or refill faster if necessary.
58 LOADER EMPTY • Loader hopper is empty « Check loader and material supply.
59 BATCHTOLERANCE • Batch is out of tolerance « Reduce the <DRIBBLE CMD> val-
ue.
« Increase <DRIBBLE TIME>.
« Check feeder for flushing.
« Increase <BATCH TOL>.
60 BATCHTIME2HIGH • The actual batch time has exceeded « Increase the <FAST DRIVE
the desired batch time plus the batch COMD>. Increase the <GRACE>
time grace period. or <BATCH TIME>.
« Increase feeder capacity.

Table: 2 LWB alarms

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 Alarm Messages- Cause and Remedy 9
Display messages 9.3

9.3 Display messages

Message Cause Remedy

Out of Range • Maximum permissible input value « Enter a value within the permitted
Tare Failed has been exceeded. limits of the parameter. See the
specific programming manual for
more information.
Nak’d Feeder Run- • Not acknowledged as the command « Stop the batcher before making the
ning cannot occur when the batcher is entry.
running.

Table: 3 Messages

9.4 Batcher won’t start - displayed messages

Message Cause Remedy

Wait • No batch setpoint is entered. « Enter an operating <BAT SIZE>.

• Feedfactor, if required, is <0>. « Enter an <Initial Feedfactor>.
• Interlock has failed. « Check interlocks.
Alsh • Automatic alarm shutdown because « Correct alarm problem and then
of an alarm. clear the alarm with the ALARM
key.
Disa • Start via bit input disabled. (Interlock « Check interlocks to the KCM.
or Run enable).

Table: 4 Won’t start

9.5 Batcher won’t run in GRAV

Message Cause Remedy

Batcher remains in • Conditions for gravimetric control « Check input for forced VOL func-
VOL control not fulfilled. tion.

Table: 5 Grav problem

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9 Alarm Messages- Cause and Remedy
9.5 Batcher won’t run in GRAV

9.5.1 Batch fluctuations-LWB

Alarms Cause Remedy

General batch • Vibrations. « Improve the location of the scale.

fluctuations LWB – Increase the filter length display in
program parameter TUNING
menu, <DISPLAY FILTER>.
– Increase the tolerance limit in pro-
gram parameter ALARM menu,
<BAT TOL>.
• Irregular discharge. « Install different feeder screws when
operating at low feeder-screw
speeds.
• Irregular motor speed. « Check the motor setting and the
pick-up, perhaps the discharge
feeder screws are sticking.
• Friction on the scales « Check all mechanical connections
(to be ascertained with a static to the scale, they must be flexible.
weight test) The scale may not touch anything.
« Replace scale.
Table 1 of 2

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 Alarm Messages- Cause and Remedy 9
Batcher won’t run in GRAV 9.5

Alarms Cause Remedy

General batch During Refill: If using <During Batch>

fluctuations LWB refill function.
(continued)
« Increase lower refilling level in pro-
• Increased degree of feeder-screw gram parameter PRODUCT
filling or even the material is flowing CHANGE menu, <REFILL MIN>.
through during refilling. Reduce the refilling speed or fit dif-
• Pressure increase in the hopper dur- ferent feeder screws if necessary.
ing refilling. The reduction in pres- « Make sure that the air can escape
sure when refilling is completed af- more easily. Replace the hopper's
fects the weight. air filter if necessary.
• Friction on the scales « Check all mechanical connections
(to be ascertained with a static to the scale, they must be flexible.
weight test) The scale may not touch anything.
• Pressure fluctuations in the storage Replace scale.
container caused by ventilation, suc- « Improve ventilation, install a pres-
tion or insufficient ventilation. sure compensation on the vent
connection during the suction.
During Refill: If using <During Batch>
refill function.
• Fluidized material caused by the « Increase lower refilling level in pro-
vortices of air in the hopper during gram parameter PRODUCT
refilling. CHANGE menu, <REFILL MIN>,
reduce the refilling speed if neces-
• Continuous trickle from the refilling sary.
organ.
• The weight can be adversely affect- « With pneumatic slide gates make
ed if refilling is not stopped in time sure that the slide gate closes suf-
(within a few seconds). ficiently.
Where liquids are being processed,
the refilling valve must be located
directly above the hopper.
Increase mode-switch delay in pro-
gram parameter PRODUCT
CHANGE menu, <POST REFILL
DELAY>.
• Hopper is overfilled. The material is « Reduce the top refilling level in pro-
touching the inlet thus causing fric- gram parameter PRODUCT
tion. CHANGE menu, <REFILL MAX>.
page 19, reduce the refilling speed.

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10 Appendix
10.1 Special KCM LWF features

10 Appendix

10.1 Special KCM LWF features

10.1.1 SFT Addressing

Unlike the SCM, the KCM does not switch the power of each individual
SFT. Thus, if 2 or more SFT's have the same address, a different
mechanism is used to change the address of an individual SFT. SFT
version 'S' and later version SFTs, have special means to allow read-
dressing of individual SFTs with the same address. These are:
1. A command to poll and identify SFT's with the same address based
on their serial number.
2. A command to change the address of a SFT also based upon serial
number.
Terminology:
• New SFT: software version = 'S' or later
• Old SFT: software version 'N' to 'R'
• Note: SFT version 'M' (1st FAST SFT 1997) will not automatically
address since they have no means to change the address 'on the
fly'
• Spare SFT: SFT has address <0>
• Poll: Polling the internal channel address 0 to 12 to see on which
address any connected SFT responds
• Auto Address: Automatically change the address of a Spare SFT to
the next available address
• Auto 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 same address after
addressing.
5. If there are several SFT's occupying the same address, these SFT's
get addressed to the next available address.
6. If an old SFT is found together with new ones on the same address,
the new ones get readdressed, the old one stays at the same address.
Auto readdressing by user command only rules:
The rules are the same as for auto addressing but:
1. All new SFT's get readdressed to 1, 2, 3 … n where the old SFT's
will stay on their current address.

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 Appendix 10
Special KCM LWF features 10.1

2. SFT's get addressed in the order they are found. Thus, if there is no
conflict and the addresses are 1…n, the final addresses will be the
same as before.

10.1.2 Refill Algorithms for the KCM

Refill modes selections include:

– Manual
– Automatic-Auto
– Automatic_Terminate

Refill Mode: Manual

Manual refill mode is designed for those applications, particularly for
low federate applications where bulk material will be randomly added
to the batcher. (Fig.10.1)

Weight

Refill Max

Refill Min
NW Low
0
Refill Window
Refill Alarm RT

Time
Fig. 10.1 Manual refill function diagram

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

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10 Appendix
10.1 Special KCM LWF features

above the value RT is the Refill Timer setting. When the net weigh
drops below the NW Low value, the controller switches to VOL control.

Refill Mode: Auto

Automatic refill mode-terminate is designed for those applications
where material addition to the batcher is from an automated refill sys-
tem. (Fig.10.2)

Hopper
Weight

Refill Max

Refill Min

Net Weight Low

Empty

Refill Window
active high

VOL
active high

1 2
Refill Alarm
active high

Time
PRD

Fig. 10.2 Auto refill function diagram

At point #1, the refill timer expires and the refill timeout alarm acti-
vates. This resets the Refill Window. At point #2, the Refill Timer alarm
has been cleared by the operator.
Note:
• PRD = post refill delay time

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 Appendix 10
Special KCM LWF features 10.1

Refill Mode: Auto Terminate

Automatic refill mode-terminate is designed for those applications
where material addition to the batcher is from an automated refill sys-
tem. (Fig.10.3)

Hopper
Weight

Refill Max

Refill Min

Net Weight Low

Empty

Refill Window
active high

VOL
active high

1 2 3
Refill Alarm
active high

Time
PRD

Fig. 10.3 Auto terminate refill function diagram

At point #1, the refill timer expires and the refill timeout alarm acti-
vates. 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

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10 Appendix
10.1 Special KCM LWF features

10.1.3 Refill using the integrated loader function

If the <Loader> function parameter is set to <On> and <Refill> is <En-

abled> and the loader enable bit input is activated, the internal KCM
loader algorithm is enabled.

Normal operation sequence:

– When the refill completes, it waits for a programmable <Valve
Close Timer>.
– If the proximity high level switch input is deactivated, the loader
motor starts.
– When the loader 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 un-
til it stops the motor.

• Alarm conditions:
– High level proximity input does not get activated after the maxi-
mum load time.
– High level proximity input is not activated before a refill

A normal refill and load cycle is shown next. (Fig.10.4)

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 Appendix 10
Special KCM LWF features 10.1

Hopper
Weight

Refill Max

Refill Min

Refill Window
active high

Loader Motor
Hi=On

Prox SW input
Hi = no material

VCT 2 sec Time

Fig. 10.4 Normal refill and load cycle function diagram

Notes:
• VCT = valve close time
• Prox Switch input High = no material at probe

The next diagram (Fig.10.5) shows the refill & load cycle when loading
of the loader hopper fails

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10 Appendix
10.1 Special KCM LWF features

Hopper
Weight

Refill Max

Refill Min

Refill Window
active high

Loader Motor
Hi=On

Prox SW input
Hi = no material

Loader Alarm

VCT Time
MLT

Fig. 10.5 Normal refill but failed loading function diagram

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

The next diagram (Fig.10.6) shows refill with empty loader due to
failed proximity switch

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 Appendix 10
Special KCM LWF features 10.1

Hopper
Weight

Refill Max

Refill Min

Refill Window
active high

Loader Motor
Hi=On

Prox SW input
Low = material

Loader Alarm

Time
DT

Fig. 10.6 Refill with empty loader due to a failed high level prox. switch

Notes:
• DT = discharge time
• Prox Switch input Low = material at probe

The next diagram (Fig.10.7) shows refill during loading of the loader
hopper

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10 Appendix
10.1 Special KCM LWF features

Hopper
Weight

Refill Max

Refill Min

Refill Window
active high

Loader Motor
Hi=On

Prox SW input
Hi = no material

Loader Alarm

Time
ST
VCT

Fig. 10.7 Refilling while loading the hopper loader function diagram

Note:
VCT = valve close time
ST = shutdown time for the loader motor

The next diagram (Fig.10.8) shows loading an empty hopper.

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 Appendix 10
Special KCM LWF features 10.1

Hopper
Weight

Refill Max

Refill Min

Refill Window
active high

Loader Motor
Hi=On

Prox SW input
Hi = no material

DT Time
#1 2 sec
VCT
SH

Fig. 10.8 Loading an empty loader and refilling function diagram

Notes:
• SH = loader motor shutdown time
• DT = discharge time
• VCT = valve close time
• #1 refers to when the loader is full and the high level proximity
switch is On.

When the refill does not complete by the weight level, there is a pro-
grammable <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>. Af-
ter this time, it will reopen the valve. This cycle continues until the refill
is completed.

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10 Appendix
10.2 Programming the loader function

10.2 Programming the loader function

Use this procedure to program the KCM for the internal loader func-
tion. (Fig.10.8) This is not for the HCU loader function.

The Level Indicator must be placed so that it is covered when the load-
er is full. The loader motor will stop and start based on this signal.
1. Connect the motor contactor to a relay output of the Motor Drive
Board (e.g. REL 3).
motor
2. Connect the Refill valve to a relay output of the Motor Drive Board
(e.g. REL 2).
level indicator
3. Connect the level indicator to a bit input of the Motor Drive Board
(e.g. IN 1).
4. In the I/O menu, program the following parameters:
refill signal – <MDU IN1> to <Loader Level>
– <MDU REL 3> to <Loader>
– <MDU REL 2> to <Refill>
5. In the security menu, change the security mode of the loader menu
to <RD/WR>. This will not be possible if a bit input is assigned to
DATA LOCK and the bit input is not activated. In this case, activate
the data lockout input or program the corresponding bit input in the
I/O menu to <None>.
6. In the Loader menu, program the <LOADER FUNCTION> to
<On>.
KCM
7. In the product change menu, program appropriate refill levels and
set <REFILL> to <Enable>.
The loader will start and the batcher will refill.
Fig. 10.9 KCM with Loader

Note:
• The loader will only work if refill is enabled.
• Refill and loader can be interlocked with Run/Stop input of the
batcher controller. When programming <REFILL> to <If Running>,
the loader will only run if the batcher also runs.
• If a bit input is programmed to <Ldr Enable>, the loader will only
work if the corresponding bit input is activated.
• Section 10.3 discusses HCU programming parameters.

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 Appendix 10
Programming parameters for HCU 10.3

10.3 Programming parameters for HCU

This table shows parameter number and description, which can be en-
tered in the section 6.12 for HCU loader control. For a detailed de-
scription of all parameters see document 0290023601.

Param Number/ Param description KSU Min Max Step Default Actual
Param. D
P1 – Load Timer (Cycle 3) Load 5 sec 300 sec 1 sec 20 sec
P2 – Clear Timer (Cycle 4) LineClr 0 sec 30 sec 1 sec 0 sec
P3 – Discharge Timer (Cycle 6) Disch 2 sec 90 sec 1 sec 10 sec
P4 – Filter Delay Timer Fill Dly 1 sec 5 sec 0.1 sec 5 sec
P5 – Filter Pulse Timer Fil Pul 0 sec 0.5 sec 0.1 sec 0.1 sec
P6 – Motor Timer (Cycle 1) Motor 30 sec 1620 30 sec 5 min
sec
P7 – Load Delay Timer (Cycle 2) Ld Dly 0 sec 20 sec 1 sec 5 sec
P8 – Discharge Delay Timer (Cycle 5) Dis Dly 0 sec 20 sec 1 sec 5 sec
P9 – Input Filter: Receiver Proximity Sensor In: Rec 0.1 sec 10 sec 0.1 sec 3 sec
P10 – Input Filter: Buffer Hopper Proximity Sensor In: BuH 0.1 sec 10 sec 0.1 sec 3 sec
P11 – Input Filter: Supply Hopper Proximity Sensor In: SuH 0.1 sec 10 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 Mask Xor Msk 7F(dec12
7)
P18 – Oper M (Operating Mode) Oper M 1
1 = Self contained with discharge valve, 2 = Single
central with discharge valve, 3 = Self contained, 4 =
Single Central
P19 – Clean Filter Clean M 1
0 = disables all cleaning, 1 = clean during discharge
cycle, 2 = clean during load cycle, 3 = clean during
both discharge and load cycles.
P20 – Discharge Mode, 1 = Fill mode, 2 = LWB mode Disch 1
P21 – Controller Address HCUAdd 0x01
P22 – Controller Software Version HCU SW
P23 – Supply Hopper Low Alarm Timer Al ShLo 0 sec 600 sec 10 sec 0 disable
P24 – Differential Pressure High Alarm Timer Al DPHi 0% 100% 1% 0 disable
P25 – Load Cycle Alarm Counter Al Cycle 0 cycle 20 cycle 1 cycle 0 disable
P26 – Discharge Valve Alarm Timer Al Valve 0 sec 15 sec 1 sec 10 sec
P27 – On/Off Counter O/F Cnt N/A
P28 – Run Time Counter Run Cnt N/A
P28 – Handheld display Software version HSU SW N/A
P63 – Digital input states Dig In N/A

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10 Appendix
10.4 Drive status tables

10.4 Drive status tables

10.4.1 DC Drive hex status codes

Notes:
• Failure modes occur on bits 7 to 15, excluding 9
• These codes are displayed at the KCM interface

Bit Function Hex Code

0 1 = Motor Run. 0 = Stop. 0001

1 1 = safety switch closed. 0 = open. 0002
2 1 = Drive enable input closed. 0 = open. 0004
3 1 = Bit 1 Input activated (low level). 0 = not 0008
activated, (high level).
4 1 = Bit 2 Input activated (low level). 0 = not 0010
activated, (high level).
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 1 = Safety relay failure 1000
13 1 = General motor failure. 2000
14 1= Control-less running 4000
15 1 = EEPROM failure. 8000

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 Appendix 10
Drive status tables 10.4

10.4.2 Vibratory drive hex status codes

Notes:
• Failure modes occur on bits 7 to 15., excluding 9
• These codes are displayed at the KCM interface

Bit Function Hex Code

0 1 = Motor Run. 0 = Stop. 0001

1 1 = safety switch closed. 0 = open. 0002
2 1 = Drive enable input closed. 0 = open. 0004
3 1 = Bit 1 Input activated (low level). 0 = not 0008
activated, (high level).
4 1 = Bit 2 Input activated (low level). 0 = not 0010
activated, (high level).
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
12 1 = Frequency limit 1000
13 1 = General drive failure. 2000
14 1 = Polarity error 4000
15 1 = Hardware failure. 8000

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10 Appendix
10.4 Drive status tables

10.4.3 Stepper drive hex status codes

Notes:
• Failure modes occur on bits 7 to 15., excluding 9
• These codes are displayed at the KCM interface

Bit Function Hex Code

0 1 = Motor Run. 0 = Stop. 0001

1 1 = safety switch closed. 0 = open. 0002
2 1 = Drive enable input closed. 0 = open. 0004
3 1 = Bit 1 Input activated (low level). 0 = not 0008
activated, (high level).
4 1 = Bit 2 Input activated (low level). 0 = not 0010
activated, (high level).
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 = Safety relay failure. 1000
13 1 = General motor failure. 2000
14 Not used. 4000
15 1 = EEPROM failure. 8000

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 Appendix 10
Drive status tables 10.4

10.4.4 AC drive interface hex status codes

Notes:
• Failure modes occur on bits 7 to 15., excluding 9
• These codes are displayed at the KCM interface

Bit Function Hex Code

0 1 = Motor Run. 0 = Stop. 0001

1 1 = safety switch closed. 0 = open. 0002
2 1 = Drive enable input closed. 0 = open. 0004
3 1 = Bit 1 Input activated (low level). 0 = not 0008
activated, (high level).
4 1 = Bit 2 Input activated (low level). 0 = not 0010
activated, (high level).
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
12 Not used. 1000
13 Not used. 2000
14 Not used. 4000
15 1 = EEPROM failure. 8000

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 99

10 Appendix
10.5 SFT status table

10.5 SFT status table

This table shows the table of the possible Status displayed in the scale
menu at the variable SFT Status 6.8.2.

Bit Function Hex Code

0 1 = 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 range error 2000
14 1 = Temperature window range error 4000
15 1 = General alarm 8000

Example:
0183= group mode, group leader, filter on, weight conversion com-
plete.

Hex 0 1 8 3
Bits 0000 0001 1000 0011

15 0

Fig. 10.10SFT hex codes

Page 100 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Appendix 10
Service variables 10.6

10.6 Service variables

This table shows the Service Index which can be entered for Service
Variables on page 51. A service technician can enter current values
for reference.
Desc Variable Current Value
PreLoad MF=SP Preload MF value with SP upon KCM starts or large SP changes
KLink Tx Delay Enable K-Link to delay TxD to prevent network overloads
Empty DC Value of drive command when emptying the batcher. Default is 70%.
Auto Span Limit Limit in actual range of the allowed span deviation from 1.000 to allow a
auto-span calculation to proceed. Default is 0.98-1.02 or an entry of
0.02.
Com1 Read Comm board K-Port 1 reads per second; <=100
Com1 Write Comm board K-Port 1 writes per second:<=10
Com1 Err Comm board K-Port 1 error counter:<= 1/hour
Com2 Read Comm board K-Port 2 reads per second:<=100
Com2 Write Comm board K-Port 2 writes per second:<=10
Com2 Err Comm board K-Port 2 error counter:<= 1/hour
Host Read Host channel reads per second: <=100
Host Write Host channel writes per second: <=10
Host Err Host channel error counter: <= 1/hour
IntCh msgs Internal channel (SFT/MDU) messages per second
IntCh err Internal channel (SFT/MDU) error counter
IntCh Load Internal channel (SFT/MDU) loading in percent: <= 50%
IntCh Node Internal channel (SFT/MDU) last failed node
IntCh Opcode Internal channel (SFT/MDU) last opcode
ResConfPort Resets the config port to defaults
RefArr Dev Lim Maximum allowed variance in Feedfactor from Empty to Full points on
the Refill Array curve
KCDR-K10S When set to <1> configures K-Port1 to function with a K-Commander-
KCDR, a separate K-Link unit (black box) or KDU using extended soft-
ware. When this entry is set to <0> K-Port1 returns to its normal function.
If <KPORT1 PROT> is set to <KSL> and this entry is set to <1> then K-
Port1 baud rate is selectable.
ReprogCommBd When this variable is set to <1> and KCM power is cycled, automatic re-
programming of the comm board by the KCM will occur. This value is re-
set to <0> after the programming activity is complete.

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 101

10 Appendix
10.7 LWB PSR Map

10.7 LWB PSR Map

PSR(Process number) Description

2 RUN • Motor/machine running
3 DISABLE • Run disabled by Interlock input or
run enable input
4 ENABLE • Drive output enabled
5 ALS IN • Alarm shutdown input active
6 ALS OUT • Alarm shutdown output active
7 AL RELAY • Alarm relay active
8 HARD ALARM • Complement of AL_Rel
9 SOFT ALARM • On for any alarm present
13 EMPTYING • Machine is being emptied by Empty
function
15 WAIT • batcher received a start command
but is waiting
20 START_OK • Start input will start batcher
22 K-LINK INIT COM- • K-Link initialization has been com-
PLETE 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_FULL • Loader receiver is full
34 HCU_BUF_FULL • HCU alarm
35 HCU COMMFAIL • HCU communication failure to CPU
36 HCU_LOADING • HCU loading status
40 HARD_INTERLOCK • Drive (MDU) hard interlock input sta-
tus
51 GEAR_SW_OUT • Hi (Lo) gear switch output enabled
52 BLOWOFF_OUT • Filter blowoff function set

Page 102 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Appendix 10
LWB ASR Map 10.8

PSR(Process number) Description

64 DISP_PRESENT • KCM/KD display present
65 CPU_INIT_CPL • CPU initialization complete
66 MASS_MODE • Unit in Grav mode
67 CALIB • Currently running an auto calibrate
routine
69 REFILL • Batcher is refilling by automatic
means
70 REF_TIMEOUT • Refill timer has expired
75 LOADER_FULL • Loader full input to control
76 LOADING • Loader motor is running
77 LOAD_ENA • Loader is enabled to run
78 DRIBBLE • Batcher is in dribble mode
79 BATCH_COMPLETE • Batch is completed.

Table: 6 PSR MAP

10.8 LWB ASR Map

V See section 9.2 for alarm specifics.

ASR(Alarm number) Description

00 HARDWARE ERROR • KCM Hardware error. EEPROM da-
ta is corrupt. For example, this mes-
sage will occur after updating or
changing firmware on the KCM.
01 KPROM MEM FAIL • The K-PROM cannot be accessed
by the KCM CPU.
02 KPROM*KGR*FAIL • Checksum error in kgr file area.
03 POWER GLITCH • Power dip detected. CPU did not re-
set.

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10 Appendix
10.8 LWB ASR Map

ASR(Alarm number) Description

05 INT CHAN FAIL • Internal channel has failed to com-
municate 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 • Number of SFTs found during poll-
INCORRECTNUM.SFT ing does not equal that required.
08 BAD SFT STATUS • SFT is showing an incorrect status.
09 NO MDU FOUND • The KCM CPU did not find a motor
drive on the internal channel on
power-up.
10 MOTOR ALARM • The KCM CPU lost the motor drive
on the internal channel while in oper-
ation.
11 • Motor drive has lost communication
MDU SERIAL TIMEOUT with the KCM CPU and then turns off
all digital outputs and shuts of drive
power.
12 MDU THERMAL OVL • Drive temperature has been ex-
ceeded > 75 deg C. Drive stops.
13 MDU SPEED DEV • No speed feedback signal is present
when motor is asked to run.
• Speed deviation from target > ± 5
rpm
• Wrong motor voltage programmed.
14 • Motor current limit is exceeded.
MOTOR OVERLOAD
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.

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 Appendix 10
LWB ASR Map 10.8

ASR(Alarm number) Description

15 • Safety relay failed to close contacts
MDU SAFETY RELAY on power up and contacts remained
closed after power down.
16 • Dual tach signals connected, one
MOTOR/ENCDR FAIL failed.
• Over-voltage on drive power supply.
• Motor voltage applied but no speed
feedback.
• Drive temperature > 85 deg. C.
17 • Speed feedback but no motor volt-
MDU UNCONTROLLED age applied.
18 • EEPROM checksum failed.
MDU EEPROM FAILED

19 MDU DRIVE FAILED • MDU drive pcb has failed. (vibratory

drive only. Drive coil current too
high)
20 MDU POLARITY • Coil polarity is incorrect on the vibra-
tory drive. (Vibratory feeder only)
• Displacement frequency out of
range.
21 HCU REMOVED • HCU was removed.
22 HCU ALARM • HCU has an alarm.
23/01 • EEPROM failed.
HCU EEPROM FAILED

24/02 • The controller's digital output driver

HCU DRIVER FAILED has detected a fault.
25/03 • Material is below the level of the
HCU SUPP.HOPP.LOW supply hopper proximity sensor.
• Sensor failed.
26/04 • The differential pressure across the
HCU D.P.ALARM filter is too high indicating a clogged
filter.

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10 Appendix
10.8 LWB ASR Map

ASR(Alarm number) Description

27/05 If P20 Discharge Mode =01“Fill” mode
HCU CYC.COUNT AL then:
• Max. numbers of load cycle exceed-
ed, because Buffer Hopper Low in-
put has been active (on) for more
than the allowed load cycles. The
Buffer Hopper Low signal going in-
active 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 sig-
nal going inactive clears the load cy-
cle counter.
28/06 • Discharge valve has failed to either
HCU DISCH VALVE open or close properly. This alarm is
automatically disabled in P18 Oper-
ating Modes 03 and 04.
29/07 • Receiver is still full after discharge.
HCU REV.FULL AL.
• Receiver proximity switch too sensi-
tive adjusted or failed.
30 • Protocol of KGR file does not match
KLINK WRONG KGR that required by the installed com-
munication circuit card.
31 KLINK NO KGR • No KGR file loaded
32 HPORT FAIL • Host communication pcb error.
33 HPORT FAIL INIT • Host communication pcb could not
be initialized.
34 • Improper pcb installed in the host
HPORT ILLEGAL BD port location.
35 KPORT FAIL • K-Port has failed
36 KPORT FAIL INIT • K-Port communication pcb could not
be initialized.
37 • Host communication pcb is installed
KPORT ILLEGAL BD on the wrong port location-(K-Port).
38 • One or more feeder parameters are
KGR PARAM ERROR not correct for the specified feeder.

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 Appendix 10
LWB ASR Map 10.8

ASR(Alarm number) Description

39 EXT IO FAIL • The MODBUS I-O connection has
failed.
40 • Digital input on KCM selected for Ex-
EXT ALR ACTIVATED ternal Alarm is active.
41 INTERLOCK FAIL • Drive pcb Run Enable digital input is
open during operation.
42 START IGNORED • Start conditions not fulfilled.
43 MASSFLOW HIGH • The current massflow is above the
tolerance entered in <ALARM>
menu parameter <MF ERR+>.
44 MASSFLOW LOW • The current massflow is below the
tolerance entered in <ALARM>
menu parameter <MF ERR->.
45 DRIVE CMD CEILING • Drive command has reached the
limit <DC CEILING>
46 DRIVE CMD HIGH • The drive command has exceed the
value <DRV CMD HI> Limit in the
<ALARM> menu.
47 DRIVE CMD LOW • The drive command has dropped
below the value <DRV CMD LO>
Limit in the <ALARM> menu.
48 • DC motor brushes may be wearing
CHECK_MOTOR_BRUS out and ready to fail.
HES

52 FEEDFACT. BAD • Feedfactor is zero or feeding condi-

tion changed so that the feedfactor
exceed the set limit in the <ALARM>
menu <FF DEV LIMIT>.
53 • The weight on the scale is above the
SCALE OVERRANGE scale gross range permitted.
54 • The weight on the scale is below the
SCALE UNDERRANGE zero or gross weight < 0.
55 NETWT > LIMIT • The material weigh in the hopper is
above the limit set in the <ALARM>
menu. <NW HI LIMIT>.
56 NETWT < LIMIT • The material weigh in the hopper is
below the limit set in the <ALARM>
menu.<NW LO LIMIT>.

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10 Appendix
10.8 LWB ASR Map

ASR(Alarm number) Description

57 REFILL EXPIRED • The programmed refilling time (pro-
gram parameter <ALARM> menu,
<MAX REFILL TIME> was exceed-
ed without refilling being completed.
58 LOADER TIMEOUT • Loader hopper is empty
61 • Adaptive gain is 10 or below.
LOW CONTROL GAIN

52 FEEDFACT. BAD • Feedfactor is zero or feeding condi-

tion changed so that the feedfactor
exceed the set limit in the <ALARM>
menu <FF DEV LIMIT>.
53 • The weight on the scale is above the
SCALE OVERRANGE scale gross range permitted.
54 • The weight on the scale is below the
SCALE UNDERRANGE zero or gross weight < 0.
55 NETWT > LIMIT • The material weigh in the hopper is
above the limit set in the <ALARM>
menu. <NW HI LIMIT>.
56 NETWT < LIMIT • The material weigh in the hopper is
below the limit set in the <ALARM>
menu.<NW LO LIMIT>.
57 REFILL EXPIRED • The programmed refilling time (pro-
gram parameter <ALARM> menu,
<MAX REFILL TIME> was exceed-
ed without refilling being completed.
58 LOADER_EMPTY • Loader is empty.
59 • Batch tolerance exceeded.
BATCH_TOLERANCE

60 BATCHTIME2HIGH • Batch time exceeded.

Page 108 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Appendix 10
Parameter listing-LWB 10.9

10.9 Parameter listing-LWB

Menu Variable Value

Home
Batch Size
Batched
Batched%
Drive Cmd-%
Net Weight
Mot RPM
Not always visible Screw RPM-rpm/

Displacement(vib)
Ave FF
Total
Product Change
Menu
General sub Refill
Refill Max
Refill Min
Init Feedfactor

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10 Appendix
10.9 Parameter listing-LWB

Menu Variable Value

Product Change Fast DC

Menu

Batch sub
Dribble DC
Batch Time
Dribble Time
Maximum Batch Size
Batch Count
Calibration Menu
Calibration sub Initial Feedfactor
Average Feedfactor
Cal Prod Fed
Act Prod Fed
Span
not for vibratory Cal Correla
not for vibratory Cal Corr Lim
not for vibratory Cal DC-%
not for vibratory Cal Time [sec]
Feedfactor sub
Init FF
Avg FF

Page 110 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Appendix 10
Parameter listing-LWB 10.9

Menu Variable Value

Alarm Menu
Limits sub Batch Tolerance-%
FF Dev Limit
Max Refill Time
NW Hi Limit-%
NW Lo Limit-%
Batch Time Grace
Alarm Menu

Set-up sub
Alarm Delay-sec.
Startup Delay-sec.
Stops Clrs Alarms
ALR Number
ALR Mode
Stop By: Read only

Tuning Menu
Control Gain
Adaptive Tune
Stop Pert
Stable Weight Count
Preact Weight
Sample Time
Post Batch Jog

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10 Appendix
10.9 Parameter listing-LWB

Menu Variable Value

Feedfactor Menu
Initial Feedfactor
Average Feedfactor
Feedfactor Menu

For vibratory only

FF@8%, FF@12%
FF@17%, FF@23%
FF@33%, FF@50%
FF@70%, FF@100%
Refill Menu
Refill Enable
Refill Max
Refill Min
Post Refill Delay
Refill
Refill Mode
Flt Clear Time
Scale Menu
General sub Tare
Span
Net Weight
Gross Weight
Scale Range

Page 112 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Appendix 10
Parameter listing-LWB 10.9

Menu Variable Value

Scale Menu SFT Required

SFT sub
SFTs
SFT Selected
SFT Addressed
SFT Weight
SFT Type
SFT Status
SFT #
SFT SN#
SFT Temperature
Machine Menu
General sub Setpoint Mode
Units
Run Time - hours
Fdr Address
Application
Language
Screen Saver
Motor sub
Gear Reduction
Pick-Up Teeth
Actual Power
Maximum Motor Power
Maximum Motor Voltage

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 113

10 Appendix
10.9 Parameter listing-LWB

Menu Variable Value

Motor sub Maximum Motor Speed

MDU Status
Vibratory only KV Device
Vib Span
Machine Menu

Performance sub
Int Channel
KCM Temperature
Torque
Brush Remain
I-O Menu
Digital Inputs CPU1
CPU2
CPU3
CPU4
MDU1
MDU2
Ext1
Ext2
Ext3

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 Appendix 10
Parameter listing-LWB 10.9

Menu Variable Value

I-O Menu

Digital Inputs
Ext4
Ext5
Ext6
Ext7
Ext8
I-O Menu

Digital Outputs
CPU1
CPU2
CPU3
CPU4
MDURelay1
MDURelay2
MDURelay3
Ext1
Ext2
Ext3
Ext4
Ext5
Ext6
Ext7
Ext8
Ext Total Pulse

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 115

10 Appendix
10.9 Parameter listing-LWB

Menu Variable Value

I-O Menu DigiOut Map

Digital Outputs

I-O Menu

Setpoint sub
Source
AinValue-%
Ain Min-%
Ain Max-%
Deadband-%
I-O Menu

Analog Out Menu

CPU
Ext1
Ext2
Ext3
I-O Menu

Modbus I-O Menu

Address 80
Address 81
Address 82
Address 83

Page 116 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Appendix 10
Parameter listing-LWB 10.9

Menu Variable Value

Loader Menu
Loader Function
Max Load Time
Shutdown Time
Discharge Time
Valve Close Time

HCU Loader Refer to 0290023601

System Menu
Host Prot
Host File
K-Port 1 Prot
Baud Rate
K-Port 2 Prot
Config Mode
SW#
HW#
MDU#
Password
Security Menu
Product Change
Alarm
Tuning
Feedfactor
Refill

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 117

10 Appendix
10.9 Parameter listing-LWB

Menu Variable Value

Security Menu Scale

Machine Set-Up
I-O Set-Up
Loader
HCU Loader
System
Fdr Being Viewed
Tot Key
SP Access
Vol/Alarm Clear

Page 118 KCM LWB Programming Docu-No.: 0590020606-EN Rev. 1.5.0

 Index

INDEX Batch% 17 External Totalizer Pulse 55

BATCHED 17 F
BAUD RATE 64 FAST DC 21
Symbols BRUSH REMAIN 52 Fast Drive Command 21
Brush Remain 52 FDR ADDR 41
BATCH TOL- 28
C FDR BEING VIEWED* 67
A
CAL CORREL 25 Feeder Name 42
ACT. PROD FED 24 CAL DC 25 Feeder Number 41
ACTION 66 CAL PROD FED 24 Feeder Run Time 41
Active Cycle 62 CAL-CORR LIM 25 Feeder Stopped By 30
Active Time 62 Calib Correlation 25 FEEDFACTOR 67
Actual Motor Power 44, 48 CALIB TIME 25 Feedfactor deviation limit 28
Actual Product Fed 24 Calibrate Corr Limit 25 FF DEV LIMIT 28
ADAPT TUNING 32 Calibrate Drive Cmd 25 Filter Clear Time 36
ADAPTIVE TUNE 32 Calibrate time 25 FLT CLEAR TIM 36
Adaptive Tuning 32 Calibration Product Fed 24 FUNCTION 54, 55, 57
ADDR 80 - 83 59 29
AIN MAX 56
Clear Alarm on Stops G
COMMAND 62 GEAR REDUC 44, 46, 48,
AIN MIN 56 Command 62
AIN VALUE % 56 49
CONF PROT 64 Gear Reduction or Total Gear
ALARM 67 Control Type 41
ALARM DELAY 29 Reduction 44, 46, 48, 49
CTRL GAIN 32 Grav problem 81
Alarm Delay 29
ALARM MODE 29 D GROSS WEIGHT 37
Alarm mode function 31 DEABAND% 58 Gross Weight 37
ALARM NUM 29 DEADBAND 56 H
ALR 29 Deadband 56 HCU CYCLE 62
Alsh 81 KCM TEMPURATUR- 52 HCU LOADER* 67
Analog In Value Max 56 Delivered Weight 17 HCU STATUS 63
Analog In Value Min 56 DETAILS 59 HOST FILE 64
Analog Input Source 56 DIG IN 53 HOST PROT 64
Analog Input Value % 56 DIG OUT 55 RUN TIME- 41
Analog Output 57 Digital input 53 HW # 65
Analog Output Deadband 58 Digital Input Function 54
Analog Output Function 57 Digital Input Status 54 I
Analog Output Maximum 58 Digital Output 55 INIT FF 20, 23, 26, 33
Analog Output Minimum 57 Digital output Function 55 Initial Feedfactor 20
Analog Output Value % 57 Digital Output State 55 Initial feedfactor 23, 26, 33
AOUT MAX. 58 Digital Output Status 55 INT CHANNEL 52
AOUT MIN 57 DIGOUT MAP 55 Internal Channel 52
AOUT NUM 57 Disa 81 I-O SETUP* 67
AOUT VALUE% 57 DISCHARGE TIME 61 K
AUTO FF CALIB 20, 24 Discharge Time 61 KCM Temperature 52
AUTO READDRESS 38 DISPLACE 17 K-PORT 2 PROT 64
AUTO TARE 36, 37 Displacement 17 K-PORT1 PROT 64
Average Feedf 18 Dribble Drive Command 21 KSC feeder selection 9
Average Feedfactor 18, 23, DRIVE CMD 17 KSC LWF overview screen 10
26, 33 Drive command 17 KSL LWF programming menu
AVG FF 18, 23, 26, 33 Drive command high limit 28 structure 8
B E KSL overview page for LWF 9
Backup Action 66 EMPTY FDR 21 KV DEVICE 47
BAT SIZE 17 Entered Password 66 L
Batch Refill Control 35 Equipment required LANGUAGE 41
Batch Size 17 71 LOADER FUNCTION 61
BATCH% 17 EXT TOT INC 55 LOADER* 67

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 119

Index

LWF alarms 80 Remote Start 95 Refill Level Maximum 19, 35

M P13 – Input Filter Refill Level maximum 19
MACHINE 67 Remote Stop 95 Refill Level Minimum 19, 35
MAX BAT SIZE 22 P14 – Input Filter Refill Level minimum 22
MAX LOAD TIME 61 Discharge Valve Switch 95 REFILL MAX. 19, 35
Max Load Time 61 P16 – Input Filter REFILL MIN 19, 22, 35
MAX MOT VOLTAGE 44 Discharge Request 95 Refill Mode 35
Max Motor Power 44, 48 P18 – Oper M (Operating Mode) Refill or Refill Enable 35
MAX REF TIME 28 95 Refill time max 28
MAX. MOT POWER 44, 48 P19 – Clean Filter) 95 Refill timer option 22
Maximum Motor Speed 44, P2 – Clear Timer 95 Refill timer procedure
46, 48, 49 P20 – Discharge Mode 95 71
MDU STATUS 45, 46, 47, P21 – Controller Address 95 REFILLL MAX. 19, 21, 35
48, 49 P22 – Controller Software Version REFILLMODE 35
MDU Status 45, 46, 47, 95 MAX MOT SPEED- 44, 46,
48, 49 P27 – On/Off Counter 95 48, 49
MDU# 65 P28 – Handheld display Software S
Messages 81 version 95 S.VAR 51
MF @ 100 % DC 27, 34 P28 – Run Time Counter 95 SAMPLE TIME 32
MF @ 12% DC 27, 34 P3 – Discharge Timer 95 SCALE 67
MF @ 17% DC 27, 34 P4 – Filter Delay Timer 95 SCALE RANGE 37
MF @ 23% DC 27, 34 P5 – Filter Pulse Timer 95 Scale range 37
MF @ 33% DC 27, 34 P6 – Motor Timer (Cycle 1) 95 SCREEN SAVER 42
MF @ 50% DC 27, 34 P63 – Digital input states 95 SCREW RPM 17
MF @ 70% DC 27, 34 P7 – Load Delay Timer (Cycle 2) Screw Speed 17
MF @ 8% DC 27, 34 95 HCU TIME - 62
Motor Control Gain 32 P8 – Discharge Delay Timer Security 67
MOTOR RPM 17 (Cycle 5) 95 Selected Alarm Mode 29
Motor Speed 17 P9 – Input Filter Service Variable Name 51
Receiver Proximity Sensor
Motor Voltage 44 Service Variable value 51
95 41
N PARAM NAME 63
SETPOINT MODE
Nak’d Feeder Running 81 Setpoint mode 41
PARAM NUM 63 SFM calibration process when
Name of Selected Alarm 29 PARAM VALUE 63
NET WEIGHT 17, 22, 37 used as a feeder. 69
Parameter name 63 SFT # 39
Net weight 17, 22, 37 Parameter Value 63
Net weight high limit 28 SFT ADDRESSED 39
PASSWORD 66 SFT Adressed 39
Net weight low limit 28 Pert 32
Node # Of Selected SFT 39 SFT Configuration 38
PICK UP TEETH 44, 46, SFT CUTOFF 32
Number of Selected Alarm 29 48, 49
Number of SFT’s Required 38 SFT CutOff Frequency 32
POLARITY 54, 55 SFT SELECTED 39
NW HI LIMIT 28 Polarity 54, 55
NW LO LIMIT 28 SFT Serial # 39
Poll 38 SFT SN # 39
O POST REFILL DELAY 35 SFT Software 39
Operator overview loop 7 Post Refill delay 22 SFT STATUS 39
Out of Range 81 Post Refill Vol/Grav Delay 35 SFT Status 39
Preact Weight 32
P PREACT WGT 32
SFT TEMPERATURE 39
P1 – Load Timer 95 SFT Temperature 39
PRODUCT CHANGE 67 SFT TYPE 39
P10 – Input Filter Programming requirements 12
Buffer Hopper Proximity SFT Type 39
Sensor 95 R SFT WEIGHT 39
P11 – Input Filter REBIND NOW 59 SFT weight 39
Supply Hopper Proximity REFILL 19, 21, 35, 67 SFT’s REQUIRED 38
Sensor 95 Refill Enable 19 SFTs 38
P12 – Input Filter Refill enable 21 SHUTDOWN TIME 61

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 Index

Shutdown Time 61 ACTUAL POWER- 44, 48

SOURCE 56 Weight Sample Time 32
SP ACCESS 68 Weight Span 25, 37
SPAN 25, 37 Won’t start table 81
Specifications
Device name 12
Manufacturer 12
Service application 12
Speed pickup Teeth 44, 46,
48, 49
STARTUP DELAY 29
Startup Delay 29
STATE 54, 55
Status 63
STOP 32
STOP BY 30
STOP CLRS ALARM 29
STOP PERT 32
SW# 65
SYSTEM SETUP 67
T
TARE 37
Tare Failed 81
Tare weight 37
TIMER OPTION 22
TORQUE-% 52
Torque-% 52
TOT KEY 67
TOTAL 18
Totalizer 18
TRACETICK 51
Tracetick 51
TUNING 67
U
Units selection 41
V
VALVE CLOSE TIME 61
Valve Close Time 61
VAR VALUE 51
VIB DISP SPAN 47
Vibratory Displacement SPAN
47
Vibratory FF 100% 27, 34
Vibratory FF 12% 27, 34
Vibratory FF 17% 27, 34
Vibratory FF 23% 27, 34
Vibratory FF 33% 27, 34
Vibratory FF 50% 27, 34
Vibratory FF 70% 27, 34
Vibratory FF 8% 27, 34
Vibratory Type 47
VOL/ALARM CLR 68
W
Wait 81

Docu-No.: 0590020606-EN Rev. 1.5.0 KCM LWB Programming Page 121

 Chapter 3:
Feeder
Documentation
 OPERATING AND
MAINTENANCE INSTRUCTIONS

Feeder KT20

Read this manual prior to operating

or servicing the equipment. This
manual contains all safety labels and
warnings.

0890000002-EN Rev. 1.0.0

 Service
If you need assistance, please call your local service center or:
K-TRON (Switzerland) Tel. 0041 (0) 62 / 885 71 71
Industrie Lenzhard Fax 0041 (0) 62 / 885 71 80
CH-5702 Niederlenz

K-TRON (U.S.) Tel. 001 (0) 856 / 589 90 83

Rt 55 and Rt 553 Fax 001 (0) 856 / 589 56 64
Pitman, NJ 08071

Web: http://www.ktron.com

Before you call...

« Do you have alarm displays? Can you eliminate their causes?
« Have you modified part of the system, product or operating mode?
« Have you tried to eliminate the fault in accordance with the operating
instructions?
« Note down the 6 digit project or job number. This can be found at the
machine or in the project manual.
• Example of project number: 400545

Using the manual:

« This arrow identifies an individual action.
1. Numbers identify a sequence of actions which have to be executed
step-by-step.
V This symbol identifies a general safety note.

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.: 0890000002-EN “K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part of
operating personnel. Further, reference is made to the purchase order, acceptance or other document that contains
the express K-Tron disclaimer of warranties for a statement of the provisions limiting or disclaiming certain warranties
Datum: 2008/Sep/16 with respect to the Company's equipment. Except as otherwise expressly provided by K-Tron in any such document,
K-TRON MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NOR
Original: 0890000002-EN ANY OTHER WARRANTY, EXPRESS OR IMPLIED, WITH RESPECT TO THE EQUIPMENT.”
If an error or ommission is found, please contact: documentation@ktron.com.
 Table of contents

1 Safety notes ............................................................. 5

1.1 Safety symbols definitions ......................................... 5
1.1.1 Electrical Hazard Icon ............................................... 6
1.1.2 Ground Icon .............................................................. 6
1.1.3 No Hands Icon .......................................................... 6
1.1.4 Power Icon ................................................................ 6
1.2 Responsibilities of the owner .................................... 7
1.3 Proper use ................................................................. 7
1.4 Organizational measures .......................................... 7
1.5 Safety-conscious work .............................................. 8
1.6 Safety devices ........................................................... 8
1.7 High voltage .............................................................. 8
1.8 Additional equipment ................................................. 9
1.9 Customer service and repairs ................................... 9
1.10 Shut-down procedure ................................................ 9

2 Assembly and function ......................................... 10

2.1 Feeder types ........................................................... 10
2.2 Structure .................................................................. 11
2.3 Feed screw types and applications ......................... 12
2.3.1 Screw types and applications .................................. 13
2.3.2 Twin screw sizes and throughput ............................ 13
2.4 Outlet tube configurations ....................................... 14
2.5 Gearing reduction .................................................... 14
2.6 Warnings and safety devices .................................. 15
2.6.1 Safety devices ......................................................... 15
2.6.2 Warnings ................................................................. 15

3 Technical data ....................................................... 16

4 Installation ............................................................. 17
4.1 Transportation ......................................................... 17
4.2 Unpacking ............................................................... 18
4.3 Mounting the feeder ................................................ 19
4.3.1 Installing volumetric feeder ..................................... 19
4.3.2 Installing gravimetric feeder .................................... 20
4.4 Adjusting the feeder (D-Platform Scale) .................. 21
4.5 Oil ventilation plug .................................................. 21
4.6 Connecting the feeder ............................................. 22
4.7 Taking the feeder into operation ............................. 22
4.8 Storage .................................................................... 23

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 3

 5 Operation ............................................................... 24
5.1 Notes on operation .................................................. 24
5.2 Switching on/off ....................................................... 24

6 Cleaning ................................................................. 25
6.1 Switching off the machine before maintenance work 25
6.2 Cleaning .................................................................. 25
6.2.1 Cleaning without parts removal ............................... 26
6.2.2 Cleaning with parts removal .................................... 26
6.3 Replacing the hopper .............................................. 27
6.4 Replacing the feed screws ...................................... 28
6.4.1 Removing the feed screws ...................................... 28
6.4.2 Installing the feed screws ....................................... 29
6.5 Replacing the horizontal agitator ............................ 30
6.5.1 Replacing the three part agitator on KM-KT20 ........ 30
6.5.2 Replacing the three part agitator on KC-KT20 ........ 31
6.5.3 Replacing the one-piece agitator (used for ATEX) .. 31
6.6 Replacing the vertical agitator (optional) ................. 32
6.6.1 Removing the vertical agitator ................................. 32
6.6.2 Installing the vertical agitator ................................... 32
6.7 Replacing the agitator hopper ................................. 33
6.7.1 Removing the agitator hopper ................................. 33
6.7.2 Installing the agitator hopper ................................... 33

7 Maintenance .......................................................... 34
7.1 Maintenance Intervals ............................................. 34
7.2 Replacing seals ....................................................... 35
7.2.1 Replacing the screw seals ...................................... 35
7.2.2 Installing the seal ................................................... 35
7.3 Replacing the drive motor ....................................... 36
7.3.1 Preparing the removal ............................................ 36
7.3.2 Removing the motor ................................................ 36
7.3.3 Installing the motor .................................................. 36
7.4 Replacing the tachometer ...................................... 37
7.4.1 Removing the tachometer ...................................... 37
7.4.2 Installing the tachometer ......................................... 38
7.5 Lubrication ............................................................... 39
7.5.1 Oil level inspection .................................................. 39
7.5.2 Oil change ............................................................... 39
7.6 Replacing the bearings ........................................... 39

8 Troubleshooting .................................................... 40
8.1 Troubleshooting table .............................................. 41

Page 4 Docu-No.: 0890000002-EN Rev. 1.0.0

 Safety notes1
Safety symbols definitions1.1

1 Safety notes

Installation, commissioning and programming of the specified

equipment should only be undertaken by qualified personnel.

1.1 Safety symbols definitions

V The safety alert symbol is used to alert to the potential personal in-
jury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.

V CAUTION indicates a potentially hazardous situation which, if not

avoided, may result in property damage.

V CAUTION with safety alert indicates a potentially hazardous situ-

ation which, if not avoided, could lead to light bodily injuries.

V WARNING indicates a potentially hazardous situation which, if not

avoided, could lead to heavy bodily injury or to death.

V DANGER indicates a extremely hazardous situation which, if not

avoided, could lead to heavy bodily injury or to death.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 5

1 Safety notes
1.1 Safety symbols definitions

1.1.1 Electrical Hazard Icon

This sign indicates an electrical hazard. It is located on covers and
doors. Only qualified personnel are allowed to remove these covers or
open the doors.

1.1.2 Ground Icon

This sign indicates that a ground/PE connection is required.

1.1.3 No Hands Icon

Do not place hands or other body parts into moving parts or machine.

1.1.4 Power Icon

Power off and disconnect air supply before working on the equipment.

Page 6 Docu-No.: 0890000002-EN Rev. 1.0.0

 Safety notes1
Responsibilities of the owner1.2

1.2 Responsibilities of the owner

V Ensure that only qualified and trained personnel work with the
feeder.
V Establish personnel responsibilities for operation and
maintenance.
V Ensure that the personnel has read and understood the operating
instructions to all installation components, particularly this chapter
"Safety notes".
V Strictly follow the operating and maintenance instructions.
V The plant owner must replace immediately damaged or missing
components.
V The operator has to avoid the entry of foreign substances reaching
the feeder (metal parts, stones) by appropriate methods.
V The plant owner is responsible for compliance with legally
prescribed accident prevention and safety regulations.

1.3 Proper use

V Use feeders for dry bulk material and liquids only as stationary
equipment.
V Only operate the feeder in conjunction with the appropriate control
and drive equipment from K-TRON.
V Only operate the feeder in accordance with the specified technical
data.
V When processing dangerous materials, also comply with the
safety notes which govern the handling of such materials.
V Any modifications and changes on safety devices are prohibited
V Do not use the equipment in a manner not intended by the
manufacturer.
V Never use feeder to process materials which may cause a
chemical reaction with the materials of the feeding units.
V Not suitable for mixing or crushing bulk material.

1.4 Organizational measures

V Always keep the operating instructions near the feeder, within

easy reach. Ensure that they are always complete and legible.
V Observe the safety notes for the connected feeding devices.
V In addition to the operating instructions, always comply with
generally prescribed safety regulations governing accident
prevention and environmental safety.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 7

1 Safety notes
1.5 Safety-conscious work

1.5 Safety-conscious work

V Read the operating instructions, in particular these safety notes,

and follow these instructions.
V Ensure that only authorized personnel enter the working and
danger area of the feeder.
V Any changes (including changes in the operational behaviour)
which affect safety must be immediately reported to the
responsible member of the staff.
V Always keep safety in mind while working.
V Before working on the feeder always switch the feeding equipment
off at the main power switch.

1.6 Safety devices

V Operating the feeder without safety devices:

– is dangerous for the health and life of the operator or third
persons
– can damage the feeding units or other material
V Never alter the mechanical safety devices or the electrical control
system for the safety devices. Increased risk of accident.
V Only operate the feeder if all safety devices are installed and fully
functional.
V Check that all safety devices operate properly every day.
V Never open or remove covers or hoods while the equipment is in
operation.
V Never operate the feeder when the housing is open.
V Do not modify the electrical safety devices, for example fuses.
Increased risk of accident.
V Only use the specified fuse types when replacing fuses.
V Replace damaged cable joints and connections immediately.

1.7 High voltage

V Only qualified electricians may work on the electrical equipment of

the feeder.
V High voltage occurs at the motor connections.
V After switching off the main power supply there are still some
internal electrical components of the motor drive carrying high
voltage which discharges slowly.
V Protect electrical parts of the feeder against humidity.

Page 8 Docu-No.: 0890000002-EN Rev. 1.0.0

 Safety notes1
Additional equipment1.8

1.8 Additional equipment

V Modifications to the feeding equipment are prohibited.

V The operator is responsible for complying with all safety
regulations related to interoperation with any additional
equipment, e.g. refilling units.

1.9 Customer service and repairs

V Have repairs to the feeder carried out by

– by the responsible K-Tron customer service (customer service
address is found on the inside cover)
– or –
– by specialized personnel trained by K-Tron.
V Only use original K-Tron parts.

1.10 Shut-down procedure

V The operator is responsible for the proper removal and disposal of

the feeding equipment from service.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 9

2 Assembly and function
2.1 Feeder types

2 Assembly and function

2.1 Feeder types

The feeder is available in the following types:

Type Description Field of application

Volumetric
K-MV-KT20 Twin screw feeders with a maximum Feeding of bulk materials which flow
K-CV-KT20 feed screw diameter of 20 mm. The easily to heavily. Heavy-flowing
feeding tools can be exchanged powders (e.g. pressed, humid or
rapidly. bridging) as well as fibers and flakes
can require a flow aid which prevents
Gravimetric bridging (optional).
K-ML-KT20 Gravimetric feeders are equipped with
a weighing system. As a rule the Different feed screws are available for
weighing system consists of 3 K-SFT the various requirements placed by the
load cells which are mounted on a bulk material (see the machine data
frame. sheet or spare parts list).

K-ML-D5-KT20 KT20 feeders can be mounted on a D5

scales in special cases.

K-CL-24-KT20 KT20 Compact feeder is mounted on a

SFS24 scale.

K-MV-KT20 K-ML-D5-KT20 K-ML-KT20

K-CV-KT20 K-CL-24-KT20

Fig. 2.1 Feeder types

Page 10 Docu-No.: 0890000002-EN Rev. 1.0.0

 Assembly and function2
Structure2.2

2.2 Structure

Overall view Modular KM and Compact KC production series

(1) Hopper lid
(2) Seal
1
(3) Hopper
2
(4) Gearbox for agitator and 11
feed screw
(5) Agitator hopper 3
(6) Outlet tube
(7) Feeding screws
(8) Horizontal agitator 10
4
(9) V-clamping ring 9 10
4
(10) Motor 8
5
(11) v-clamping ring
6
(12) Base plate 7
7 12

Fig. 2.2 Overall view

Method of operation
The feeder is part of a feeding equipment. The minimum configuration
of the equipment consists of a feeder, controller and motor control
unit.
The feed material (Bulk material) is transported from the refill system
to the hopper onto the feed screw. A motor drives the feed screw and
the horizontal agitator (screw filler). The feed screws transport the
bulk material outwards in a constant flow. The feed rate is controlled
by the controller via the speed of the motor and the gearing reduction.
Options:
• A vertical agitator with separate motor drive prevents bridging in the
hopper (only on KM series).
• Shear Hopper (moving inner rubber hopper) with separate motor
drive prevents bridging in the hopper (only on KM series).
• Different hopper sizes available (only on KM series).
• Air purge for screw seals.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 11

2 Assembly and function
2.3 Feed screw types and applications

2.3 Feed screw types and applications

Type Code Feeding Screws

Floodable and mildly cohesive powder.

Twin concave TCC Low friction when compresses.
coarse
TCF
Twin concave fine
Free flowing and non- free flowing pow-
Twin spiral coarse TSC ders, hygroscopic materials, flakes.
Used only in special cases
Twin spiral fine TSF

Free flowing and compacting, sticky

Twin auger coarse TAC powders. Hygroscopic materials, flakes.

Twin auger fine TAF

Very free flowing, free flowing, dusty.

Double spiral DSC hygroscopic Flakes, Pellets, Granules
coarse
Double spiral fine DSF

• Twin and double screws are used in pairs.

• Many other screw configurations exist. Extended length screws and
ones with outboard support bearings are available.
• Nominal twin screw diameters are roughly the model size. e.g. T20
has 20 mm diameter screw sets.
• Double screw flights do not intermesh, twin screws flights inter-
mesh.

Page 12 Docu-No.: 0890000002-EN Rev. 1.0.0

 Assembly and function2
Feed screw types and applications2.3

2.3.1 Screw types and applications

1. Auger screw
2. Spiral screw 6
3. Concave screw
4. Diameter 1 4
5. Tube length 5
6. Pitch
for concave screws double
pitch is indicated (Tab 2.3.2)
2

Fig. 2.3 Screw applications

2.3.2 Twin screw sizes and throughput

Capacity is nominal. The properties of the bulk material being fed may
result in a different capacity than that shown.

Screw type Nominal Dia Capacity Pitch

mm 3
dm /u mm/inch

T20 twin concave coarse 20 0.0033 20 / 0.79

T20 twin concave fine 20 0.0013 11 / 0.43
T20 twin auger coarse 20 0.0054 20 / 0.79
T20 twin auger fine 20 0.0019 8 / 0.31
T20 twin spiral coarse 20 0.0039 20 / 0.79
T20 twin spiral fine 20 0.0019 10 / 0.39
T20 double spiral coarse 20 0.0033 20 / 0.79
T20 double spiral fine 20 0.0016 10 / 0.39

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 13

2 Assembly and function
2.4 Outlet tube configurations

2.4 Outlet tube configurations

1. Tube diameter
1
2. Horizontal discharge
3. Tube length
4. Cap
5. Vertical discharge with outboard bearings
6. Bellow (Flexible connection)
2 7. Outboard bearings
3

7
5

Fig. 2.4 Outlet tube configurations

2.5 Gearing reduction

At the feeders the gearing reduction is controlled by changing the gear
box with different gear reductions.
Type Gearing Gearing reduction (at a motor speed
of 2000 r.p.m)

KM...KT20 A 2,683 : 1 auf 745 U/min

KC...KT20 B 5,6 : 1 auf 357 U/min
C 12,95 : 1 auf 154 U/min
D 1,634 : 1 auf 1223 U/min

Page 14 Docu-No.: 0890000002-EN Rev. 1.0.0

 Assembly and function2
Warnings and safety devices2.6

2.6 Warnings and safety devices

2.6.1 Safety devices

Safety devices are located at the following positions on the feeder:
• Outlet tube (7)
1 2
3 • Hopper (5)
• Connected refilling unit with bellow (2)
4
• Filter bag on the hopper ventilation nozzle (1)
5 • Only for volumetric devices: Safety grid in the hopper (4)

8
7

Fig. 2.5 Safety devices

V Operate the feeding device only with the installed safety devices.
V Do not reach into the rotating feed screw or agitator.

2.6.2 Warnings
The warning shown in is applied to the following positions at the
feeder:
• At the agitator hopper (see Fig. 2.5/6)
• At the outlet tube (see Fig. 2.5/8)
• At the hopper (see Fig. 2.5/5)

The warning shown in is applied to the following positions at the

feeder:
• At the gearbox
• At the vertical agitator

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 15

3 Technical data
2.6 Warnings and safety devices

3 Technical data

Manufacturer K-TRON (Switzerland) Ltd.

Designation • K-CV-KT20
• K-MV-KT20
• K-ML-KT20
• K-ML-D5-KT20
• K-CL-24-KT20

Marking
or declaration by the manufacturer

Motor feed screws See machine data sheet, motor plate and declaration of conformity

Fusing See wiring diagram

Gearing Oil filled gearing for feeding tools and horizontal agitator
Lubrication Type Shell Cassida GL 150 or as specified
Content:
KT20: 0,12 l

Horizontal-agitator (optional) see machine data sheet

Motor vertical-agitator (optional) see machine data sheet, motor plate,

Gearing vertical-agitator (optional) see machine data sheet, motor plate,

Noise < 70 dB (A)

Feed rate see machine data sheet,

Feeding tools see machine data sheet,

Hopper capacity see machine data sheet,

Weight see mechanical drawings

Material of parts contacting feed Rust- and acid-proof steel

material DIN W.- No. 1.4404/1.4435
AISI 316L

Ambient temperature during 0 to 50°C 32 to 122°F

operation

Temperature of the feed material -15 to 80°c 0 to 176°F

Page 16 Docu-No.: 0890000002-EN Rev. 1.0.0

 Installation4
Transportation4.1

4 Installation

V Only have the feeder connected and commissioned by authorized

personnel.

Ambient conditions
V Only use explosion-proof feeders in hazardous areas.
V Install the feeder only in surroundings conforming to the technical
data (see Section 3) and in accordance with the safety notes (see
Chapter 1).

4.1 Transportation

V Before a gravimetric feeder is transported secure the load cell(s).

V Check if v-clamping ring are firmly secure.
V Only transport the feeder with a crane or equivalent lifting gear.
V In order to avoid damage to the feeder only use belts with sufficient
lifting capacity for the crane (for the weight of the feeder see the
mechanical drawings).
V Only fasten the belts at the marked points on the stand or frame
(see 4.1).
V The belts have to be sufficiently long for the belts not be overload-
ed and tear. The angle should be smaller than 60°. The belt
should, however, not touch the conical extension hopper.
V Only remove the yellow transport safety guard after installation of
the feeder (see Fig. 4.6).

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 17

4 Installation
4.2 Unpacking

Fig. 4.1 Fastening and length of the transport belts

4.2 Unpacking
1. Remove the feeder carefully from the packaging.
2. Check whether the supplied goods are complete and check them
for transport damage.
3. Report any damage immediately to K-Tron.
4. Protect the cable ducts on the inside of the frame before attaching
the transport belts.
5. Fasten the belts at the marked points on the stand or frame
(see 4).
6. Ensure that the transport belts do not slip (e.g. by using clamps).

Page 18 Docu-No.: 0890000002-EN Rev. 1.0.0

 Installation4
Mounting the feeder4.3

4.3 Mounting the feeder

1. Select a level and vibration-free installation location
(max. inclination: 5 0/00 oder 0.3°).
2. Clean the installation location
3. Install the feeder.

4.3.1 Installing volumetric feeder

210 50

200
Fig. 4.2 Drilling diagram for base plate

1. Drill the holes (9 mm or 11 mm) for the base plate (see Fig. 4.2).
The outlet side is on the right.
2. Position the feeder and screw it to the base plate by means of
suitable screws.

Fig. 4.3 Fastening the feeder

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 19

4 Installation
4.3 Mounting the feeder

4.3.2 Installing gravimetric feeder

V Do not throw, hit or drop the scale.

V Do not drop any objects on to the scale.
V Do not turn the scale upside down more than 5 minutes. The pos-
sibly fitted oil shock absorber will leak and become unusable.
V Only hold and lift the scale at the bottom and handle carefully.

For information on the dimensions of gravimetric feeders or feeders

with frame or stand see the dimensional drawings in the project
manual.

« Install the feeder in accordance to the dimensional drawings.

Feeder KCL KT20
1. Level the scale and level out any irregularities. Max. Deviation 5 0/00
1 2. Securely mount the scale on to the mounting surface.
3 3. Remove the knurled screws (3) from the scale(1).
4. Gently place feeder (2) on to the scale and secure with the knurled
2 screws.
« Mount the hopper (if not already mounted) (see chapter 6.3).
3

Fig. 4.4 Mounting feeder on to the

platform scale

Remove transport safety guard (3-Point Suspension Scale))

(1) Loosen screw (4) and remove it.
4
(2) Loosen screw (2) to lower the hopper on to the load cell (3).
(3) Remove screw (2) and transport safety guard (1).
3
1 (4) Securely fasten screw on bracket with load cell without twisting
the rubber shock absorber on top of the load cell.

Fig. 4.5 Transport safety guard

Page 20 Docu-No.: 0890000002-EN Rev. 1.0.0

 Installation4
Adjusting the feeder (D-Platform Scale)4.4

4.4 Adjusting the feeder (D-Platform Scale)

« Adjust the supporting bolt (2) while the feeder is empty until it
contacts the feed screw housing (1).

1
2

Fig. 4.6 Adjusting the feeder

4.5 Oil ventilation plug

V If the plastic screw plug is not replaced with the ventilation screw,
the overpressure created during operation will push the gear seals
out.

1. Remove the plastic screw plug (1).

2. Insert the supplied ventilation screw (marked "Oil").

Oil

Fig. 4.7 Replace ventilation screw

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 21

4 Installation
4.6 Connecting the feeder

4.6 Connecting the feeder

Improper connection of the feeder can cause danger to life through

electric shock.
V The feeder may only be connected by qualified electricians.
V Observe the local regulations.

1. Connect the feeder in accordance with the electrical wiring

diagram.
2. Ground the feeder carefully.

Connect the ground connection to a low-impedance equipotential

bonding (≤ 0.1 Ω), see the grounding information on the feeder.

Provide a lockable main switch to disconnect the main power supply

from the feeder.

Carefully follow all wiring and shielding procedures as indicated on the

provided wiring diagrams and operating instructions of the controls.

4.7 Taking the feeder into operation

V Do not place any bulk materials into the feeder until feed screw ro-
tation and security to the drive shafts are verified. Feed screws
may become disengaged if the motor rotation is incorrect.

1. Before the first activation ensure that the agitator hopper and feed
screw are free of objects such as screws, packaging rests, etc.
2. Switch on the feeder with the connected controls.
3. Check the parameters according to the machine‘s programming
list.
For more information see controller operating and programming
instructions.

When switched on the screws turn counterclockwise.

Page 22 Docu-No.: 0890000002-EN Rev. 1.0.0

 Installation4
Storage4.8

4.8 Storage
1. Empty the feeder prior to shipment or storage and attach the
MSDS data sheet describing the product last fed in the machine.
2. Dismantle on gravimetric feeders the load cell (s).
- or -
Secure the load cell (s) with transport safety guard.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 23

5 Operation
5.1 Notes on operation

5 Operation

5.1 Notes on operation

Risk of injury at the rotating agitator and at the rotating feed screws.
V Operate the feeder only with a hopper or a corresponding
protective grating.
V Do not reach into the hopper, agitator hopper or feed screws
during the feeding process.
V Do not bring hair, clothing and tools into the feeder.
V Only operate the feeder with the outlet tube.
V Only switch on the feeder when the gearing and motor cover are
mounted.
V Never use the feeder to process materials which may cause a
chemical reaction with the materials of the feeder, for example
feed materials containing the following substances:
– Acid
– Iodine
– Chromium
– Bromium
V When feeding dangerous materials observe the safety notes
applying for handling these materials.

Excessive vibrations will cause the feeding to become imprecise.

« Avoid vibrations and do not touch the feeder during operation with
scales.

5.2 Switching on/off

« Before switching on ensure that the agitator hopper and feed
screw are free of objects such as screws, packaging rests, etc.
« See controllers operating instructions.
« Switch on/off the feeder with the connected controls
For more information see controller operating and programming
instructions.

Page 24 Docu-No.: 0890000002-EN Rev. 1.0.0

 Cleaning6
Switching off the machine before maintenance work6.1

6 Cleaning

When carrying out maintenance work on the switched-off feeder there

is a danger of injury through unintentional switching-on.
V Switch off the feeding system before carrying out maintenance
work on the feeder and secure it against unintentional restarting
(see section 6.1).

6.1 Switching off the machine before

maintenance work

1. Switch off the machine at the main switch.

2. Secure the main switch with a lock.
3. Attach a danger sign to the main switch.
4. Turn off compressed air for all the pneumatic devices.

6.2 Cleaning

Aggressive and toxic cleaning agents damage the feeder and

represent an increased accident risk.
V Do not clean the feeder with corrosive cleaning agents.
V Use only safe cleaning agents and disinfectants in feeders used
for foods.
V Ensure that no cleaning agent residues are left on the components
which come into contact with the feed material, e.g. on hopper
connections, outlet tube and feed screw.
V Clean in the area of the drive motor only with slight air stream.
V Do not clean the agitator and feed screw with high-pressure
devices.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 25

6 Cleaning
6.2 Cleaning

6.2.1 Cleaning without parts removal

The v-clamp only forms the connection between the hopper and the
agitator hopper.
V Secure the hopper for overturn.

« In case of external soiling, clean all the components of the feeder

with a damp cloth and use normal industrial cleaners.
1
Cleaning the inside
2 1. Empty the feeder.
3 2. Switch off the machine (see Section 6.1).
3. Loosen and remove the v-clamping ring (2).
4. Remove the seal (3).
5. Remove the hopper (1).
4 6. On 3-point suspension scale swivel the feeder away via the hinge
(5).
7. Rinse out the agitator hopper (4).
8. After cleaning, mount the unit in the reverse order.

Fig. 6.1 Cleaning without parts re-

moval

6.2.2 Cleaning with parts removal

1. Carry out step 1 to step 6 from section 6.2.1.
2. In order to clean the feeder more thoroughly remove the following
parts:
– Agitator (see Section 6.5)
– Outlet tube (see Section 6.4.1)
– Feed screws (see Section 6.5.1)
3. After cleaning, mount the unit in the reverse order.

Page 26 Docu-No.: 0890000002-EN Rev. 1.0.0

 Cleaning6
Replacing the hopper6.3

6.3 Replacing the hopper

• 6mm Allen wrench

The v-clamping ring only forms the connection between the hopper
and the agitator hopper.
V Always let the retaining hinge latch in order to stabilize the feeder
(5).

• The seal (3) between the agitator hopper (4) and the hopper (1) can
continue to be used when the hopper is replaced.
• In case of gravimetric feeders: When loosening and mounting the v-
clamping ring always ensure that the hinge (5) remains latched in.
• For KC...KT20 (see chapter 6.5.2).

2
3

Fig. 6.2 Replacing the hopper

1. Loosen and remove the v-clamping ring (2).

2. Remove the hopper (1) and seal (3).
3. Mount the new hopper (1) with seal (3) and v-clamping ring (2).
4. Tighten the v-clamping ring (2).

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 27

6 Cleaning
6.4 Replacing the feed screws

6.4 Replacing the feed screws

Observe the following points when the feed screws is/are replaced:
« Ensure that the hopper and agitator hopper are empty.
« Remove the twin screws simultaneously.
« Do not damage the screw bearing shaft during installation and
removal.

90° 1

Fig. 6.3 Connection of feed screw

Bayonet connection
In order to loosen/lock the screw turn it by approx. 90° on the bearing
shaft.
• 6-mm Allen key
• 4mm Screw driver

6.4.1 Removing the feed screws

1. Switch off the machine (see Section 6.1).
2. Clean the agitator hopper (2) and hopper (1) thoroughly.
3. Remove the outlet tube (6). The seal (4) remains at the flange of
1
the agitator hopper (2).
4. Turn the screws by 90° counterclockwise and then pull it out.
5. Remove the feed screws (5).
6. Clean the outlet tube(6), agitator hopper (2) and bearing shafts in
2
the housing completely.
3
7. Clean the location holes of the new screws thoroughly so that they
4
can be fastened properly.

5
6

Fig. 6.4 Removing the screws

Page 28 Docu-No.: 0890000002-EN Rev. 1.0.0

 Cleaning6
Replacing the feed screws6.4

6.4.2 Installing the feed screws

V When installing the screws do not damage the O-ring at the screw
bearing shaft.
V Do not use a hammer to have the screws latch in.

1. Ensure that there are no feed material residues in the feed screw
housing or at the screw bearing shaft.
2. Before installing the feed screws check the screw bearing shaft for
scratches or sharp edges and eliminate these.
3. Turn the twin screws so that the helixes of the one screw move in
the gaps of the helixes of the other screw (see Fig. 6.5).

Fig. 6.5 Positioning the screws

4. Slide the screws onto the bearing shaft so that the carrier surface
1 2 in the screw holes show in the same direction as the leading-in
surface of the bearing shaft.

Fig. 6.6 Aligning the screw hole

to the bearing shaft

5. Place the screws on the bearing shaft and rotate them by

90° clockwise

Fig. 6.7 Installing the screws

6. Pull the screw carefully in order to check whether the bayonet

connection has latched in.
7. Fasten the outlet tube.
8. Let the feeder run without bulk material in order to check the
correct installation.

V Do not reach into the rotating feed screws or agitator.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 29

6 Cleaning
6.5 Replacing the horizontal agitator

6.5 Replacing the horizontal agitator

Danger through sharp agitator blades!

While disassembling without protective gloves, the agitator can cause
cutter wounds at the hands.
V Always wear protective gloves when working on the agitator.

Feeding different bulk materials may require the agitator to be

changed. Agitators with four blades or special agitator models can be
supplied for various applications (see spare part list).

• 6-mm Allen wrench

• 10mm Ring open end wrench

6.5.1 Replacing the three part agitator on KM-KT20

Disassembly:
1. Switch off the machine (see Section 6.1).
2. Loosen and remove the v-clamping ring (2).
3. Remove the hopper (1) and seal (3).
4. Turn the agitator (6) counterclockwise to loosen the agitator
1 retainer (7).
5. Remove the agitator retainer (7), agitator (6) and the distance
2 tube (5).

5 3
Assembly:
6 1. Clean the thread of the agitator bearing shaft (4).
7
2. Clean the inner thread of the agitator retainer (7).
3. Slide the distance tube (5) onto the agitator bearing shaft (4).
4
4. Slide the agitator retainer (7) through the new agitator (6).
5. Slide the agitator retainer (7) through the distance tube (5).
6. Screw in the agitator (6) clockwise and tighten it firmly.
7. Place the hopper (1) and seal (3) onto the hopper bowl. Ensure
that the seal does not reach into the hopper.
8. Fasten the v-clamping ring (2).
Fig. 6.8 Replacing the agitator

Page 30 Docu-No.: 0890000002-EN Rev. 1.0.0

 Cleaning6
Replacing the horizontal agitator6.5

6.5.2 Replacing the three part agitator on KC-KT20

Disassembly:
1. Switch off the machine (see Section 6.1).
5
2. Remove safety grid (1).
4
3. Loosen the agitator screw (2).
4. Remove the agitator retainer (3), agitator (4) and the distance
tube (5).
1
Assembly:
2
3 1. Clean the thread of the agitator screw (2).
2. Clean the inner thread of the agitator retainer (3).
3. Push in the agitator screw (2) all the way in towards the agitator
bearing.
4. Slide the distance tube (5) onto the agitator screw (2).
5. Slide the agitator retainer (3) through the new agitator (4).
6. Slide the agitator retainer (3) through the distance tube (5) and
screw it on with the agitator screw (2).
7. Mount the safety grid (1).
Fig. 6.9 Replacing the agitator

6.5.3 Replacing the one-piece agitator (used for ATEX)

Disassembly:
1. Switch off the machine (see Section 6.1).
2. Loosen and remove the v-clamping ring (2).
3. Remove the hopper (1) and seal (3).
4. Turn the agitator (6) counterclockwise to loosen and remove it.

1
Assembly:
1. Clean the thread of the agitator bearing shaft (4).
2
2. Clean the inner thread of the agitator (6).
3. Screw the agitator (6) clockwise onto the agitator bearing shaft (4)
3
and tighten it firmly.
6
4. Place the hopper (1) and seal (3) onto the hopper bowl. Ensure
that the seal does not reach into the hopper.
5. Fasten the v-clamping ring (2).

Fig. 6.10 Replacing the agitator

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 31

6 Cleaning
6.6 Replacing the vertical agitator (optional)

6.6 Replacing the vertical agitator (optional)

Danger through sharp agitator blades!

While disassembling without protective gloves, the agitator can cause
cutter wounds at the hands.
V Always wear protective gloves when working on the agitator.
V Use the crane to lift the hopper lid together with the agitator.

6.6.1 Removing the vertical agitator

1. Loosen air plug and cables and remove it.
2. Dismantle filter (1) and bellow (2) from the hopper lid (3).
3. Lose the v-clamping ring (3).
4. Use the crane to lift the hopper lid together with the agitator.
1 – By lack of space is it possible to lift the complete feeder or to lift
2 3 the hopper together with the vertical agitator. Check for clamped
4 connection from the v-clamp.
5
5. Remove seal (5)
After cleaning dry up all component.

Fig. 6.11 Removing vertical agitator

6.6.2 Installing the vertical agitator

1. Check the parts before fitting for damage or wear and replace as
necessary.
2. Place the seal (5) on the auf den hopper seam.
3. Lift the hopper lid (3) together with the agitator into operating
position.
4. Close the v-clamping ring (3)
5. Mount the filter (1) and the bellow (2).

Page 32 Docu-No.: 0890000002-EN Rev. 1.0.0

 Cleaning6
Replacing the agitator hopper6.7

6.7 Replacing the agitator hopper

Carry out the steps described below when the following parts are
changed:
• Agitator hopper
• Seals (screws, horizontal agitator)
• Bearings

• 6-mm Allen wrench

6.7.1 Removing the agitator hopper

1. Switch off the machine (see Section 6.1).
2. Remove the hopper and agitator (see Section 6.5.1).
1
5 3. Remove the feed screws (see Section 6.4.1).
4. Loosen the holding bolt (4) at the agitator hopper wit the Allen
2 wrench.
5. Open the retaining latch (1).
6. Remove the agitator hopper (3).
3
7. Clean all the parts.

4
Fig. 6.12 Replacing the agitator hopper

6.7.2 Installing the agitator hopper

1. Before carrying out the installation ensure that all the parts are
clean.
2. Before carrying out the installation ensure that all the seals (5) are
positioned correctly.
3. Position the agitator hopper (3) and open the retaining latch (1).
4. Align the agitator hopper (3) over the pin pair (2) and screw it tight
with both holding bolts (4).
5. Close the retaining latch (1).
6. Install the feed screws (see Section 6.4.2).
7. Install the agitator and hopper (see Section 6.5).
8. Adjust the feeder if platform scale is used (see Section 4.4).

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 33

7 Maintenance
7.1 Maintenance Intervals

7 Maintenance

When carrying out maintenance work on the switched-off feeder there

is a danger of injury through unintentional switching-on.
V Switch off the feeding system before carrying out maintenance
work on the feeder and secure it against unintentional restarting
(see section 6.1).

• Only qualified and trained personnel may carry out maintenance

work on the feeding equipment.
• Only qualified electricians may work on the electrical equipment.

7.1 Maintenance Intervals

Element Checkpoints when in operation Interval

Mechanical Eliminate dust accumulation > 5 mm As required

through cleaning
Seals (leakage inspection) As required ( feed product dependent)
Oil level every 3 months
Oil change 10000 hours or 2 years
Bearings inspection 2 years
Bearing change 25000-30000 hour
Electrical Motor brushes As required (see motor specs.)

Page 34 Docu-No.: 0890000002-EN Rev. 1.0.0

 Maintenance7
Replacing seals7.2

7.2 Replacing seals

• 6-mm Allen wrench
• Screwdriver, size 4, flat

There are three seals at the feeder which can be replaced as required.
• Feed screw seal (1)
2
• Agitator seal (2)
• Sealing ring (3)
The seals prevent the bulk material from leaking out of the feeder and
the backflow of bulk material into the drive systems.
3
The sealing ring is free of wear.
Only replace the other seals if bulk material exits at the leak shafts of
the agitator and screws.

1 7.2.1 Replacing the screw seals

1. Switch off the machine (see Section 6.1).
2. Remove the hopper, agitator, screws and agitator hopper (see
Section 6.7.1).
3. Remove the old seal (1, 2 and 3) using the screw driver. Do not
damage the gearbox in the surrounding of the seal and screw
bearing shaft when removing the seal.

Fig. 7.1 Seals

7.2.2 Installing the seal

If the sealing lips are pointing to the wrong direction the sealing is not
guaranteed.

1. Clean the seal environment.

2 2. Select a seal which is suitable for the feeder type.
3. In order to ensure that the seal is not damaged when being slid
over the screw bearing shaft (2), lubricate the seal lips (3) lightly
with silicone grease and slide it onto the screw bearing shafts.
1
4. Slide the screw seal (1) onto the screw bearing shafts.
The sealing lips point towards the agitator hopper.
5. Install the agitator hopper, screws, agitator and hopper. If the
components can be assembled smoothly then the seals are
properly fitted.
6. Adjust the feeder if platform scale is used (see Section 4.4).
Fig. 7.2 Mounting direction

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 35

7 Maintenance
7.3 Replacing the drive motor

7.3 Replacing the drive motor

• 13-mm wrench
• 2.5-mm Allen key

7.3.1 Preparing the removal

1. Switch off the machine (see Section 6.1).

2. Disconnect the motor connections at the motor terminal box.

7.3.2 Removing the motor

1. Use an 13-mm wrench to loosen the 4 screws at the motor while a
second person secures the motor.
2. Remove the motor from the drive housing.

7.3.3 Installing the motor

1. Adjust the motor coupling sprocket (2) by using a 2.5-mm Allen
2
key so that the coupling (3) fits between coupling sprockets (4) and
5 4 3 1
(2) leaving 1 mm gap.
2. Slide the motor (1) to its place. Guide the coupling so that it latches
in into its counterpart in the coupling sleeve (3).
3. Insert the mounting bolts and tighten them .
4. Connect the motor and take the feeder into operation.
Fig. 7.3 Installing the motor

Page 36 Docu-No.: 0890000002-EN Rev. 1.0.0

 Maintenance7
Replacing the tachometer7.4

7.4 Replacing the tachometer

• 3 mm Screwdriver
• Test equipment for tachometer
• Gauge
• Feeler gauge (0,2 mm/0.0078")

The gearwheel of the tachometer generator is mounted at one end of

the coupling. (see Fig. 7.3 /5).

7.4.1 Removing the tachometer

1. Switch off the machine (see Section 6.1).
X 2. Screw off the cable cover of the tachometer and disconnect the
cable (4) from the tachometer generator.
4
3. Remove the tachometer (1) with bracket (2) from the gearbox.
4. Measure Distance X from the surface of the tachometer to the
bracket and note it.
5. Loosen the nuts (3) and remove the tachometer from the bracket.
1
3
2

Fig. 7.4 Removing the tachometer

generator

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 37

7 Maintenance
7.4 Replacing the tachometer

7.4.2 Installing the tachometer

1. Mount the new tachometer with the supplied accessories to the
bracket.
+ 5 VD C
com 2. Screw the nuts so far onto the tachometer generator that the
measured Distance X between the surface of the tachometer and
the bracket is reached.
3. Fasten the bracket with tachometer by means of the mounting
bolts (2 pieces) only loosely to the gearbox.
1
4. Use the feeler gauge to set gap A between the gearwheel (2) and
the tachometer (1) so that the feeler gauge can still be moved
slightly in the gap.
A
2 5. Tighten the mounting bolts at the bracket.
6. Remove the feeler gauge and turn the gearwheel.
The gearwheel and tachometer generator may not touch each
other.
7. Connect the tachometer generator cable and mount the cover
sheet.
8. Supply the tachometer generator with the test equipment with
power and check whether it functions correctly while the
gearwheel rotates. No pulse may be missing during one rotation of
the gearwheel.
9. In order to check the correct installation let the feeder run without
bulk material.
Fig. 7.5 Installing the tachometer
generator

For more technical information about the tachometer

see project manual.

Page 38 Docu-No.: 0890000002-EN Rev. 1.0.0

 Maintenance7
Lubrication7.5

7.5 Lubrication

V Remove any oil spillage immediately with an oil-binding agent in

compliance with environmental requirements.

V Signs of changes in the oil can be seen with the naked eye. Fresh
oil is clear to the eye and has a typical smell and a specific product
color. Clouding or dark appearance indicate water and/or contam-
ination. If you detect such abnormalities, the oil must be changed
immediately.

For oil type and content refer to chapter 3, technical data.

7.5.1 Oil level inspection

Quarterly
« Check the oil level on the gear box through the inspection plug with
the oil sight glass.
The oil level must be in the middle of the sight glass (1If there is not
enough oil do following:
1. Unscrew slightly the oil inspection plug (2), oil must run out.
2. If there is insufficient oil, fill in oil through the ventilation hole (1)
Oil until oil runs out of the oil-level inspection hole.
1 2 3. Tighten oil inspection plug.

Fig. 7.6 Lubrication

7.5.2 Oil change

1. Loosen ventilation plug (1).
2. Remove inspection plug (2) and drain off oil in a proper container.
3. Screw in slightly the oil inspection plug (2) do not tighten it.
4. Fill up oil through the ventilation hole (1) until it flows out of the
inspection hole (2).
5. Tighten both oil inspection and ventilation plug.
6. Check oil level according to chapter 7.5.1.

7.6 Replacing the bearings

« Check the temperature of the drive housing. If the temperature
rises and unusual noises are to be heard in the drive housing, the
bearing are damaged.
« Replace the bearings in case of damage.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 39

8 Troubleshooting
7.6 Replacing the bearings

8 Troubleshooting

Eliminating faults in a feeder which is running can cause serious

accidents.
V Switch off the feeding system before every intervention and secure
it against unintentional restarting (see Section 6.1).
V Gravimetric feeding units have a plug-in connection to the feeder
motor. In order to disconnect the feeder motor from the power
supply, disconnect the plug-in connection.

1. Always switch off the feeders before carrying out repairs.

2. Check the feeder (see Section 8.1).
3. Please observe the error messages which are displayed on the
connected control device or host computer (see operating
instructions for the relevant control device).
4. Document faults and call the local service center (customer
service see inside cover).

Page 40 Docu-No.: 0890000002-EN Rev. 1.0.0

 Troubleshooting8
Troubleshooting table8.1

8.1 Troubleshooting table

Malfunction/Error Possible cause Remedy

Feeder does not • No connection or no power « Check the connections.

transport any
material
Screws rotates • Motor connections incorrect « Check the connections.
incorrectly
Screws and/or • Foreign bodies in feeder « Remove the foreign bodies.
agitator does/do not • Feed material piling-up in the outlet « Dismantle the outlet tube and
rotate tube eliminate the pile-up.
• Motor does not get any power from « Check the settings at the motor
the motor controller controller.
« Check the motor controller.
« Check wiring.
• Gear box overheated « Check oil level and quality.
« Check bearings.
Feed rate not • Foreign bodies in feed material « Empty and clean the feeder.
constant • Feed material forms bridging in the « Empty the feeder and check the
hopper material flow in the hopper.
Gear box leaking • Internal pressure to high « Check ventilation plug.
• Damaged sealing « Replace sealing (K-Tron).

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 41

8 Troubleshooting
8.1 Troubleshooting table

Page 42 Docu-No.: 0890000002-EN Rev. 1.0.0

 Chapter 4:
Pneumatic
Documentation
This Chapter Does
NOT Apply To This
Manual.
 Chapter 5:
Weighing
Documentation
 5508
SFT Weighing Theory for SCM and KCM

Theory of Operation for

K-Tron SFT Weight
Sensors With SCM, KSHM
or KCM Controls

Rev: C Produced by the K-Tron Institute

5508
SFT Weighing Theory for SCM and KCM

“No part of this publication may be reproduced or transmitted in any form or by any
means electronic or mechanical including photocopy, facsimile or computer generated
distribution without written permission from the K-Tron Institute. All translation
rights are reserved by the K-Tron Institute . The K-Tron Institute has made every effort
to ensure the accuracy and validity of this document. However, errors and omissions
may have occurred. If an error or omission is found, please contact the K-Tron Institute
at (856)256-3267.

Information in this manual is correct as of the date of publication. K-Tron assumes no

responsibility for damages resulting from misuse of the equipment or negligence on the
part of operating personnel.”

Rev: C Produced by the K-Tron Institute

 5508
SFT Weighing Theory for SCM and KCM

Table of Contents

K-Tron SFT Weight Sensors..........................................................................1

Overview..................................................................................................1
Types of K-Tron SFT Weight Sensors ....................................................2
SFT Applications and Scale Configurations............................................3
SFT Weight Theory of Operation ............................................................12
SFT Technical Specifications ..................................................................18
SFT Communications in the SmartConnex or SmartConnex II Control
System Using the SCM, KSM or KCM.......................................................20
Overview..................................................................................................20
Verifying SFT Communications..............................................................22
SFT Status Codes.....................................................................................25
Wiring and Color Codes in SCM Systems ..............................................27
Index ................................................................................................................34

Rev: C Produced by the K-Tron Institute

 5508
SFT Weighing Theory for SCM and KCM

K-Tron SFT Weight Sensors

Overview

Intro
This section describes the various types of SFT weight sensors
currently used with K-Tron feeding equipment.

Definitions
Term Definition
Addressing The procedure of assigning a unique code to each
SFT.
B scale A scale that uses the scale mounted SFT in a knife
edge force reduction strategy.
D scale A scale that uses the scale mounted SFT in a
flexured force reduction strategy. An outline
diagram is found later.
KCM SmartConnex II controller
KSM controller A low cost version of a controller used in
SmartConnex applications. Replaced by the KCM.
SCM The feeder controller in the SmartConnex
environment now replaced by the KCM.
SFT Smart Force Transducer
SmartConnex This is the system architecture that uses LON as the
network connection.
SmartConnex II This is the system architecture that uses RS485
serial as the network connection. Replaces
SmartConnex architecture.
Weight The serial data channel between the SFT and the
Channel feeder controller over which the SFT data is sent.

Rev: C Produced by the K-Tron Institute

5508.2
SFT Weighing Theory for SCM and KCM

Types of K-Tron SFT Weight Sensors

Intro
There are four types of SFTs used with SCM, KSM and KCM
controllers. They are the 6 Kg open sensor used with B scales, D5 scales,
and WF series feeders. Then there is SFT II-M and SFTII-L SFTs for
standalone LWF applications typically. Lastly, there is the SFT III used
with SWB feeders and SFM flow-meters. It is also used with the K4 G
feeder system. SFTs also come in different versions of internal software.
That is explained here.

Type Used with

SFT –std SFTs of version L or earlier cannot be used with
SCM, KSM or KCM controls. They only work with
K10S controls. However, all SFTs are backwards
compatible. That is KCM compatible SFTs work
with SCM/KSM and K10S controls.
Fast SFTs High conversion rate SFTs required for
SmartConnex applications-SCM and KSM. These
SFTs use version “M” software and later.
SFT for KCM SFTs for KCM must use revision “S” software or
later for use of the Auto Re-addressing feature. The
KCM can use SFTs of version “M” but the auto-re-
addressing feature will not work

This section will focus on the two current types of SFT load sensors, the
standalone SFT used with non-scale loss-in-weight systems and the
basic or scale mounted SFT used in scales and the W300/W600 weigh
bridge. If other K-Tron sensors are used, refer to document 5501 or
5502.

Rev: C Produced by the K-Tron Institute

 5508.3
SFT Weighing Theory for SCM and KCM

SFT Applications and Scale Configurations

Intro
The SFT exists in two forms. The first form is a standalone sensor with
integral overload stops and a force reduction system to reduce loads
from as much as 1000 kg to 500 gm at the vibrating wire. The second
device, the scale mounted SFT fits into a "B","D5" scale or WF300 or
WF600 belt feeder weigh bridge. This device has little force reduction
and its full scale loading is 6 kg. The standalone SFT is designed to
support a point load. The internal SFT is designed to accept forces from
a discrete scale sub-system through a load pin assembly.

The points of commonalty are:

• Single vibrating wire design

• Internal microcomputer provides a serial signal for actual
weight
• 1 part in 4,000,000 resolution
• Extremely low displacement
• Very stiff measurement system

Please note that some SFTs will have a DB-9 connector, others may not and
these devices are wired directly into the control system. Please consult factory
for SFT part numbers, they are different for WBF and LWF. Additionally,
some SFTs may be intrinsically safe and others may be gas purged.

Continued on next page

Rev: C Produced by the K-Tron Institute

5508.4
SFT Weighing Theory for SCM and KCM
SFT Applications and Scale Configurations, Continued

Basics of SFT
operation
The applied force is connected by mechanical members to the vibrating
wire. The internal circuits cause the wire to vibrate at its second
fundamental frequency. The frequency is then related to the load on the
cell. As in a violin string, as the tension increases so does the frequency.
As the applied load increases, the measured frequency increases. This is
converted and corrected for temperature and non-linearity effects by an
internal microprocessor and the resulting output is sent to the control
system on the Weight Channel. The weight output is a serial data
stream that represents the applied weight to the SFT.

Overview of
the standalone
SFT
The standalone SFT provides force reduction, load stabilization and
overload protection to the sensitive components of the SFT. It can be
used as a single load sensor but is most commonly used in multiples of
three to provide inherent load stabilization.

Standalone large capacity SFT II-L

The standalone SFTs are designed to be used in harsh environments

and are sealed to IP65, or Nema 4 standards.

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.5
SFT Weighing Theory for SCM and KCM

SFT Applications and Scale Configurations, Continued

Standalone small capacity-SFT II-M type

Force

SFT III
Force

Note:
The SFT III cannot be replaced in the SWB weigh bridge. The weigh
bridge with the SFT must be replaced as a complete unit if failed.

Continued on next page

Rev: C Produced by the K-Tron Institute

5508.6
SFT Weighing Theory for SCM and KCM
SFT Applications and Scale Configurations, Continued

6 kg SFT for WF300/WF600 and D and B scales

Force

The SFT for the WF300/600 has the applied weight to the top of the
sensor on the weight anvil as shown. The SFT used for the B scales and
used in the D5 weighing module has the weight applied to bottom of
the SFT. The scale range for this SFT is 6 kg.

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.7
SFT Weighing Theory for SCM and KCM

SFT Applications and Scale Configurations, Continued

SFT applications
In using the SFT in a 3 point weighing system , the K-Tron loss-in-
weight feeder is suspended between three load cells mounted on the
supporting structure of the feeder. The feeder is suspended in such a
way that it's center of gravity always falls within the triangle described
by the load cells. This three-point weighing system is the most accurate
and stable arrangement, provided that the plane described by the
triangle is perfectly (or nearly perfectly) horizontal, and the center of
gravity is at or about the level of the weighing plane. The weight signals
from the three load cells are transmitted to the control system, where
they are summed to give the total system gross weight (the weight of
the hopper, feeder, and material). Data is transmitted to the feeder
controller by a serial data communication channel.

SFT Mounting - Plan View SFT Mounting - Sid e View

SFT SFT

K-Tron Modular loss-in-weight feeders of various model types uses

smart force transducers (SFTs) as described above,

Continued on next page

Rev: C Produced by the K-Tron Institute

5508.8
SFT Weighing Theory for SCM and KCM
SFT Applications and Scale Configurations, Continued

Standalone SFT II ranges plus 6 Kg SFT

The range of the SFT on the SFT label is in Newtons. Divide Newtons
by 10 to reach the kilogram range below. The feeder controller displays
weight in kilograms or pounds.

SFT Range Total Gross Capacity ( 3xSFT )

6 Kg ----
12 Kg 36 Kg
18 Kg 54 Kg
30 Kg 90 Kg
60 Kg 180 Kg
90 Kg 270 Kg
120 Kg 360 Kg
200 Kg 600 Kg
300 Kg 900 Kg
500 Kg 1500 Kg
1000 Kg 3000 Kg

SFT III ranges

The range of the SFT on the SFT label is in Newtons. Divide Newtons
by 10 to reach the kilogram range below. The feeder controller displays
weight in kilograms or pounds.

SFTIII Range
6 Kg
20 Kg
50 Kg
100 Kg

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.9
SFT Weighing Theory for SCM and KCM

SFT Applications and Scale Configurations, Continued

Scale mounted SFT overview

Firstly, the scale mounted SFT basic design functions in either a B scale,
D scale or WF300/WF600 weight bridge. We will show the subtle
differences in the mechanics.

The functional operation of the scale mounted SFT is identical to that of

the standalone variety with the following exceptions.

The scale mounted SFT is not sealed in any way.

The scale mounted SFT has no way to stabilize the applied load.
The scale mounted SFT has no large capacity overload protection.

The range for all scale mounted SFTs whether located in a WF300 weigh
belt feeder, B scale or the D-Scale are 6 Kg.

SFT for B scale and D scale

Molex
Plug SFT

Mounting Boss Input Rod

for LWF
Force

Continued on next page

Rev: C Produced by the K-Tron Institute

5508.10
SFT Weighing Theory for SCM and KCM
SFT Applications and Scale Configurations, Continued

SFT in a D-
Scale
This graphic shows the use of the SFT in a scale. The scale shown is a D
scale. Note that if the D scale is used, the SFT alone cannot be replaced.
The entire weighing module must be replaced.

Load

SFT

SFT in a W300/W600
Input Button Force
for WBF

Molex
Plug SFT

Mounting Boss

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.11
SFT Weighing Theory for SCM and KCM

SFT Applications and Scale Configurations, Continued

SFT in a W300/W600

This graphic shows the use of the SFT in a W300 weighbridge.

6
1 2 1

5 4
SFT

Item Description
1 Fixed bar
2 Weigh bar
3 Moving weigh belt
4 Weigh bridge housing
5 Load pin with overload protection
6 Stabilizing flexure

Scale mounted
SFT range

SFT Range Description

6 Kg The other type of SFT, the scale mounted SFT is used
inside the B and D5 scale and the Weigh Belt Feeder
weigh bridge. It is 6 Kg in capacity. It is not sealed and
depends upon the scale housing for protection.

Rev: C Produced by the K-Tron Institute

5508.12
SFT Weighing Theory for SCM and KCM
SFT Weight Theory of Operation

Principle of
operation of the
SFT
The SFT exploits the dependency of a vibrating wire's resonant
frequency on its tension to measure applied loads. Through mechanical
means, the applied load is transmitted to the wire, causing a change in
its resonant frequency from which the value of the applied load is
computed by the onboard microprocessor.

Magnets

F1
Vibrating
String

Weight

A fully calibrated (linearized, spanned and temperature compensated)

signal is transmitted via RS485 serial communication to the K10S
controller, either in rack or chassis configuration.

Employing the principle of induction, the wire is electronically excited

to vibrate at it's resonant frequency. A magnetic field, provided
through the use of permanent magnets, is created across the wire's
plane of vibration. (The wire possesses a rectangular cross section to
constrain vibration to a single plane.) The wire is electrically
conductive and is connected at its ends to an exciter circuit. Through
special feedback techniques the exciter circuit simultaneously senses the
wire's frequency and produces an alternating current in the wire to
maintain resonant vibration, regardless of its frequency value.

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.13
SFT Weighing Theory for SCM and KCM

SFT Weight Theory of Operation, Continued

Principle of operation of the SFT, con’t

Because a high vibration frequency is desirable to avoid signal

contamination, the wire is pre stressed and forced to vibrate at its
second harmonic (two anti-nodes) at all times. The following diagram
attempts to show how a load might apply tension to the vibrating
string. "T" represents tension in the string and "Freq" describes the
resulting frequency.

Vibrating wire technology

Freq

Weight

The wire's resonant frequency is not a linear function of applied tension

but, in practice, is almost parabolic. Its representation is shown as Fw,
the value of which is measured by the microprocessor. However, over
the range of loads that is used, the curve is straight to within 2-3 %. To
calculate the applied load from the sensed frequency, microprocessor-
based regression techniques are used. Typically, the range of
frequencies from no load to full load is from 11 kHz to 18 kHz. While
the range is fixed, the zero point is not but is taken into account in the
conversion.

Continued on next page

Rev: C Produced by the K-Tron Institute

5508.14
SFT Weighing Theory for SCM and KCM
SFT Weight Theory of Operation, Continued

Vibrating wire technology, con’t

However, rather than computing the weight value from Fw directly, a

high frequency is counted for a number of integral periods of Fw. This
generates a representation of Fw in a high precision digital form that
can be counted in a short period. This allows the calculation of 1 ppm
weight values with certainty. A four step regression is calculated in
order to straighten the curve. To assure the utmost precision,
linearization coefficients for each SFT are individually established at the
factory and reside in an EEPROM that is mounted internally to the SFT.

Environmental
issues
Of the possible environmental sources of error only temperature
variations require compensation. The effects of ambient magnetic field,
changes in atmospheric pressure, relative humidity, etc. have been
found to be negligible. To adjust for changes in ambient temperature, a
thermal sensor is installed within the SFT. Each SFT's thermal response
characteristics are determined through testing at manufacture, and
appropriate coefficients are registered in the EEPROM for continuous
electronic temperature compensation.

The temperature detector located inside the SFT provides a frequency

output of about 6 kHz for ambient temperature and its output is based
upon on a formula calculated in degrees Kelvin. This internal frequency
is shown as Ft and is used by the microcomputer to correct the weight
value for temperature effects.

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.15
SFT Weighing Theory for SCM and KCM

SFT Weight Theory of Operation, Continued

SFT block diagram

SFT
t f
s N Exciter
+11.3
N s +5V Vdc

Weight RS-485 Weight/

Force Measurement uC RxD Internal
reduction Processor RS-485 Channel
system TxD

Temp EEPROM
C

Applied
Force

Continued on next page

Rev: C Produced by the K-Tron Institute

5508.16
SFT Weighing Theory for SCM and KCM
SFT Weight Theory of Operation, Continued

SFT Start-up operation

When the SFT is powered up, it must be able to communicate on the

serial channel with the other SFTs which are connected to that serial
data channel. Very much like a telephone party line, the controller
which as the buss-master controls the communication activity on the
weight channel must distinguish between SFTs. It does this by
assignment of an address that acts like a unique telephone number in
the party line example. Once the assignment has been made, the data
(address) is stored in the on-board EEPROM along with the
linearization data that was computed in the factory calibration
procedure. The linearization data is not changeable by the user.

SFT SFT SFT

#1 #2 #3

Serial
Weight
Channel

The SFT communicates by RS485 serial data communications. The

communication hardware protocol is RS485 and is a four wire
transmission scheme with differential receiver and transmit lines
connected as shown to the controller weight channel.

The K10S controller uses the “Weight Channel” designation for data
connections to the SFTs. For KCM/SCM and KSM, the designation is
the “Internal Channel” as in those cases, the motor drive and other
tightly connected K-Tron hardware also resides in this data channel.

One merely connects all SFT receive signals in parallel, same polarity to
same polarity and the same is done for the transmit signals. The result
is connected directly to the controller via the SFT Interface Pc board.
The communication protocol is 9 bit serial binary and is decoded by the
controller as absolute weight from each SFT. The 9th bit is used to
identify the following character as an address. This type of
identification is particularly efficient. No addresses may be the same.

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.17
SFT Weighing Theory for SCM and KCM

SFT Weight Theory of Operation, Continued

SFT Start-up
operation,
con’t
An address of "0", turns the SFT "off" and makes it ready to accept a
new address from "1" to "15" or a hex "F". Typically, addresses 1-6 are
used for most feeder applications. Only in Quad K10S software is
addressing critically specified.

If the SFT fails when in operation or the weight channel cable is

disconnected, the weight channel SFTs line at the controller will show a
"t" at that address location indicating a Weight Channel serial
communication time-out condition. This is a fault that will cause a
"Weight Processor Failure" alarm. In a later section, failure conditions
will be fully described.

Rev: C Produced by the K-Tron Institute

5508.18
SFT Weighing Theory for SCM and KCM
SFT Technical Specifications

Intro
This section outlines the general specifications for the K-Tron SFT.

Specs for standalone SFTs

Repeatability: -+0.001% of full scale

Combined Error: -+0.03% of full scale
Stability: -+0.03%
Resolution: 1: 4,000,000 parts in 80 msec.
Maximum Load at SFT: 12 Kg to 1000kg
Operating Temperature Range: 14 F to 140 F (-10 C to 60 C)
Storage Temperature Range: -13 F to 176 F (-25 C to 80 C)
Compensated Temperature Sensitivity: +0.0006%/F or (+0.0001%/C)
Vibration Suppression: 35-40dB at 0.1G from 0-40Hz
Shock Tolerance:
SFTII-M: 75G in all directions (without re-calibration);
100G in all directions (with re-calibration)
SFTII-L: 150 G in all directions (without re-calibration);
500G in all directions (with re-calibration)
Signal Transmission Type and Distance: differential; 1,640ft (500m) max
Creep: 0.02% of full scale; 30 min at 72 F (22 C)
Hysteresis: 0.02% max
Repeatability: <+ 0.001% over 2 seconds
Warm-up Time: 30 minutes
Output: RS485, serial data or computer data in hex format
Power Consumption: 0.27 watt at 9 Vdc supply
Voltage Requirements: 7.2-12.5 Vdc
Enclosure Rating: NEMA 4, IP65
Overload protection: K-SFT11-M; +1000 Kg, -100 Kg
k-SFT II-L: +200%, -50% of range

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.19
SFT Weighing Theory for SCM and KCM

SFT Technical Specifications, Continued

Specs for scale

mounted SFTs
Repeatability: -+0.001% of full scale
Combined Error: -+0.03% of full scale
Stability: -+0.03%
Resolution: 1:4,000,000 parts
Maximum Load at SFT: 6Kg
Operating Temperature Range: 14 F to 140 F (-10 C to 60 C)
Storage Temperature Range: -13 F to 176 F (-25 C to 80 C)
Compensated Temperature Sensitivity: +0.0006%/F or (+0.0001%/C)
Vibration Suppression: 35-40dB at 0.1G from 0-40Hz
Shock Tolerance: 75G in all directions (without re-calibration);
100G in all directions (with re-calibration)
Signal Transmission Type and Distance: differential; 1,640ft (500m) max
Creep: 0.02% of full scale; 30 min at 72 F (22 C)
Hysteresis: 0.02% max
Warm-up Time: 30 minutes
Output: RS485, serial data or computer data in hex format
Power Consumption: 0.27 watt at 9 Vdc supply
Voltage Requirements: 7.2-12.5 Vdc
Enclosure Rating: Not fully sealed

Rev: C Produced by the K-Tron Institute

5508.20
SFT Weighing Theory for SCM and KCM
SFT Communications in the SmartConnex or
SmartConnex II Control System Using the SCM, KSM
or KCM
Overview

Intro
This section demonstrates how the SFT communicates with the
SmartConnex control system.

SFT data link

The Smart Force Transducer (SFT) communicates with the SCM on an
RS485 communication channel. This is much different from what you
may be used to with typical “strain gauge” type load cells. The SFT can
not be checked with a multi-meter. There is neither a current or milli-
volt output to measure.

The SFT is either mounted as a stand alone load cell or it is installed in a

scale. The SFT signal (A) passes through a scale interface board-SIB-(B)
mounted in a junction box located out at the feeder stand if the SCM is
mounted remote to the feeder or directly to the SCM if the SCM is
attached to the feeder.

The weight information is then transmitted on an RS485 cable (C)

(normally in the same cable with speed and dc power) to SCM.

Refer to the diagrams on following page:

Part Function
A This is the RS485 weight channel from the SFT(s) to
the feeder mounted scale interface card or direct to
the SCM/KCM. The SFT wiring and color codes are
found at the end of this manual section.
B This is the scale mounted interface card.(SIB pc)
9191-601650, Rev. D. Refer to manual section
#0390020602 for SCM or 0490020605 for KCM for a
detailed description. This board contains Tx and Rx
diagnostic LEDs.
C Normally a single shielded cable is wired from the
feeder SIB pc card to the SCM

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.21
SFT Weighing Theory for SCM and KCM

Overview, Continued

SFT comm.
block
diagrams

Remote SCM/
KCM/KSM

(A
RS485, 3 channels
)

(B) (C
)

diagnositc
LEDs

(A
RS485, 3 channels
)

Local SCM/
KCM/KSM

Rev: C Produced by the K-Tron Institute

5508.22
SFT Weighing Theory for SCM and KCM
Verifying SFT Communications

Intro
This section will help you set-up communications on the Weight
channel between the SFTs and the SCM.

Procedure for SFT operation in SCM system

Step Action
1 First you should check all wiring.

Wiring Reference section

SCM #0390020602
KCM #0490020605
Wiring diagrams for the project.
For KSM applications, see the specified drive pcb wiring
details.

2 Check to see that the SCM/KCM is powered.

3 If used, check to see that 12.0 Vdc is getting to the scale
interface board or 11.3 Vdc to the SFTs. The red LED should
be lit on the SIB pc board.
4 If used, the transmit (Tx) and receive (Rx) LEDs should be
both blinking on the scale interface board.
5 Check the page or menu of your K-Tron display where the
SFT information is found. Locate the SFT configuration line:
If your feeder has 3 SFTs you should see:
-123--------------

or if your feeder has a scale with only 1 SFT you should see:
-1----------------

6 If LEDs on the scale interface board are not blinking or the

SFT configuration line does not display the correct SFTs,
refer to SCM/KCM electronics manual. Check all SCM
wiring.

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.23
SFT Weighing Theory for SCM and KCM

Verifying SFT Communications, Continued

SFT failure codes

The first indication that a weighing failure has occurred is an alarm
“Weight Proc Failure” or “Incorrect Number of SFTs”. Immediately
visit the Scale menu, SFT sub-menu to investigate. Take a look at the
SFT configuration or map line.

ex: SFT Config: - f 2 3 - - - - - - - , SFT #1 has failed

Two failure codes may appear. The “t” in place of the SFT address
implies that the controller has lost communications with the SFT. An “f”
in that position indicates an SFT failure. With an “f” condition, merely
replace the SFT. When troubleshooting a “t” condition, bear in mind
that any problem that interferes with data communication between SFT
and controller may be the problem. Weight channel cabling, a failed SIB
pcb if used, a bad controller or a SFT failure of the data communications
portion may be the cause. Some times, the “?” code appears. This is due
to electrical noise on the weight/internal data channel. Check your
wiring and shielding.

Refer to the SFT outline drawing on page 15 to get an idea of what SFT
failure results in what code presentation. Failure of the components
shadowed in black will present a “f” code while the ones in gray,
present a “t” code. Bear in mind that some codes reflect operational
problems that might indicate an SFT failure but are not. For example,
status code of “009183” will produce a “Weight Processor Failure” and
the letter “f” in the offending SFT address. By rights, you would
replace the SFT, but the problem is that the SFT is under-ranged and as
a result is in General Alarm. So be careful.

Additionally, the alarm condition “Incorrect Number of SFTs” is a

weight related failure as well. It happens when the number of SFTs
found during polling do not agree with the value “Number of SFTs
Required” entered by the user.

Please use the following list to uncover the problem behind the SFT
error code that is posted on the SFT Configuration display in lieu of the
SFT address.

Continued on next page

Rev: C Produced by the K-Tron Institute

5508.24
SFT Weighing Theory for SCM and KCM
Verifying SFT Communications, Continued

SFT failure codes, con’t

Code Problem
f The SFT has failed. Replace the SFT.
t There is a communication failure on the weight channel. The
SFT, Scale Interface pc board, weight channel cable or K10S
controller may be faulty. Use the K-Tron Institute SFT tester
to solve the problem.
? Address conflict or static or electrical noise on the weight
channel. Check for shared addresses and then look at system
and SFT grounding.

Rev: C Produced by the K-Tron Institute

 5508.25
SFT Weighing Theory for SCM and KCM

SFT Status Codes

Intro
This section shows status codes for the SFT, fast version. The list show
is the bit list for the error codes. It is a three byte error code.

SFT version II status codes

23: set, if Ft frequency time out

22: set, if Fw frequency time out
21: set, if Ft frequency too high
20: set, if Ft frequency too low

19: set, if Fw frequency too high

18: set, if Fw frequency too low
17: Reserved for OIML, OIML Version
16: reserved for OIML, EPROM checksum error

15: general alarm

14: temperature window range error
13: weight window range error
12: weight frequency is out of range

11: temperature frequency is out of range

10: set, if K-FFP (fast frequency processor) error
09: EEPROM read or write error
08: set, if weight conversion complete

07: set, if filter on

06: not used
05: set, if baud rate range error
04: set, if error received

03: SFT is in continuos weighing mode

02: not used
01: synchronous mode address leader – set, if a group leader
00: SFT is in synchronous mode – set, if in a group mode

Continued on next page

Rev: C Produced by the K-Tron Institute

5508.26
SFT Weighing Theory for SCM and KCM
SFT Status Codes, Continued

SFT version II status codes, con't

For example if the status line reads 0101901 then the following table
demonstrates how to read the hexadecimal code.

1 0 1 9 0 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00
0 0 0 1 0 0 0 0 0 0 0 1 1 0 0 1 0 0 0 0 0 0 0 1

The error code in hex reads 10 19 01.

Rev: C Produced by the K-Tron Institute

 5508.27
SFT Weighing Theory for SCM and KCM

Wiring and Color Codes in SCM Systems

Intro
This section provides wiring information for SFTs in the SCM system.

SFT to SCM wiring

SCM X1
Pink
Com 6
Gray
+Vdc 5
Brn
Tx- 4
Wht SFT
Tx+ 3
Yel
Rx- 2
Grn
Rx+ 1
X5
4 Lon B X2
Pink
3 Lon A Com 6
Gray
2 Lon B +Vdc 5
Brn
1 Lon A Tx- 4
Wht SFT
X6 Tx+ 3
4 Com Yel See Note 1
Rx- 2
Grn
3 +12 Vdc Rx+ 1
2 Lon B
X3
Pink
1 Lon A Com 6
Gray
X23 +Vdc 5
Brn See Note 1
6 Rly2 NO Tx- 4
Wht SFT
5 Rly2 Com Tx+ 3
4 Rly2 NC Yel
Rx- 2
Grn
3 24 V Proc 2 Rx+ 1
2 24 V Proc 1
X8
1 Enc1- 5

X22 Enc1+ 4
6 Rly1 NO
Com 3
5 Rly1 Com
+5 Vdc 2
4 Rly1 NC Sig 1
3 24 V Proc 2

2 24 V Proc 1 X21
Arm+ 5
1
Arm- 4
X20
Fld+ 3
3 L1
Fld- 2
2 L2/N
PE 1
1 PE

Continued on next page

Rev: C Produced by the K-Tron Institute

5508.28
SFT Weighing Theory for SCM and KCM
Wiring and Color Codes in SCM Systems, Continued

KCM to SFT wiring example

SFT Gray
KCM
Pink 1600 W DC Drive
Green
Yellow
Speed
White Blue Sensor
Brown
Yellow Red
J8

6 5 4 3 2 1

6 5 4 3 2 1 J7 Com Sig +5Vdc

K4 J2
6 5 4 3 2 1DPDT
J4 4 3 2 1

12 11 10 9 8 7 6 5 4 3 2 1 J1 8 7 6 5 4 3 2 1
J6

L1 N PE PE Mtr Mtr
Drive Enable Safety + -

DC Motor
115 Vac line in

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.29
SFT Weighing Theory for SCM and KCM

Wiring and Color Codes in SCM Systems, Continued

KSM to SFT wiring example

KSM HMD
SFT
1 1 1 1
Host Com Com +12V +12 +12V Gray
2 2 2 2
Host TxD+ RxD+ Com Com Com Pink
3 3 3 3
Host TxD- RxD- RxD+ TxD+ TxD+ Grn
4 4 4 4
Host RxD+ TxD+ RxD- TxD- TxD- Yel
5 5 5 5
Host RxD- TxD- TxD+ RxD+ RxD+ Wht
6 6 6
JP5 TxD- RxD- RxD- Brn
Aux Sw 1 IN1 JP2 J3 J4
Aux Sw 2 IN2 Tach
3 +5V 1 +5V
Aux Sw IN3
4 Fa 2 Fa
Aux Sw IN4
5 Fb 3 Fb
Com
6 Com 4 Com
Aux Out OUT1
Aux Out 7 OUT2 J2
8
Aux Out OUT3
M+ 1 +
Aux Out 9 OUT4 M
M- 2
Aux Com 10 Com
PE 3 -
JP3 4
PE
1 PE 5 PE
Analog In Com In Com
2 N 6 Power N
Analog In 20ma In 20ma 1
3 Safety +15V 7
Analog In 5V In 5V 2 L2
4 Safety SW Safety IN 8
Analog In 10V In 10V 3 L1 Power L1
DENA +15V
JP4 4 J6
Enable SW DENA IN+
1 5 DENA IN- K1 Com 1 Loader
Fin - Fin -
2 6 DENA Com K1 NO 2
Fin + Fin + Loader
3 Option pcb 7 3
Iout- Iout- IN1 +15V K1 NC
4 8 IN1 Sig K2 Com 4
Iout+ Iout+ Refill Valve
9 IN1 Com K2 NO 5
JP8 Refill Valve
10 K2 NC 6
IN2 +15V
1 Vin +
Required +15V 11 IN2 Sig K3 Com 7 Alarm
2 Vin -
for KSM Com 12 IN2 Com K3 NO 8 Alarm
remote GRD 3 GRD J1 J5
JP6

Vcc 1
Out 2
Loader Proximity SW
Com 3

Aux SW

Continued on next page

Rev: C Produced by the K-Tron Institute

5508.30
SFT Weighing Theory for SCM and KCM
Wiring and Color Codes in SCM Systems, Continued

Wiring SFTs to 9191-601650 scale interface

These next diagrams show the wiring for SFTs that are connected
directly to the 9191-601650 Scale Interface pc board, rev. D, LK-1 and
LK-2. These terminal strips are set for two SFTs each. Please note which
SFT number you are connected to so the SIB mounted switch can be
correctly activated to supply power to the connected SFTs.

LK-1/LK-2
Grey
1
Pink
2
Yellow
3
Green SFT
4
Brown
5
White
6
Black - Sh'ld
7
Scale Interface Pc Board
91910601650

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.31
SFT Weighing Theory for SCM and KCM

Wiring and Color Codes in SCM Systems, Continued

Wiring SFTs to 9191-601650 scale interface

LK-1/LK-2
Org/Wht
1
Wht/Org
2
Wht/Blue
3
Blue/Wht SFT
4
Wht/Green
5
Green/Wht
6
Black - Sh'ld
7
Scale Interface Pc Board
9191-601650

Continued on next page

Rev: C Produced by the K-Tron Institute

5508.32
SFT Weighing Theory for SCM and KCM
Wiring and Color Codes in SCM Systems, Continued

Junction box connections for large capacity SFTs

This graphic depicts the internal terminal block for the large standalone
SFTs where wiring is connected. Merely push the wire into the terminal
hole as shown. Follow the color code that comes next.

SFT Mounted Field Connector

Com Rx- Tx-

1 2 3 4 5 6

Vcc
11.3 Vdc Rx+ Tx+

SFT Color Table

Connections
Pin 1 Org/Wht
Pin 2 Wht/Org
Pin 3 Green/Wht
Pin 4 Wht/Green
Pin 5 Blue/Wht
Pin 6 Wht/Blue

Continued on next page

Rev: C Produced by the K-Tron Institute

 5508.33
SFT Weighing Theory for SCM and KCM

Wiring and Color Codes in SCM Systems, Continued

SFT color code- to scale interface 9191-601650

Scale Interface Color Table A Color Table B Signal

Connections Name
LK-1, LK-2 At SIB
Pin 1 Org/Wht Grey +11.3 Vdc
Pin 2 Wht/Org Pink Common
Pin 3 Wht/Blue Yellow RxD-
Pin 4 Blue/Wht Green RxD+
Pin 5 Wht/Green Brown TxD-
Pin 6 Green/Wht White TxD+
Pin 7 Shield Black - Shield Shield

Rev: C Produced by the K-Tron Institute

5508.34
SFT Weighing Theory for SCM and KCM
Index

B P
Basics of SFT operation, 4 Principle of operation of the SFT, 12
Procedure for SFT operation in SCM system, 22
D
S
Definition summary, 1
Scale mounted SFT applications, 10
Scale mounted SFT outline for B scale and D scale, 9
E Scale mounted SFT outline W300/W600, 10
Environmental issues, 14 Scale mounted SFT overview, 9
Scale mounted SFT range, 11
SFT block diagram, 15
G SFT comm. block diagrams, 21
Glossary SFT data link, 20
Addressing, 1 SFT failure codes, 23
B scale, 1 SFT Start-up operation, 16
D scale, 1 SFT to SCM wiring, 27
Fast SFTs, 2 SFT version II status codes, 25
SCM, 1 Specs for scale mounted SFTs, 19
SFT, 1 Specs for standalone SFTs, 18
SmartConnex, 1 Standalone SFT applications, 7
Standalone large capacity SFT outline, 4 Standalone SFT ranges, 8
Standalone small capacity, 5 Summary table for color code- SFT to scale interface, 33
Weight Channel, 1
V
J Vibrating string graphic, 13
Junction box connections for large standalone SFTs, 32
W
O W300/W600 SFT application, 11
Overview of the standalone SFT, 4 Wiring SFTs direct to 9191-601650 scale interface pc
board, 30
Wiring SFTs to 9191-601650 scale interface, 30, 31

Rev: C Produced by the K-Tron Institute

 Chapter 6:
Drive
Documentation
 OPERATING AND
MAINTENANCE INSTRUCTIONS

KCM

k KCM

k KCM

Read this manual prior to opera-

ting or servicing the equipment.
This manual contains all safety
labels and warnings.
Original Operating Instruction
0490020605-EN Rev. 1.6.0

II 3D IP65 T65°C
 Service
If you need assistance, please call your local service center or:

K-TRON (Switzerland) Tel. 0041 (0) 62 / 885 7171

Industrie Lenzhard Fax 0041 (0) 62 / 885 7180
CH-5702 Niederlenz

K-TRON (U.S.) Tel. 001 (0) 856 / 589 0500

Rt 55 and Rt 553 Fax 001 (0) 856 / 589 8113
Pitman, NJ 08071

Premier Pneumatics, Inc. Tel. 001 (0) 785 / 825 1611

606 N. Front St. Fax 001 (0) 785 / 825 8759
Salina, KS 67402-0017

Web: www.ktron.com

Before you call...

 Do you have alarm displays? Can you eliminate their causes?
 Have you modified part of the system, product or operating mode?
 Have you tried to eliminate the fault in accordance with the operating
instructions?
 Note down the project or job number. This can be found at the machine
or in the project manual.
• Example: 0400545

Using the manual:

 This arrow identifies an individual action.
1. Numbers identify a sequence of actions which have to be executed
step-by-step.
▲This symbol identifies a general safety note

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.

If an error or omission is found, please contact:

documentation@ktron.com.
Docu-No.: 0490020605-EN “K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part of
operating personnel. Further, reference is made to the purchase order, acceptance or other document that contains
Datum: 2010/Aug/25 the express K-Tron disclaimer of warranties for a statement of the provisions limiting or disclaiming certain warranties
with respect to the Company's equipment. Except as otherwise expressly provided by K-Tron in any such document,
Original: 0490020605-EN K-TRON MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NOR
ANY OTHER WARRANTY, EXPRESS OR IMPLIED, WITH RESPECT TO THE EQUIPMENT.”
 Table of contents

1 Safety Notes ......................................................................................................................... 9

1.1 Safety symbol definitions ....................................................................................................... 9
1.1.1 Electrical Hazard Icon .......................................................................................................... 10
1.1.2 Ground Icon ......................................................................................................................... 10
1.1.3 ATEX Icon ........................................................................................................................... 10
1.2 Operator responsibilities ...................................................................................................... 11
1.3 Proper use ........................................................................................................................... 11
1.4 Organizational measures ..................................................................................................... 11
1.5 Safety-conscious operation ................................................................................................. 12
1.6 Safety devices ..................................................................................................................... 12
1.7 High voltage ......................................................................................................................... 12
1.8 Additional equipment ........................................................................................................... 13
1.9 Customer service and repairs .............................................................................................. 13
1.10 Removal from service .......................................................................................................... 13

2 Assembly and Function .................................................................................................... 14

2.1 Field of application ............................................................................................................... 14
2.1.1 Gas ...................................................................................................................................... 14
2.1.2 Dust ..................................................................................................................................... 14
2.1.3 Dust deposits and glow temperature ................................................................................... 15
2.1.4 Abbreviations ....................................................................................................................... 16
2.1.5 Additional programming information .................................................................................... 17
2.2 KCM overview ..................................................................................................................... 18
2.3 KCM structure ...................................................................................................................... 19
2.3.1 Enclosure ............................................................................................................................. 19
2.3.2 Circuit assemblies ............................................................................................................... 21
2.4 Safety devices and warnings ............................................................................................... 22
2.4.1 Safety devices ..................................................................................................................... 22
2.4.2 Warnings ............................................................................................................................. 22

3 Technical Data ................................................................................................................... 23

4 Installation .......................................................................................................................... 29
4.1 Unpacking and set-up .......................................................................................................... 29
4.2 Dimension KCM ................................................................................................................... 30
4.2.1 Tools .................................................................................................................................... 31
4.3 Terminal descriptions .......................................................................................................... 32
4.3.1 Terminal block specifications ............................................................................................... 32
4.3.2 Keying diagrams for specified connectors ........................................................................... 32
4.4 CPU connection summary ................................................................................................... 33
4.4.1 CPU DB-9 Configuration port - P1 ....................................................................................... 33
4.4.2 CPU digital I-O - J8 .............................................................................................................. 33

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 3

4.4.3 CPU frequency and analog I-O - J9 ..................................................................................... 33
4.4.4 CPU input power - J10. ........................................................................................................ 34
4.4.5 Internal channel; CPU to Drive - J11 ................................................................................... 34
4.5 K-Port connection summary ................................................................................................ 35
4.5.1 K-Tron K-Port protocols ....................................................................................................... 35
4.5.2 K-Port protocol table ............................................................................................................ 35
4.5.3 K-Port details ....................................................................................................................... 36
4.5.4 K-Port 1 connections ........................................................................................................... 36
4.5.5 K-Port 2 connections ........................................................................................................... 36
4.6 Host port connections .......................................................................................................... 37
4.6.1 Host port details ................................................................................................................... 37
4.6.2 Host connections for AB-DF1 and Modbus using K-Port comm board ................................ 37
4.7 Drive connection summary .................................................................................................. 38
4.7.1 Drive digital inputs- J1 ......................................................................................................... 38
4.7.2 Drive Internal Channel; Drive to CPU - J3 ........................................................................... 38
4.7.3 Drive SFT connections - J4/J7/J8 ........................................................................................ 39
4.7.4 Drive output relays - J5. ....................................................................................................... 40
4.7.5 AC Interface specific output relays - J9/J6 .......................................................................... 40
4.7.6 DC motor drive power - J6. .................................................................................................. 41
4.7.7 DC motor drive feedback - J2 .............................................................................................. 41
4.7.8 Change DC motor shaft rotation .......................................................................................... 41
4.7.9 Stepper drive specific connections ...................................................................................... 42
4.7.10 Universal stepper motor drive power - J6 ............................................................................ 42
4.7.11 LoPo/HiPo stepper motor drive power - J6 .......................................................................... 42
4.7.12 Stepper motor drive feedback - J2 .......................................................................................43
4.7.13 Stepper drive rotation error .................................................................................................. 43
4.7.14 Vibratory drive power - J6 .................................................................................................... 44
4.7.15 Vibratory drive feedback - J2 ............................................................................................... 44
4.7.16 Vibratory drive phase angle correction ................................................................................ 44
4.7.17 AC interface drive power - J6 .............................................................................................. 45
4.7.18 AC interface frequency feedback - J2 .................................................................................. 45
4.7.19 AC interface analog I-O - J9 ................................................................................................ 46
4.8 I-O wiring connections ......................................................................................................... 47
4.8.1 Safety input wiring to KCM Drive - J1 .................................................................................. 47
4.8.2 Drive enable input to KCM Drive - J1 .................................................................................. 47
4.8.3 Digital input #1 and #2 at Drive pc board - J1 ...................................................................... 48
4.8.4 Drive output relays K1-K3 - J5 ............................................................................................. 48
4.8.5 AC interface drive output relay K4 - J9 ................................................................................ 49
4.8.6 AC interface drive output relay K5 - J9 ................................................................................ 49
4.8.7 AC interface drive output relay K6 - J6 ................................................................................ 49
4.8.8 KCM CPU digital outputs - J8 .............................................................................................. 50
4.8.9 KCM CPU digital inputs - J8 ................................................................................................ 50
4.8.10 KCM CPU analog output - J9 ..............................................................................................51
4.8.11 KCM CPU analog input - J9 ................................................................................................. 51
4.8.12 KCM CPU frequency input - J9 ............................................................................................52
4.9 Connecting the KCM ............................................................................................................ 53
4.9.1 General wiring instructions .................................................................................................. 53
4.9.2 Recommended wire sizes and maximum lengths ............................................................... 54
4.10 Power wiring; specific requirements .................................................................................... 55

Page 4 Docu-No.: 0490020605-EN Rev. 1.6.0

4.10.1 Power mains disconnect requirements ................................................................................ 55
4.10.2 Protective ground ................................................................................................................ 55
4.10.3 AC input wiring details to KCM ............................................................................................ 55
4.10.4 Shielding and cable glands .................................................................................................. 56

5 KCM Set-Up ........................................................................................................................ 57

5.1 Initial set-up for KCM CPU .................................................................................................. 57
5.1.1 CPU jumper settings, CPU pc board ................................................................................... 57
5.1.2 CPU jumper settings, K-Port pc board ................................................................................ 58
5.1.3 KCM CPU DIP switch setting .............................................................................................. 58
5.1.4 KCM addressing with CPU DIP switch positions 1-5 ........................................................... 58
5.1.5 K-Port 1 function via KCM CPU DIP switch positions 6-8 ................................................... 59
5.1.6 K-PROM configuration ......................................................................................................... 59
5.2 Initial set-up for KCM drives ................................................................................................ 60
5.2.1 Drive jumper settings-all drive types listed .......................................................................... 60
5.3 DC drive set-up .................................................................................................................... 61
5.3.1 DC drive selection notes: ..................................................................................................... 61
5.3.2 DC motor selection table by drive type and line voltage ...................................................... 61
5.3.3 450/1600 Watt DC drive pc board DIP switch settings ........................................................ 62
5.3.4 Additional jumper settings for 450 watt drive ....................................................................... 62
5.4 AC drive set-up .................................................................................................................... 63
5.4.1 AC drive interface pc board DIP switch settings .................................................................. 63
5.5 Stepper drive set-up (all types) ............................................................................................ 64
5.5.1 Stepper motor programming table ....................................................................................... 64
5.5.2 Stepper drive pc board DIP switch settings ......................................................................... 64
5.6 Vibratory drive set-up .......................................................................................................... 65
5.6.1 Vibratory drive pc board DIP switch settings ....................................................................... 65
5.6.2 Vibratory drive adjustment ................................................................................................... 65

6 Transportation, Storage, Disposal ................................................................................... 67

6.1 Notes on transportation ....................................................................................................... 67
6.2 Notes on storage ................................................................................................................. 67
6.3 Notes on disposal ................................................................................................................ 67

7 Operation ............................................................................................................................ 68
7.1 Initial operation .................................................................................................................... 68
7.1.1 KCM-SD LED status display ................................................................................................ 69
7.1.2 LED function listing .............................................................................................................. 69
7.2 Emergency stop procedure ................................................................................................. 70
7.3 Switching ON and OFF ........................................................................................................ 70

8 Cleaning ............................................................................................................................. 71
8.0.1 Cleaning .............................................................................................................................. 71

9 Maintenance ....................................................................................................................... 72
9.0.1 Required skills/training for maintenance of the KCM ........................................................... 72
9.0.2 General tools required ......................................................................................................... 72
9.1 Preventive maintenance ...................................................................................................... 72

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 5

9.2 KCM CPU LEDs .................................................................................................................. 73
9.2.1 KCM CPU pc board LEDs ................................................................................................... 74
9.2.2 KCM CPU K-Port pc board LEDs ........................................................................................ 74
9.3 KCM Drive and Power Supply Details ................................................................................. 75
9.3.1 Drive board LEDS ................................................................................................................ 75
9.3.2 KCM Drive pc board LEDs-all types .................................................................................... 76
9.4 KCM fuse replacement ........................................................................................................ 77
9.4.1 Auto-resetting drive fuses .................................................................................................... 77
9.4.2 Resetting auto-resetting fuses ............................................................................................. 77
9.4.3 List of auto resetting fuses ................................................................................................... 78
9.4.4 Replacing fuses ................................................................................................................... 78
9.4.5 1600 watt dc motor drive fuse location-0000002610 ........................................................... 79
9.4.6 450 watt dc motor drive fuse location-0000007405 ............................................................. 79
9.4.7 Vibratory drive fuse location-000000684 ............................................................................. 79
9.4.8 AC motor drive interface fuse location-000003413 .............................................................. 80
9.4.9 Stepper drive interface fuse location-0000005987 .............................................................. 80
9.5 KCM service connection ...................................................................................................... 81
9.5.1 Forcing the Config Port to UserIF protocol .......................................................................... 81

10 Troubleshooting ................................................................................................................ 82
10.1 General information on fault detection ................................................................................. 82
10.1.1 Measuring motor power ....................................................................................................... 82
10.1.2 Measure and adjust speed frequency signal ....................................................................... 82
10.2 DC motor drive problems and solutions ............................................................................... 83
10.3 DC drive hex status codes ................................................................................................... 84
10.4 Vibratory drive problems and solutions ................................................................................ 85
10.5 Vibratory drive hex status codes ..........................................................................................86
10.6 Stepper drive problems and solutions ................................................................................. 87
10.7 Stepper drive hex status codes ........................................................................................... 88
10.8 Stepper alarm LED flash sequence ..................................................................................... 89
10.9 AC interface drive problems and solutions .......................................................................... 90
10.10 AC drive interface hex status codes .................................................................................... 91
10.11 General KCM system alarms ............................................................................................... 92

11 Optional Devices ................................................................................................................ 98

11.1 Host communication circuit cards ........................................................................................ 98
11.2 Encoder interface circuit card .............................................................................................. 98
11.3 Field power supply ............................................................................................................... 99
11.4 SFT expander circuit card .................................................................................................. 100
11.5 Daisy chain connector ....................................................................................................... 100

12 Appendix .......................................................................................................................... 101

12.1 Cable length specifications ................................................................................................ 101
12.1.1 DC motor cable lengths: 230 Vac ...................................................................................... 101
12.1.2 DC motor cable lengths: 115Vac ....................................................................................... 101

Page 6 Docu-No.: 0490020605-EN Rev. 1.6.0

12.1.3 Cable lengths for speed feedback signals ......................................................................... 102
12.2 KCM I/O defaults ............................................................................................................... 103
12.2.1 Default KCM Programmable I-O table. .............................................................................. 103
12.2.2 I-O function selection ......................................................................................................... 104
12.3 I-O function and KCM state indications ............................................................................. 106
12.3.1 State indications ................................................................................................................ 106
12.4 General KCM service variables ......................................................................................... 108
12.5 KCM wiring examples ........................................................................................................ 110
12.5.1 System wiring examples .................................................................................................... 110
12.5.2 KCM to KSU-II wiring at K-Port 1/2 ................................................................................... 110
12.5.3 KCM to KSL wiring at K-Port 1 .......................................................................................... 111
12.5.4 KCM to KSC wiring at K-Port 1- Digi card ......................................................................... 112
12.5.5 KCM to KSC wiring at K-Port 1- Moxa card ....................................................................... 113
12.5.6 KCM to KSC wiring at K-Port 1- K-Tron converter ............................................................ 114
12.5.7 KCM to WAGO I-O wiring at K-Port 2 ................................................................................ 115
12.5.8 KCM without SIB board - dc motor - 0000002610 ............................................................. 116
12.5.9 Remote KCM with SIB pcb at feeder ................................................................................. 117
12.5.10Stepper drive wiring example for 0000005987 ................................................................. 119
12.5.11Encoder Line Driver Board ............................................................................................... 120
12.5.12Vibratory feeder wiring example - 0000000684 ................................................................ 121
12.5.13AC drive wiring example - 0000003413 ............................................................................ 122
12.5.14450 watt DC drive wiring example - 0000007405 ............................................................. 123
12.5.15KCM interlock wiring example .......................................................................................... 124
12.5.16Hi/Lo Auto gear external switching circuit ......................................................................... 125
12.5.17Field wound DC motor wiring example ............................................................................. 126
12.5.18KCM to HCU wiring example ............................................................................................ 127
12.5.19KCM to LSR wiring example ............................................................................................. 127
12.5.20KF2- to KCM Host port wiring ........................................................................................... 128
12.5.21BM-85 to KCM Host port wiring ........................................................................................ 129
12.5.22Schematic of SIB board-9191601650 ............................................................................... 130
12.5.23Belt slip wiring for WBF and WBB applications. ............................................................... 131
12.6 Summary of KCM I-O ........................................................................................................ 132
12.6.1 CPU I-O ............................................................................................................................. 132
12.6.2 Common Drive I-O ............................................................................................................. 133
12.6.3 SFT Connections for all drives .......................................................................................... 133
12.6.4 Specific 450/1600 Watt DC Drive connections .................................................................. 134
12.6.5 Specific Stepper Drive connections ................................................................................... 134
12.6.6 Specific Vibratory Drive connections ................................................................................. 135
12.6.7 Specific AC Drive connections .......................................................................................... 135
12.7 Declaration of Conformity KCM ......................................................................................... 136
12.8 Declaration of Conformity KCM SS ................................................................................... 137

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 7

Page 8 Docu-No.: 0490020605-EN Rev. 1.6.0
 Safety Notes 1
Safety symbol definitions 1.1

1 Safety Notes

In case of KCM which are used in hazardous areas also observe the
safety notes and information for explosion-proof KCM.

Installation, commissioning and programming of the specified

equipment should only be undertaken by qualified personnel.

1.1 Safety symbol definitions

▲ This is the safety alert symbol. It is used to alert you to the potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

▲ CAUTION used without the safety alert symbol indicates a

potentially hazardous situation which, if not avoided, may result in
property damage.

▲ CAUTION with safety alert indicates a potentially hazardous

situation which, if not avoided, could lead to light bodily injuries.

▲ WARNING indicates a potentially hazardous situation which, if not

avoided, may result in death or serious personal injury.

▲ DANGER indicates an imminently hazardous situation, which if

not avoided, will result in death or serious injury.

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 9

1 Safety Notes
1.1 Safety symbol definitions

1.1.1 Electrical Hazard Icon

This sign indicates an electrical hazard. It is located on covers and
doors. Only qualified personnel are allowed to remove these covers or
open the doors.

1.1.2 Ground Icon

This sign indicates that a ground/PE connection is required.

1.1.3 ATEX Icon

Important information to explosion protection.

Page 10 Docu-No.: 0490020605-EN Rev. 1.6.0

 Safety Notes 1
Operator responsibilities 1.2

1.2 Operator responsibilities

▲ 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, particularly these safety
notes.
▲ The operator must have damaged or missing components
replaced immediately.
▲ The operator of the KCM is responsible for compliance with the
legally prescribed accident and safety regulations.

1.3 Proper use

▲ The operation of the device in hazardous areas is only allowed in

areas with classification zone 22.
▲ Only operate the device in conjunction with the feeder equipment
from K-Tron.
▲ Only operate the device in accordance with the specified technical
data.
▲ Avoid larger dust deposits on the device.
▲ When processing dangerous materials, also comply with the
safety notes which govern the handling of such materials.
▲ Any modifications and changes on safety devices are prohibited
▲ Do not use the equipment in a manner not intended by the
manufacturer.
▲ Do not use the equipment in a manner not intended by the
manufacturer.

1.4 Organizational measures

▲ 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 safety.

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 11

1 Safety Notes
1.5 Safety-conscious operation

1.5 Safety-conscious operation

▲ Read the operating instructions, in particular these safety notes,

and follow these instructions.
▲ Ensure that only authorized personnel enter the working and
danger area of the equipment.
▲ Any changes (including changes in the operational behavior)
which affect safety must be immediately reported to the
responsible member of the staff.
▲ Always keep safety in mind while working.
▲ Before working on the equipment always switch the feeding
equipment off at the main power switch.

1.6 Safety devices

▲ The electrical safety devices must not be altered. This increases

the danger of accidents.
▲ Never operate the device with the housing open.
▲ Replace damaged cables and connections immediately.
▲ Only operate the feeding equipment if all safety devices are
installed and fully functional.
▲ Check that the safety devices on the KCM and on the feeding
equipment operate properly daily.
▲ Never open or remove covers or hoods while the feeding
equipment is in operation.
▲ If accessing KCM internal components, allow 3 minutes to lapse
prior to opening the enclosure. This ensures safe discharge of high
voltage components.

1.7 High voltage

▲ 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.

Page 12 Docu-No.: 0490020605-EN Rev. 1.6.0

 Safety Notes 1
Additional equipment 1.8

1.8 Additional equipment

▲ Modifications to the equipment are prohibited.

▲ The operator is responsible for complying with all safety
regulations related to interoperation with any additional
equipment.

1.9 Customer service and repairs

▲ Have repairs to the equipment carried out by

– your authorized K-Tron customer service center
or
– qualified personnel, trained by K-Tron.
▲ Only use original K-Tron parts for repairs.

1.10 Removal from service

▲ The operator is responsible for the proper removal and disposal of

the equipment from service.

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 13

2 Assembly and Function
2.1 Field of application

2 Assembly and Function

2.1 Field of application

KCM XPC3 stands for K-TRON Control Module and XPC3 for Explo-
sion-protection of Category 3.
The KCM is a control and a drive module for K-Tron feeders. The KCM
is normally mounted directly on the feeder. It can also be mounted re-
motely.The KCM is used as controller in process engineering for feed-
ing processes which require explosion protection in zone 22.

2.1.1 Gas
Zone Description Use of KCM

Encompasses areas in which it is to be

expected that a dangerous explosive at-
Zone 0 Not allowed
mosphere arises permanently, over a
long period or frequently.
Encompasses areas in which it is to be
Zone 1 expected that a dangerous explosive at- Not allowed
mosphere arises occasionally.
Encompasses areas in which it is not to
be expected that a dangerous explosive
Zone 2 Not allowed
atmosphere arises. When it still arises
then only seldom and only briefly.

2.1.2 Dust
Zone Description Use of KCM

Encompasses areas in which it is to be

expected that a dangerous explosive
Zone 20 Not allowed
air/dust atmosphere arises permanent-
ly, over a long period or frequently.
Encompasses areas in which it is to be
expected that a dangerous explosive
Zone 21 Not allowed
air/dust atmosphere arises occasional-
ly.
Encompasses areas in which it is not to
be expected that a dangerous explosive
Zone 22 Allowed
air/dust atmosphere arises. When it still
arises then only seldom and only briefly.

Page 14 Docu-No.: 0490020605-EN Rev. 1.6.0

 Assembly and Function 2
Field of application 2.1

2.1.3 Dust deposits and glow temperature

▲ 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. Surface temperature (Tmax) + 75 K.
Tmax = T5 mm - 75 °C

In case of dust deposits greater than 5 mm to max. 50mm:

• The difference to be observed between the glow temperature of the
material and the surface temperature (Tmax) depends on how thick
the dust layer is. The context is shown in Fig. 1 of the standard EN
60079-14 Chapter 5.3.3.2.1
• Avoid Dust deposits > 5mm (see 8 cleaning).

Dust deposits ≥ 50 mm avoid or complete covered:

• not allowed

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 15

2 Assembly and Function
2.1 Field of application

2.1.4 Abbreviations
• AB = Allen Bradley data comm-DF1 protocol
• Config port = diagnostic serial data port from KCM
• CPU = central processing unit, microprocessor
• DPDT =Relay Double Pole, Double Throw
• Drive = Common representation of all types of drive pc boards (450
watt DC drive, 1600 watt DC drive, AC drive interface, stepper
motor drive, vibratory drive)
• HCU = Pneumatic loader control
• Host Channel = serial data connection to remote host computer
• HSU = Pneumatic loader control programming interface
• HMI = human, machine interface, usually a PC utilizing a
commercial SCADA software package
• Internal Channel = serial data connection to SFTs/ loader controls,
internal motor drives and ActiFlow
• KCM = K-Tron Control Module, feeder controller
• KCM-KD = KCM with local Keypad and 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 or
KSC
• K-Port 1 and K-Port 2 = data ports for a K-Tron specific interface
• KSU-II = Single unit user interface for the KCM
• K-Vision = K-Tron line interface for up to 16 feeders
• LSR = Pneumatic loader control
• LWF = loss-in-weight feeder
• MDU = Motor Drive Unit, Drive Board
• pcb = printed circuit board
• PID = proportional, integral, differential process controller
• SCADA = supervisory, control and data acquisition system
• Smart Connex II = second version of SmartConnex architecture
• SFM = Smart Flow meter
• SFT = Smart Force Transducer
• SPDT =Relay Single Pole, Double Throw
• SPST =Relay Single Pole, Single Throw
• VOL = volumetric feeder controller

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 Assembly and Function 2
Field of application 2.1

• WBF = weigh belt feeder

2.1.5 Additional programming information

See the following documents for more detailed programming informa-
tion.
• Operation for LWF/WBF/PID/SFM/VOL Feeder = 0490020611
• Operation for LWB/WBB/SFB Feeder = 0490020612
• LWF Programming = 0590020601
• WBF programming = 0590020602
• PID programming = 0590020603
• SFM programming = 0590020604
• VOL programming = 0590020605
• LWB programming = 0590020606
• WBB programming = 0690020602
• SFB programming = 0690020609

Note:
• The K-Tron’s supplied operating instructions describe how to use
the connected feeder.

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2 Assembly and Function
2.2 KCM overview

2.2 KCM overview

The KCM is the controller member of the SmartConnex II family. This
family is comprised of a KSU-II remote display unit, a K-Vision for up
to 16 feeders and a KSC for interface for up to 30 feeders.
The KCM is comprised primarily 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 re-
mote DC drives.
This manual will describe the full family of KCM components, including
all drive applications supported.
The KCM is available in two packages: full local keypad and display
(KCM-KD) or 4 LED status display (KCM-SD).

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 Assembly and Function 2
KCM structure 2.3

2.3 KCM structure

The KCM includes the following components, some which are option-
al.

2.3.1 Enclosure
First, the pc board assemblies are housed in an extruded aluminum
box 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

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2 Assembly and Function
2.3 KCM structure

Fig. 2.2 KCM-SD

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 Assembly and Function 2
KCM structure 2.3

2.3.2 Circuit assemblies

The KCM CPU pc board is mounted to the rear of the front swing-out
cover. The drive pc board with KCM power supply is mounted to the
bottom heatsink plate of the housing. (Fig. 2.3)
There are two choices for the on-board KCM operational display. First,
a fully functional display and keypad assembly may be mounted to the
rear of the KCM cpu pc board and permit access via the front of the
cover for all operational actions. (Fig. 2.1) The second choice provides
only the four status LEDs that indicate machine running and alarm.
(Fig. 2.2) The first case permits operation of the KCM without any oth-
er external components and is suited for simple machine mount instal-
lations where operator interaction is required at the controller. The
second case requires the addition of one or more of the following:
KSU-II, KSC or KSL user interface. The choice depends upon appli-
cation. If the choice is made to use an external K-Tron user interface,
like the KSU-II, a K-Port Communication pc board must be mounted
to the KCM CPU pc board. If communications to a host computer or
PLC is required, a Host Communications pc board is mounted to the
KCM CPU pc board.Also connected to the KCM CPU is the K-PROM
memory module that contains all parameter and KGR file data.
Lastly, if the speed signal is differential, a plug-in circuit card permits
the receipt of this signal where normally a single ended input is re-
ceived.
KCM element identification
(1) KCM CPU circuit card 5 3 4 2
(2) KCM Drive circuit card
(3) K-Port circuit card
(4) Host comm. circuit card
(5) K-PROM circuit card

1
Fig. 2.3 KCM open

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2 Assembly and Function
2.4 Safety devices and warnings

2.4 Safety devices and warnings

▲ For operation in the allowed hazardous zone, only use certified

explosion-proof cable glands and blind covers ATEX category
2GD.

2.4.1 Safety devices

The front cover is the primary KCM safety guard. It must not be
opened unless power has been removed from the KCM.

2.4.2 Warnings
On the front panel of the KCM, either with the full keypad or LED dis-
play, the following safety messages are supplied.

Fig. 2.4 KCM safety label

Make all ground/PE connections to these points as indicated.

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 Technical Data 3
Safety devices and warnings 2.4

3 Technical Data

Specification Limitations Notations

Manufacturer K-Tron
Device name KCM
KCM SS
Device marking KCM

II 3D Ex tD IP65 T65°C
Tamb –20 to +50°C

Device marking KCM SS

II 3D Ex tD IP65 T65°C
Tamb –20 to +40°C

Applied Standards See declaration of conformity

Service application KCM must only be installed in an in-
dustrial or manufacturing power en-
vironment. Connection in a residen-
tial power system is not permitted.
Power line/supply 85-265 VAC
(100-240 VAC, +10%, -15%)
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 -10 to +50°C (14 to +122°F)
Storage temperature -25 to +70°C (-13 to +158°F)
Maximum ambient <95% at 25° C non-condensing
humidity
Pollution degree Category II
Over voltage category Category II
Table page 1 of 6

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3 Technical Data
2.4 Safety devices and warnings

Specification Limitations Notations

Maximum input power DC motor-1600 watt drive:
2.0 KVA at 230 Vac
1.2 KVA at 115 Vac
DC motor-450 watt drive:
0.5 KVA at 230 Vac
0.5 KVA at 115 Vac
Vibratory drive:
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
Table page 2 of 6

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 Technical Data 3
Safety devices and warnings 2.4

Specification Limitations Notations

Maximum output DC motor-1600 watt drive: Current range selected from motor
power 800 W at 115 Vac nominal line volt- power settings.
age
1600 W at 230 Vac nominal line
voltage
DC motor-450 watt drive:
225 W at 90 or 100 Volt motor
450 W at 180 or 200 Volt motor
Vibratory Drive:
Max. 60 W, 25-100 Hz
Stepper drive-0000005987:
1.4 or 2.46 A/coil peak per at nomi-
nal line voltage (194 watts)
Stepper drive-0000004568:
2.46 A/coil peak per at nominal line
voltage. (194 watts)
Stepper drive-0000001430:
1.4 A/coil peak per at nominal line
voltage. (49 watts)
DC motor output With 115 Vac supply:
voltage 160 Vp, square-wave
PWM 0-99.6%
With 230 Vac supply:
322 Vp, square wave
PWM 0-99.6%
Stepper motor output 48 V maximum-(PWM)* *For 0000005987 drive
voltage 24 V maximum-(PWM)** **For 0000004568 and
0000001430 drives
Motor field output-dc Pulsing DC at 2A. For dc motor drive. Special option
162 Vp DC at 115 Vac 0000000639. Not for standard
KCM.
325 Vp DC at 230 Vac
Maximum dc motor 2500 rpm at 125% drive command Maximum input frequency from the
speed motor tachometer cannot exceed
10 kHz.
Speed accuracy ±1 rpm
DC-motor
Table page 3 of 6

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3 Technical Data
2.4 Safety devices and warnings

Specification Limitations Notations

Stepper speed range 0.3-150 rpm with standard quadra- Maximum encoder frequency
ture encoder. 1250 Hz.
Tachometer signal: 5V CMOS level
with pull-up to +5VDC.
Maximum motor speed is motor de-
pendent.
Speed accuracy-stepper ±0.01 rpm
drive
Maximum current from 500 mA maximum, all Process 24 Sourced from KCM internal power
24 VDC VDC connections supplies.
Communications inter-
face
Internal data comm. 9 bit proprietary For SFT connections-six SFT per-
mitted.
External data comm. KMB Modbus, KSU-II protocol, K-Port1 and K-Port2
K10S protocol
Host data comm. Modbus RTU Requires communication adapters
Allen Bradley DF1 specific to the protocol.
ProfibusDP
Profinet
ModbusPlus
ModbusTCP
AB DeviceNet
AB EtherNet/IP
Surge immunity Meets EN61000-4-5, Criteria C Motor may stop during a surge or
transient condition.
Relay K1-K3 contact 5 A, 250 Vac, 5 A, 30 Vdc Relay K1-K2 are SPDT
ratings Maximum switching power 1250 Relay K3 is SPST
VA, 150 W
Relay K4-K6 contact 5 A, 250 Vac, 5 A, 30 Vdc On AC interface circuit board only
ratings Maximum switching power 1250 Relay K4-K6 are DPDT
VA, 150 W
Digital input ratings 0-5 Vdc input range, 24 V dc maxi- KCM CPU pc board
mum. 4.75 k pull-up resistor
Digital output ratings 40 Vdc maximum at 100 mA maxi- KCM CPU pc board
mum load
Table page 4 of 6

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 Technical Data 3
Safety devices and warnings 2.4

Specification Limitations Notations

Analog input rating 0-20 mA/4-20 mA with 100  im- Input value selected by jumpers on
pedance or the KCM CPU circuit card.
0-5 Vdc with 94.5 k impedance or
0-10 Vdc with 65.3 k impedance
or
Analog output rating 0-20 mA/4-20 mA selectable by KCM CPU pc board
software Span and zero by software pro-
gramming
Frequency input ratings input frequency range: 0-20 kHz KCM CPU pc board
Minimum pulse width: 15 sec, on/
off
Logic level: 5-12 Vdc for true
With 24 Vdc, use 2.2 kOhm Resis-
tor in series.
AC MDU speed Vmax < 25 Vdc, Vmin > 4.0 Vdc, Ion Opto-isolated input
frequency input rating (typ) > 15 mA
+ 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 SFTs/HCUs only
Program data storage Up to 8 k bytes of data stored on a K-PROM plug-in memory device
non-volatile circuit
Maximum altitude < 2000m
Table page 5 of 6

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3 Technical Data
2.4 Safety devices and warnings

Specification Limitations Notations

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

K-Tron (Schweiz) AG
Industrie Lenzhard
CH-5702 Niederlenz
Label KCM KCM K-Tron Control Module
115/230 VAC, 50/60Hz, 2 kW (max)
Year: 20nn
II 3D Ex tD A22 IP65 T65°C
K-Tron 0590024903 B Tamb -20...+50 °C

K-Tron (Schweiz) AG
Industrie Lenzhard
CH-5702 Niederlenz
Label KCM SS KCM Stainless Steel
115/230 VAC, 50/60Hz, 2 kW (max)
Year: 20nn
II 3D Ex tD A22 IP65 T65°C
K-Tron 0990021903 A Tamb -20...+40 °C

Table page 6 of 6

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 Installation 4
Unpacking and set-up 4.1

4 Installation

▲ Ensure that the KCM is connected and put into operation only by
authorized personnel.

▲ KCM mounting must be vertical.

▲ 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.

4.1 Unpacking and set-up

Carefully unpack the KCM from the shipping container and check that
all items have been supplied. The KCM may be mounted on the feed-
er.

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4 Installation
4.2 Dimension KCM

4.2 Dimension KCM

153.6
132
305
122

295 18.3
18.3
26.7 43.3

KCM

265 252 233

A
311.5
A
10.29

6.24
18.3

Fig. 4.1 KCM dimensions - in mm

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

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 Installation 4
Dimension KCM 4.2

4.2.1 Tools
The following tools are recommended when working with the KCM:
• Medium phillips screwdriver
• Small blade jewelers screwdriver
• Medium blade screwdriver
• 18 mm open end wrench
• 24 mm open end wrench

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4 Installation
4.3 Terminal descriptions

4.3 Terminal descriptions

4.3.1 Terminal block specifications

Each terminal block is made up of two components; a remov-
able plug and stationary socket. Each is keyed with plastic keys
to prevent misconnection and all are unique. Both the socket
and plug are keyed as necessary
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

4.3.2 Keying diagrams for specified connectors

8 1 8 1

J5 J6

8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

6 1 6 1

J3 J4
J7
6 5 4 3 2 1 J8 6 5 4 3 2 1

Fig. 4.2 Power pc board keying diagram

6 1 6 1

J9 J11

6 5 4 3 2 1 6 5 4 3 2 1

Fig. 4.3 KCM cpu keying diagram

1 1

J2 J1
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Fig. 4.4 K-Port pc board keying diagram

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 Installation 4
CPU connection summary 4.4

4.4 CPU connection summary

See programming manuals for configuration of I-O.

4.4.1 CPU DB-9 Configuration port - P1

Terminal Function Notes
P1-2 Rx To PC, serial port, pin 3
P1-3 Tx To PC, serial port, pin 2
P1-5 Common To PC, serial port, pin 5

4.4.2 CPU digital I-O - J8

Terminal Function Notes

J8-1 Digital Input 1 Programmable via the user interface
J8-2 Digital Input 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 interface
J8-10 Com Ground reference

4.4.3 CPU frequency and analog I-O - J9

Terminal Function Notes

J9-1 Frequency Input (+)
Programmable via the user interface
J9-2 Frequency Input (-)
J9-3 Analog Output (+)
Programmable via the user interface
J9-4 Analog Output (-)
J9-5 Analog Input (+)
Programmable via the user interface
J9-6 Analog Input (-)

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4 Installation
4.4 CPU connection summary

4.4.4 CPU input power - J10.

• Normally J10 is only used if the CPU circuit card assembly is not co-
located with the drive board. If the CPU and drive are in the same
enclosure, power comes from J11.

Terminal Function Notes

J10-1 +24 Vdc power input External power supply. (14-40 Vdc)
J10-2 Common External power supply
J10-3 Earth/Shield PE/GRD

4.4.5 Internal channel; 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 Docu-No.: 0490020605-EN Rev. 1.6.0

 Installation 4
K-Port connection summary 4.5

4.5 K-Port connection summary

▲ Based upon the KCM power budget, only one KSU-II can be
powered from the KCM.
▲ If a second KSU-II is connected 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 pc
card, use the following connection information.

4.5.1 K-Tron K-Port protocols

KMB = (K-BUS, MAIN) used by KCM, KSU-II, K-Vision and KSC
K10S = (K10S 9 bit) use for KSL to KCM
Modbus = KCM to remote I/O- e.g. WAGO

4.5.2 K-Port protocol table

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 KMB Slave node Programmable baud rate, 8E1
Fixed, 19.2 kbaud, 9 bit
KSL 1 K10S Slave node Programmable baud rate when FakeK10S
(Service variable) is on.
WAGO I-O 2 Modbus Master node Fixed 19.2 kbaud, 8E1

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4 Installation
4.5 K-Port connection summary

4.5.3 K-Port details

When a Comm board is plugged into the K-Port, two K-Port connec-
tions, 1 and 2, are available. Each K-Port supports RS232, RS485 (4
wire and 2 wire).
K-Port 1 is used for KSC, K-Vision and KSU-II to KCM connections.
K-Port 2 is used for KCM to remote Modbus I-O and KSU-II to KCM
connections.

4.5.4 K-Port 1 connections

Terminal Function Notes

J1-1 Power + 24Vdc power supply for KSU-II
J1-2 Common Ground/common from Drive power supply
J1-3 TxD+ K-Port1 RS485 TxD+
J1-4 TxD- K-Port1 RS485 TxD-
J1-5 RxD+ K-Port1 RS485 RxD+
J1-6 RxD- K-Port1 RS485 RxD-
J1-7 Tx232 K-Port1, RS232 Tx
J1-8 Rx232 K-Port1, RS232 Rx

4.5.5 K-Port 2 connections

Terminal Function Notes

J2-1 + 24Vdc power from Drive power supply for
Power
KSU-II
J2-2 Common Ground/common from Drive power supply
J2-3 TxD+ K-Port2 RS485 TxD+
J2-4 TxD- K-Port2 RS485 TxD-
J2-5 RxD+ K-Port2 RS485 RxD+
J2-6 RxD- K-Port2 RS485 RxD-
J2-7 Tx232 K-Port2, RS232 Tx
J2-8 Rx232 K-Port1, RS232 Rx

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 Installation 4
Host port connections 4.6

4.6 Host port connections

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 0590020610
Profinet
ModbusPlus 0590020608
ProfibusDP 0590020607

4.6.1 Host port details

The host port can be configured for Profibus, Profinet ModbusPlus,
Modbus TCP, DeviceNet, Ethernet IP, Modbus RTU or AB DF1.
In each case, a specific communications card for that protocol is re-
quired and must be installed into the Host port slot on the CPU circuit
card. In the case of Modbus RTU or AB DF1 protocols, the K-Port
comm board is used, only Port 1 is active for either protocol.

4.6.2 Host connections for AB-DF1 and Modbus using K-Port

comm board
Terminal Function Notes
J1-1 Power Unused
J1-2 Common Ground/common
J1-3 TxD+ RS485 TxD+
J1-4 TxD- RS485 TxD-
J1-5 RxD+ RS485 RxD+
J1-6 RxD- RS485 RxD-
J1-7 Tx232 RS232 Tx
J1-8 Rx232 RS232 Rx

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4 Installation
4.7 Drive connection summary

4.7 Drive connection summary

The first group of connections, tables 4.7.1 to 4.7.4 are common for all
drive types.

See programming manuals for application information.

4.7.1 Drive digital inputs- J1

Input #1/#2 functions are programmable.

Terminal Function 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 programmable
J1-9 Common Same as J1-6
J1-10 + 24 Vdc Same as J1-1
J1-11 Input signal #2 This input is programmable
J1-12 Common Same as J1-6

4.7.2 Drive Internal Channel; Drive to CPU - J3

Terminal Function Notes

J3-1 Power + 24 Vdc power from Drive power supply
J3-2 Common Common from Drive power supply
J3-3 TxD+ Internal data channel 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

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 Installation 4
Drive connection summary 4.7

4.7.3 Drive SFT connections - J4/J7/J8

• For the 450 watt dc motor drive, SFTs connect only to J4.

Terminal Color Function 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 data channel to SFT
J4/7/8-5 White RxD+ Internal data channel to SFT
J4/7/8-6 Brown RxD- Internal data channel to SFT

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4 Installation
4.7 Drive connection summary

4.7.4 Drive output relays - J5.

• Relay functions are programmable.

– Contact ratings: 250 Vac, 30 Vdc, 5 A, maximum

Terminal Function
J5-1 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

4.7.5 AC Interface specific output relays - J9/J6

• 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 Relay #K5-COM.
J9-9 Relay #K5-N.O.

J6-1 Relay #K6 - N.O.

J6-2 Relay #K6 - N.O.

Page 40 Docu-No.: 0490020605-EN Rev. 1.6.0

 Installation 4
Drive connection summary 4.7

4.7.6 DC motor drive power - J6.

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 L2 Second leg of a 230 Vac line
J6-8 L1 Line input (hot) either 115 Vac or 230 Vac

4.7.7 DC motor drive feedback - J2

Terminal Function Notes

J2-1 + 5 Vdc + 5 Vdc power at 100 mA for sensor power
J2-2 Input channel A from speed sensor. Also used if the sensor has on-
Frequency In A
ly a single output.
J2-3 Frequency In B Input channel B from a quadrature velocity sensor.
J2-4 Common Common for sensor

Note:
• If a SFT Interface board is mounted to the feeder and where the
KCM is remotely mounted for DC motor applications, a small circuit
card (0000006384) with a differential line receiver is plugged into J2
to receive the single differential speed signal from the feeder. The
speed signal is connected to this circuit card.

4.7.8 Change DC motor shaft rotation

To change the shaft rotation, switch the polarity of the motor armature
leads either at the KCM DC Drive or at the motor. Do this only with
power removed from the KCM.

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4 Installation
4.7 Drive connection summary

4.7.9 Stepper drive specific connections

▲ Two stepper drive wiring configurations for J6 are used. The

Universal Stepper drive, 0000005987 is described in table 4.7.10.
The LoPo and HiPo stepper drives, 0000001430 and 0000004568
are described in table 4.7.11

4.7.10 Universal stepper motor drive power - J6

Terminal Function Notes

J6-1 Stepper drive Phase 1(+) Phase 1 of the stepper drive
J6-2 Stepper drive Phase 1(-) Phase 1 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

4.7.11 LoPo/HiPo stepper motor drive power - J6

Terminal Function Notes

J6-1 Stepper drive Phase 1(+) Phase 1 of the stepper drive
J6-2 Stepper drive Phase 1(-) Phase 1 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 Neutral(L2) Neutral leg of a 115 Vac line or 230 Vac
J6-8 L1 Line input (hot) either 115 Vac or 230 Vac

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 Installation 4
Drive connection summary 4.7

4.7.12 Stepper motor drive feedback - J2

Terminal Function Notes

J2-1 + 5 Vdc + 5 Vdc power at 100 mA for sensor power
J2-2 Input channel A from velocity sensor. Also used if the sensor has
Frequency In A
only a single output.
J2-3 Frequency In B Input channel B from a quadrature velocity sensor.
J2-4 Common Common for sensor

4.7.13 Stepper drive rotation error

Switch the two encoder leads, to J2 terminal block, terminals 2 and 3
if the motor does not rotate in the proper direction.
Note:
• The alarm 14 MDU_Current will occur if this 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.

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4 Installation
4.7 Drive connection summary

4.7.14 Vibratory drive power - J6

Terminal Function Notes

J6-1 Variable amplitude and frequency power to vibratory feeder
Vibratory feeder coil (-)
drive coil.
J6-2 Variable amplitude and frequency power to vibratory feeder
Vibratory feeder coil (+)
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 Vac

4.7.15 Vibratory drive feedback - J2

Terminal Function Notes

J2-1 Signal from displacement measurement coil from the KV vibratory
Feedback coil (+)
feeder.
J2-2 Signal from displacement measurement coil from the KV vibratory
Feedback coil (-)
feeder.

4.7.16 Vibratory drive phase angle correction

Switch the two leads to J2 terminal block if the KV drive does not con-
trol properly.
Note:
• The alarm MDU_Polarity(20) will occur if this change is to be made.

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 Installation 4
Drive connection summary 4.7

4.7.17 AC interface drive power - J6

Terminal Function Notes

J6-1 Switched line power L2 to Fused and switched through relay K6 from the input line
remote motor contactor power at J6-7.
J6-2 Switched line power L1 to Fused and switched through relay K6 from the input line
remote motor contactor power at J6-8.
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
J67 L2 Second leg of a 230 Vac line
J6-8 L1 Line input (hot) either 115 Vac or 230 Vac

4.7.18 AC interface frequency feedback - J2

• For AC Drive frequency feedback input:
– Vmax < 25.0 Vdc, Vmin > 4.0 Vdc, Ion (typ) > 15 mA

Single Ended Encoder Signal

Terminal Function Notes

J2-1 + 5 Vdc + 5 Vdc power at 100 mA for sensor power
J2-2 Positive side of the opto isolator. Configured for current sink-
Connect to J2-1
ing tachometer.
J2-3 Tachometer Frequency Frequency input from the tachometer, negative side of the
Input opto isolator.Configured for current sinking tachometer.
J2-4 Common Common for sensor

Differential Encoder Signal

Terminal Function Notes

J2-1 + 5 Vdc + 5 Vdc power at 100 mA for sensor power
J2-2 Freq (+) Frequency input from the tachometer.
J2-3 Freq (+) Frequency input from the tachometer.
J2-4 Common Common for sensor

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4 Installation
4.7 Drive connection summary

4.7.19 AC interface analog I-O - J9

Terminal Function Notes

J9-1 For drive command control to external drive at 500 mA dc
Analog current output (+)
maximum source.
J9-2 Analog current output (-) For drive command control to external drive.
J9-3 For drive command control to external drive. (5 Vdc ampli-
Frequency Out (+)
tude)
J9-4 Frequency Out (-) For drive command control to external drive.
J9-5 +24 Vdc Maximum current 500 mA, fused
J9-6 See section 4.7.5
J9-7 See section 4.7.5
J9-8 See section 4.7.5
J9-9 See section 4.7.5
J9-10 Common

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 Installation 4
I-O wiring connections 4.8

4.8 I-O wiring connections

Notes:
• The <F> symbol shows the field side of the diagram. Internal
circuits are shown to aid understanding of function.
• Sections 4.8.1 to 4.8.7 define I-O for drive cards in various
configurations with sections 4.8.1 to 4.8.4 describing I-O common
to all drives.
• Sections 4.8.8 to 4.8.12 define I-O from the KCM CPU circuit card.
• See section 4.3 for terminal connections.

4.8.1 Safety input wiring to KCM Drive - J1

The maximum voltage drop across the contacts is 2.0 Vdc.
Drive – J1 Notes:
24 Vdc • Safety input wiring is made at terminal strip J1 on the drive pcb.
1
• 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.
2

Safety
Switch
In

Fig. 4.5 Safety switch wiring-Drive

4.8.2 Drive enable input to KCM Drive - J1

The maximum voltage drop across the contacts is 2.0 Vdc.
Drive – J1 Notes:
F
• The Drive Enable Input must be at 24 Vdc to permit KCM drive
3
+24
Vdc
output.
Close to
Run
4 1k • The input signal as shown in optically isolated from the KCM.
Drive Enable + • Drive enable input wiring is made at terminal strip J1 on the drive
5 pcb.
Close to Drive Enable -
Run

Com

Fig. 4.6 Drive enable wiring-Drive

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4 Installation
4.8 I-O wiring connections

4.8.3 Digital input #1 and #2 at Drive pc board - J1

Note:
• These two digital inputs are found on the Drive pcb at terminal J1.
These two inputs on the drive circuit board have the possibility to be
24 Vdc 5 Vdc
wired for either pull-up or pull down applications. Both digital inputs
F
are programmable in function.

Com
If the jumper is connected to +24 Vdc, the input must be taken to com-
+
mon to function. If the jumper is connected to common, the input must
Input 1 & 2 - be taken to at least +5 Vdc to operate.
J1-8(1)
J1-11(2) Notes:
PE
Com
• 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
Fig. 4.7 Digital input example-Drive

4.8.4 Drive output relays K1-K3 - J5

K1-K2 drive board relay wiring.
F Notes:
N.C.
J5-3(K1) • Relay 1 and Relay 2 are SPDT types, while Relay #3 is a SPST
J5-6(K2)
type.
K1, K2
N.O.
J5-2(K1) • Relay function is programmable via the user interface.
Relay J5-5(K2)
Contacts • Function is programmed as <MDUrel1, MDUrel2, MDUrel3>.
J5-1(K1)
COM
J5-4(K2) – MDUrel1 = relay K1, MDUrel2 = relay K2, MDUrel3 = relay K3
• Relay wiring is made at the drive pcb, terminal strip J5.
J5-8 – K1-NC = J5-3, K1-NO = J5-2, K1-COM = J5-1
K3 Relay
Contacts N.O. – K2-NC = J5-6, K2-NO = J5-5, K2-COM = J5-4

COM

J5-7

Fig. 4.8 Drive relays K1-K3

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 Installation 4
I-O wiring connections 4.8

4.8.5 AC interface drive output relay K4 - J9

K4 is relay that provides a run enable control signal to an external de-
vice on the AC Interface drive circuit card. When the contacts are
F closed, the AC interface is permitting an external device to run, if that
device’s interlock is wired to this relay.
Notes:
J9-7 •
K4 Relay • Relay connections on the AC drive pcb are at terminal strip J9.
contacts N.O.
– K4-NO = J9-7, K4-COM = J9-6
COM
J9-6

Fig. 4.9 AC interface relay K4

4.8.6 AC interface drive output relay K5 - J9

AC Interface relay K5 is an alarm reset relay. When an alarm is
cleared, this relay energizes for 2 seconds after an alarm clear com-
F mand from the user interface.
Notes:
J9-9
• Relay connections on the AC drive pcb are at terminal strip J9.
K5 Relay
contacts
N.O. – K5-NO = J9-9, K5-COM = J9-8

COM
J9-8

Fig. 4.10 AC interface relay K5

4.8.7 AC interface drive output relay K6 - J6

AC Interface relay K6 serves to interlock AC line power to an external
From L1-fused drive through the interlock action of the safety relay on the AC inter-
F
face. When the safety condition is true, the relay energizes connecting
fused L1 and L2 respectively to L1 Safe(J6-2) and L2 Safe(J6-1) on
K6 J6-2 connector J6. Each line is fused at 6.3 A.
Relay
N.O.
contacts Note:
• Relay connections on the AC drive pcb are at terminal strip J6
From L2-fused
– K6-NO = J6-2, K6-NO = J6-1

K6 J6-1
Relay N.O.
contacts

Fig. 4.11 AC interface relay K6

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4 Installation
4.8 I-O wiring connections

4.8.8 KCM CPU digital outputs - J8

This is an example of one of four programmable digital outputs avail-
Vx able from the KCM CPU pc board. This example is driving a relay-CR.
CPUout1=J8-6
J8
Notes:
CPUout2=J8-7 F
CPUout3=J8-8
CPUout4=J8-9 Dig CR • Four programmable outputs are available.
Out
• Functions are programmed as <CPUout1, CPUout2, CPUout3,
4.7nF
CPUout4>.
• A “low” output (sinking) condition = “true”.
• Maximum value of Vx = 40 Vdc. Maximum sink current = 100 mA
PE
Com • Connections are made at the CPU pcb, terminal strip J8.
– CPUout1 = J8-6
– CPUout2 = J8-7
– CPUout3 = J8-8
– CPUout4 = J8-9
Fig. 4.12 CPU digital output example

4.8.9 KCM CPU digital inputs - J8

This is an example of one of the four programmable digital inputs on
CPUin1=J8-1 the KCM CPU circuit card.
+5Vdc CPUin2=J8-2
F
CPUin3=J8-3 Notes:
CPUin4=J8-4
4.75k
Dig • Maximum current from terminal 3, +24 Vdc, all connections, is 350
In 10k
ma.
100nF • A low input provides an ‘ON’ condition with <Normal> polarity.
4.7nF
PE
Com
• Connections are made at the CPU pcb, terminal strip J8.
• Vin maximum = 24 Vdc
• Functions are programmed as <CPUin1, CPUin2, CPUin3,
CPUin4>.
– CPUin1 = J8-1
– CPUin2 = J8-2
– CPUin3 = J8-3
– CPUin4 = J8-4
Fig. 4.13 CPU digital input example

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 Installation 4
I-O wiring connections 4.8

4.8.10 KCM CPU analog output - J9

This circuit shows the analog output (0-20mA/4-20mA) that is avail-
CPU-J9 able from the CPU pcb at terminal J9.
F
The output function is programmed via the I-O menu, Analog Output
Analog Out (+)
+12Vdc
J9-3
sub-menu.
• I Output (+) = J9-3
Analog Out (-)
J9-4 • I Output (-) = J9-4

49.9

Com

Fig. 4.14 CPU analog output circuit

4.8.11 KCM CPU analog input - J9

This circuit shows the selectable range analog input that is available
CPU-J9 at the CPU pcb at terminal J9.
F
J9-5

Analog In+
16.2k
+
The input function is programmed via the I-O menu, Setpoint Input
118
475
- sub-menu as parameter <SOURCE> = <CPU Analog>.
14.0k 4.53k
Use only one jumper at the required location for the voltage or current
JP4

J9-6
JP3 JP2 input used.
Analog In-
0-20mA 0-5Vdc 0-10Vdc

Fig. 4.15 CPU analog input circuit

Notes:
• JP2 = 0-10 Vdc
• JP3 = 0-5 Vdc
• JP4 = 0-20 mA
– Input (+) = J9-5
– Input (-) = J9-6
• 0-20mA/4-20mA with 100  impedance
• 0-5 Vdc with 94.5 kimpedance
• 0-10 Vdc with 65.3 k impedance

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4 Installation
4.8 I-O wiring connections

4.8.12 KCM CPU frequency input - J9

This circuit shows the frequency input that is available at the CPU pcb
CPU-J9 at terminal J9.
F
The input function is programmed via the I-O menu, Setpoint Input
J9-1 2.2k
Frequency
Input (+)
sub-menu as parameter <SOURCE> = <CPU =0-10kHz>. See the
specific application programming manual for exact programming.
Frequency
J9-2 • Logic level = 5-12 Vdc for a “true”
Input (-)
• For 24Vdc Power supply use an additional 2.2kOhm resistor in
serie.
• Frequency range = 0-20 kHz
• Minimum pulse width = 15 sec
– Freq input (+) = J9-1
– Freq input (-) = J9-2
Fig. 4.16 CPU frequency input circuit

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 Installation 4
Connecting the KCM 4.9

4.9 Connecting the KCM

▲ The KCM is auto-switching for AC power. No selection is required

for 115 Vac or 230 Vac power lines.

It is necessary to make the following connections:

• Power line
• DC drive motor, stepper motor, KV1-KV3 vibratory drive or AC
interface application
• Tachometer or speed pick-up for DC drives, the feedback coil for
KV1-3 vibratory drives and the quadrature encoder output for the
stepper drive
• Necessary input/output connections for the alarm relay, for enabling
signals and/or for any other I-O functions
• Safety switch connections as required
• Data lines to operating unit and/or SCADA.

▲ Do not put material into a feeder before running the motor. Motor
direction must be determined before bulk material is added, or
feeder damage may result.

4.9.1 General wiring instructions

• Do not run AC mains or DC motor wiring in the same conduits with
signal wiring.
• All wiring must be accessible 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 provided wiring diagram for connection. The
schematics supplied in the appendix are for review only.
• Electrical connection diagram examples are found in the Appendix.

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4 Installation
4.9 Connecting the KCM

4.9.2 Recommended wire sizes and maximum lengths

Connection Wire sizes DIN mm2 and AWG and maximum lengths

Maximum: 2.5 mm2 or 12 AWG

AC power supply Minimum: 2.0 mm2 or 14 AWG
according to regulations in your country
DC motor armature and field See section 12.1. for more information
Maximum: 1.5 mm2 or 14 AWG, 100 m
Stepper motor windings
Minimum: 0.3 mm2 or 22 AWG, 30 m
Maximum: 1.3 mm2 or 16 AWG, 100 m (shielded)
Minimum: 0.3 mm2 or 22 AWG, 30 m (shielded)
Stepper motor tachometer
Scale interface pcb/encoder interface required for > 30 m
See section 12.1. for more information
Maximum: 2.5 mm2 or 12 AWG-shielded, 50 m
KV1-KV3 vibratory Minimum: 1.0 mm2 or 16 AWG-shielded, 30 m
See table in appendix
Maximum: 2.5 mm2 or 12 AWG, 35 m
Relay K1-K6
Minimum: 1.0 mm2 or 16 AWG, 25 m
Maximum: 1.3 mm2 or 16 AWG, 30 m (shielded)
Velocity feed back-single ended
Minimum: 0.5 mm2 or 20 AWG, 30 m (shielded)
Velocity feed back-differential Maximum: 1.3 mm2 or 16 AWG, 300 m (shielded)
(SIB installed) with Encoder In-
terface on Drive pcb Minimum: 0.5 mm2 or 20 AWG, 50 m (shielded)

Maximum: 1.3 mm2 or 16 AWG, 500 m (shielded)

Digital Input/output
Minimum: 0.5 mm2 or 20 AWG, 500 m (shielded)
Maximum: 1.3 mm2 or 16 AWG, 500 m (shielded)
K-Port
Minimum: 0.5 mm2 or 20 AWG, 500 m (shielded)
Maximum: 1.3 mm2 or 16 AWG, 100 meters
DC Power to KSU-II from KCM
Minimum: 0.5 mm2 or 20 AWG, 20 meters

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 Installation 4
Power wiring; specific requirements 4.10

4.10 Power wiring; specific requirements

Use this section as a guideline for power wiring installation.

▲ 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 labeled as the
disconnecting device for the connected equipment.
▲ There must be no power consuming components electrically
connected between the supply mains and the disconnecting
device.
▲ The disconnecting means or circuit breaker must not interrupt the
protective earth conductor

4.10.1 Power mains disconnect requirements

Circuit breaker must meet IEC-898, UL-1077, VDE-0641 or CSA22.2-
No.235. ABB S271 breaker with ‘K’ trip curve meets the requirement.
Note:
• Current limit is to be 15A maximum

4.10.2 Protective ground

Protective earth or ground connections must be made to KCM

ground terminals with the indicated label.

4.10.3 AC input wiring details to KCM

• KCM AC input terminals are: L1, L2, N-neutral, G-ground/PE
• For 115 VAC inputs, connect the hot wire to “L1” as it is 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

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4 Installation
4.10 Power wiring; specific requirements

4.10.4 Shielding and cable glands

▲ For operation in the allowed hazardous zone, only use certified

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).

Fig. 4.17 Cable gland shielding

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 KCM Set-Up 5
Initial set-up for KCM CPU 5.1

5 KCM Set-Up

5.1 Initial set-up for KCM CPU

▲ Do not open the KCM while under power.

5.1.1 CPU jumper settings, CPU pc board

These settings must be made for all KCM controllers. See below.
Notes:
• JP2 through JP4 selects the range for an analog input
• A jumper can be in only one of those three locations
• When CPU_Analog_Out is selected, place the jumper into the
required voltage or current location
JP Normal Position Function

[1-2] - normal processor operation

JP-1 1-2
[2-3] - processor reset
Connect [1-2] for 0-10Vdc analog in-
JP-2 1-2
put.
Connect [1-2] for 0-5 Vdc analog in-
JP-3 1-2
put.
Connect [1-2] for 4-20 mA analog in-
JP-4 1-2
put.
[1-2] - RS485-4 wire to Drive
JP-5 1-2
[2-3] - RS485, 2 wire to Drive

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5 KCM Set-Up
5.1 Initial set-up for KCM CPU

5.1.2 CPU jumper settings, K-Port pc board

These settings must be made for all KCM controllers when the K-Port
pc board is installed. See below.
Notes:
• K-Tron user interfaces include the KSU-II, the KSC K-Tron Smart
Commander, K-Vision and the KSL.
• For a host port connection, see the specific manual for that protocol.
• Use this table also when using AB DF1 or Modbus protocol.
JP Normal Position Function

[1-2] - RS485-4 wire to K-Tron user

JP-1 1-2 interface
[2-3] - RS485, 2 wire
[1-2] - RS485-4 wire to K-Tron user
JP-2 1-2 interface
[2-3] - RS485, 2 wire

5.1.3 KCM CPU DIP switch setting

Positions 1-5 set the address of the KCM on the K-Net. Positions 6-8
control the function of the K-Port channel #1.

▲ Off = <0>, On = <1> for each switch position

5.1.4 KCM addressing with CPU DIP switch positions 1-5

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

Note:
• The address of <00000> as set above is a special case. If the switch
is set to <00000>, the KCM address is set under software control
via the user interface.

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 KCM Set-Up 5
Initial set-up for KCM CPU 5.1

5.1.5 K-Port 1 function via KCM CPU DIP switch positions 6-8
K-Port #1 Function SW6 SW7 SW8

Software controlled Off Off Off

Set for KSU-II use On Off Off
Set for KSL use Off On Off
Set for KMB, 19.2 kbaud (K-Vi-
On On Off
sion, KSC or PC Tool) use
Set for KMB, 38.4 kbaud (KSC
Off Off On
or PC Tool) use

When Dip Switch 6-8 are ON for more than 2 seconds (under power),
the config port is set to User IF.

5.1.6 K-PROM configuration

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 communica-
tion data are stored therein. This exchange eliminates the need for
controller re-programming.

The K-PROM is installed upside down on the KCM CPU circuit card in
the location marked “K-PROM card”. It is secured by an M3 screw.

Fig. 5.1 K-PROM

The K-PROM stores the actual data only on power shutdown not on
CPU reset.

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5 KCM Set-Up
5.2 Initial set-up for KCM drives

5.2 Initial set-up for KCM drives

▲ Each drive board incorporates a DIP switch for programming. Pick

the correct chart for each.
▲ Each drive board also requires settings for 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.

5.2.1 Drive jumper settings-all drive types listed

These settings must be made for all KCM drives. See below.
Notes:
• Digital input #1 or #2 must be set <True-On-1> to perform the
programmed function
• A <True> condition is at least a +5 Vdc input
• Different drives use different JP jumpers for the specified function

450 W 1600 W Steppers Vibratory AC Normal Function

DC DC Position

[1-2] - RS485-4 wire to SFTs

JP-3 JP-1 JP-1 JP-3 JP-1 1-2 [2-3] - RS485, 2 wire
Position [1-2] is normal
[1-2] - Digital Input #1 input set for a
pull-up resistor. Input is active low.
JP-1 JP-3 JP-2 JP-1 JP-3 1-2 [2-3] - Digital Input #1 input set for a
pull-down resistor. Requires an ac-
tive high to force off.
[1-2] - Digital Input #2 input set for a
pull-up resistor. Input is active low.
JP-2 JP-2 JP-3 JP-2 JP-2 1-2 [2-3] - Digital Input #2 input set for a
pull-down resistor. Requires an ac-
tive high to force off.

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 KCM Set-Up 5
DC drive set-up 5.3

5.3 DC drive set-up

5.3.1 DC drive selection notes:

• For motors of less than 450 watt rating, use the 450 watt dc drive,
else use the 1600 watt dc drive
• DC drives auto-detect the input line voltage
• See next table for ratings and motor selection

5.3.2 DC motor selection table by drive type and line voltage

Notes:
• 450 watt dc drive is K-Tron part number 0000007405
• 1600 watt dc drive is K-Tron part number 0000002610

Drive Rating Nominal AC Input Motor Voltage Nameplate

Watts VAC VDC Motor Power
Watts

450 115 100 225

450 230 100 225
450 115 200 450
450 230 200 450
1600 115 100 800
1600 230 100 not allowed
1600 115 200 not allowed
1600 230 200 1600

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5 KCM Set-Up
5.3 DC drive set-up

5.3.3 450/1600 Watt DC drive pc board DIP switch settings

Action Switch Range
Pos

Tachometer Pulses Off = 100

1
per revolution On = 120

Tachometer signal Off = single channel encoder

2
type On = dual channel encoder
(345) 000 = 0, 001 = 1, 010 = 2,
Drive address 3, 4, 5
011 = 3 ..... 111 = 7
Not used 6

5.3.4 Additional jumper settings for 450 watt drive

JP Normal Position Function

[1-2] - SLM/KCM control

JP-4 1-2 [2-3] - K10S protocol
Position [1-2] is normal
[1-2] - SLM/KCM control
JP-5 1-2 [2-3] - K10S protocol
Position [1-2] is normal

Page 62 Docu-No.: 0490020605-EN Rev. 1.6.0

 KCM Set-Up 5
AC drive set-up 5.4

5.4 AC drive set-up

5.4.1 AC drive interface pc board DIP switch settings

Action Switch Range
Pos

Off = 0-20 mA
Analog Output 1
On = 4-20 mA

Function of MDU In- Off = KCM programmable

2
put 2 On = MDU alarm input
Output frequency (34) 00 = 10 kHz, 10 = 15 kHz,
3, 4
range 01 = 20 kHz, 11 = 25 kHz
Drive address (1-4) 5, 6 (56) 00 = 1, 10 = 2, 01 = 3, 11 = 4

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 63

5 KCM Set-Up
5.5 Stepper drive set-up (all types)

5.5 Stepper drive set-up (all types)

5.5.1 Stepper motor programming table

Feeder Type Max Maximum Required Stepper Drive
Motor Power
RPM Setting-W
0000001430
BSP100 60 49
0000005987
0000004568 (194 watts)
BSP125 60 49 or 194 0000001430 (49 watts)
0000005987
0000004568
BSP135 60 194
0000005987
0000004568
BSP150-S 120** 194
0000005987
0000005987
KM-T12 150 43
0000001430

5.5.2 Stepper drive pc board DIP switch settings

Action Switch Range
Pos

Drive address (0-3) 1, 2 (12) 00 = 0, 10 = 1, 01 = 2, 11 = 3

Off = 0% current to stepper mo-
tor during a stopped condition.
Output current at On = 50% current to stepper
3
STOP condition motor to hold its position during
a stopped condition.
Off = normal.

Tachometer signal Off = single channel encoder

4
type On = dual channel encoder

Page 64 Docu-No.: 0490020605-EN Rev. 1.6.0

 KCM Set-Up 5
Vibratory drive set-up 5.6

5.6 Vibratory drive set-up

For loss-in-weight feeding or loss-in-weight batching only.

5.6.1 Vibratory drive pc board DIP switch settings

Action Switch Pos Range

Drive address (1-7) 1, 2, 3 (123) 000 = 0, 001 = 1, 010 = 2, 011 = 3 ..... 111 = 7
Off = normal operation
Operating mode 4
On = reset cold start frequency

5.6.2 Vibratory drive adjustment

 Set the <Vibratory Type> parameter in the MACHINE Menu

according to the type of vibratory drive. i.e. KV1...KV3.

The displacement of the vibratory controller has to be adjusted via the

operator interface in the in the <MACHINE> menu, parameter <Vibra-
tory Span>.
Program the feedfactor values according to the following list.
 This values are set in the <CALIBRATION> menu
<FEEDFACTOR> sub-menu:
– MF@8% Drive Command
– MF@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>.

Vibratory Type Setpoint to enter Expected Displacement Max. Displacement

KV1 50 kg/hr 0.75 mm 1.0 mm

KV2 66 kg/hr 1.0 mm 1.5 mm
KV3 50 kg/hr 0.75 mm 2.0 mm

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 65

5 KCM Set-Up
5.6 Vibratory drive set-up

1. Switch the feeder to <Volumetric> mode.

3 2. Start the feeder.
3. Read displacement from label on vibratory drive.
4. Calculate <Vib Span> according to the following formula.
2
Vibratory span formula:

1
New <Vib Span> = (Displayed Vib Span)* (expected displacement/Actual displace-
ment.)

0
5. Enter calculated new <Vib Span> in the MACHINE menu. See
example.
Fig. 5.2 Displacement label

Example: Vibratory type = KV2, actual displacement = 1.1 mm, dis-

played <Vib Span> = 1.000

New <Vib Span> = 1.00 * (1.0 mm/1.1 mm) = 0.9

Page 66 Docu-No.: 0490020605-EN Rev. 1.6.0

 Transportation, Storage, Disposal 6
Notes on transportation 6.1

6 Transportation, Storage, Disposal

6.1 Notes on transportation

When transporting the KCM off-site, use the saved packing material
provided in the original shipment and re-package the KCM as re-
ceived.

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 stor-
age temperature limits as stated.

6.3 Notes on disposal

If the KCM is to be disposed, follow procedures for industrial electronic
disposal as required by law.

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 67

7 Operation
7.1 Initial operation

7 Operation

▲ Do not open the KCM while it is under power.

▲ 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 by authorized personnel.
▲

▲ The user must be trained in operation of the KCM control system

prior to first operation.
▲ Skills to operate and service the equipment can be gained through
the K-Tron Institute.

7.1 Initial operation

 Be sure that all wiring has been correctly completed.
 Verify that all equipment is properly installed and secure.
 Power the KCM and separate user interface if provided
 Verify the KCM or other display executes its start-up sequence.
 Refer to the appropriate manual for either programming or running
the KCM controller.

Page 68 Docu-No.: 0490020605-EN Rev. 1.6.0

 Operation 7
Initial operation 7.1

7.1.1 KCM-SD LED status display

k KCM

CAUTION – Disconnect power before opening .

! 115 /230 VAC , 50/60HZ, 2000 Watts (Max )

Fig. 7.1 KCM-SD LED status display

7.1.2 LED function listing

LED LED name Function

RUN LED Illuminates when the feeder is in operation.

STOP LED 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.

Note:
• When using the KCM with a display and keypad mounted to its
surface (KCM-KD), refer to manuals 0490020611 or 0490020612
for operational information.

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 69

7 Operation
7.2 Emergency stop procedure

7.2 Emergency stop procedure

• Each KCM must have a main switch to supply 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 70 Docu-No.: 0490020605-EN Rev. 1.6.0

 Cleaning 8
Switching ON and OFF 7.3

8 Cleaning

▲ Remove all power and wait 3 minutes before opening enclosure

for internal cleaning.

▲ No regular internal servicing is required of this unit.

▲ Always wear an anti-static wrist strap when working with sensitive

electronic assemblies to prevent static damage.

▲ Do not use corrosive cleaning agents.

▲ Do not allow any dust or moisture to penetrate the KCM enclosure.

8.0.1 Cleaning

▲ Wear protective gloves and eye protection when using cleaning

solutions to clean the outside of the KCM.

 To clean externally, use a damp cloth to remove debris using

normal industrial cleaners.
 Only clean the external portions of the KCM with its enclosure fully
closed.
 Only use cleaners at meet the following specifications.
– 5.0 < ph <8.5

• Phillips screwdriver is required to open the swing panel.

Notes:
• If it is necessary to clean the internal printed circuit board
components, use only dry, clean air at a maximum pressure of 4 bar
or 60 psi.
• Never permit conductive materials to come in contact with the KCM
internal printed circuit boards.

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 71

9 Maintenance
9.1 Preventive maintenance

9 Maintenance

▲ During operation and immediately after shut-down, the capacitors

and, therefore, the printed circuit boards of the KCM are under
high voltage. For this reason, before opening the KCM.
1. Disconnect the KCM from the power supply.
2. Wait at least 3 minutes before opening the KCM.

▲ Always wear an anti-static wrist strap when working with sensitive

electronic assemblies to prevent static damage.

9.0.1 Required skills/training for maintenance of the KCM

The service person must be skilled in power electronics and trained to
service the KCM.

9.0.2 General tools required

• Small flat blade screwdriver
• Phillips screwdriver

9.1 Preventive maintenance

Carry out the following preventive maintenance work after every
10,000 hours of operation or yearly:
 Check for damage and/or corrosion on the screwed connections,
particularly the AC line and motor drive terminals.
 Check the security of all connections and cable glands.
 Check the operational readiness of all external safety switches or
interlocks.

Page 72 Docu-No.: 0490020605-EN Rev. 1.6.0

 Maintenance 9
KCM CPU LEDs 9.2

9.2 KCM CPU LEDs

▲ It is dangerous to open the KCM cover without removing power as

high voltage is present on the Drive printed circuit board.

Use the internal LEDs to evaluate KCM function. A listing is provided

to help diagnose problems.

J10
33

13
1
K-Port Communication
Alive
pcb installed
2

J5
3
ISP JP5
K-Prom Error 1

1
J2

1
Memory
J-Tag Port
2
Installed 2-wire

4-Wire

2-Wire
3

JP1
JP2

4
1 1
1 4-wire 1 5
TxD1
ON TxD2
K-Port 1 6
K-Port 2
1

J2 J1
1 2 3 4 5 6 7 8 1 1 J11
GND
Pwr

TxD+
TxD-
RxD+
Rx232

Tx232
Rx232
GND
Pwr

TxD+
TxD-
RxD+

RxD-
Tx232
RxD-

RxD1
DB-9
RxD2
OPEN Config-
OFF SW1 P1
33

J9
Analog In Select 1
2 10 JP4 JP3 JP2
2
0-20ma

1 9 JP1
0-10V 3
0-5V

BootLoad Port
Reset
J3 1 4
COMMUNICATION/HOST BOARD Run
5
1 1 1 1
6
1
2
2
1

3
4
Alive
CPU 5
68340 Alarm 6
K4 TxD 7
DPDT RxD 8
9
K5 10
DPDT
J8

Fig. 9.1 KCM CPU LED locations

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 73

9 Maintenance
9.2 KCM CPU LEDs

9.2.1 KCM CPU pc board LEDs

Refer to Fig. 9.1 for locations on main cpu pcb near location J8.

LED Function Notes

Alive CPU is operational If not flashing, CPU has failed or has no dc power
TxD Transmit data on the internal Data is being sent to the drive pc board on the Internal data
channel channel. CPU is the channel master.
RxD Receive data on the internal Data is being received from the drive pc board on the Inter-
channel nal data channel. CPU is the channel master.
Alarm Alarm function KCM pc board has an alarm condition

9.2.2 KCM CPU K-Port pc board LEDs

Refer to Fig. 9.1 for locations. On K-Port communication pcb.

LED Function Notes

TxD1 Data transmitting from K-Port Data is being sent to a KSU-II, KSL or KSC user interface.
#1 If a problem, check K-Port #1 programming.
RxD1 Data is received from a KSU-II, KSL or KSC user interface.
Data received into K-Port #1
If a problem, check K-Port #1 programming.
TxD2 Data transmitting from K-Port Data is being sent to a KSU-II, Modbus I-O or KSC user in-
#1 terface. If a problem, check K-Port #2 programming.
RxD2 Data is received from a KSU-II, Modbus I-O or KSC user in-
Data received into K-Port #2
terface. If a problem, check K-Port #2 programming.
Alive If not flashing, K-Port pc board has failed or has no dc pow-
K-Port pc board is active
er
Error Indicates a K-Port error K-Port pc board has an alarm condition
ISP In System programming Active during re-programming.

Page 74 Docu-No.: 0490020605-EN Rev. 1.6.0

 Maintenance 9
KCM Drive and Power Supply Details 9.3

9.3 KCM Drive and Power Supply Details

There are a series of drive circuit boards used for a variety of drive ap-
plication. A listing is below.
Note:
• The 0000005987 stepper drive replaces both the LoPo and HiPo
stepper drive when available.

9.3.1 Drive board LEDS

The next image is the 1600 watt DC motor drive showing LED posi-
tions. Other drives will have the LEDs in different locations. Please be
careful.

ON 1 2 3 4 5 6
Alarm Alive
OFF

S1
PWR
J3
1 2 3 4 5 6

K4 K7 K5 K6

Heatsink
uC
p.u. p.u.
K4
1 1
24 Vdc
JP2

JP3

3 3
p.d. p.d.

TxD RxD
2 wire
3
JP1

1
PS-1
4 wire

Heatsink
J8

6 5 4 3 2 1
J7

6 5 4 3 2 1 F1 F2
J4
K4 J2 K3 K2 K1
SPST SPDT SPDT
6 5 4 3 2 1DPDT 4 3 2 1
J1
12 11 10 9 8 7 6 5 4 3 2 1 J5 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 J6

Fig. 9.2 1600 watt DC drive LED locations-0000002610

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 75

9 Maintenance
9.3 KCM Drive and Power Supply Details

9.3.2 KCM Drive pc board LEDs-all types

LED Function Notes

Alive CPU is operational If not flashing, Drive has failed or has no AC line power
TxD Transmit data on the internal Data is being sent to the KCM CPU pc board on the Internal
channel data channel. CPU is the channel master.
RxD Receive data on the internal Data is being received from the KCM CPU pc board on the
channel Internal data channel. CPU is the channel master.
Alarm Drive pc board has an alarm condition. Marked as <Error>
Alarm function
on the AC interface pc board.
Power Shows power at drive Only on the Vibratory drive.

Note:
• Power supplies mounted on the drive pc board surface may also
have LEDs indicating operation. If Off, check line power.

Page 76 Docu-No.: 0490020605-EN Rev. 1.6.0

 Maintenance 9
KCM fuse replacement 9.4

9.4 KCM fuse replacement

▲ Do not replace any fuse while under power.

▲ Wait 3 minutes after disconnecting KCM power prior to opening
the case.

Notes:
• Some fuses are self-resetting and require no replacement.
• Fuse replacement begins at section 9.4.4.
• It is important to discover the reason for overloading the fuse that
protects the +24 Vdc I-O supply and correct 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.

9.4.1 Auto-resetting drive fuses

Each drive uses auto-resetting fuses. Follow the next procedure to
permit reset.

9.4.2 Resetting auto-resetting fuses

1. Switch off KCM power.
2. Find the source of overload and correct the problem.
3. Wait one minute, the fuse will reset.
4. Re-power KCM.

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 77

9 Maintenance
9.4 KCM fuse replacement

9.4.3 List of auto resetting fuses

The following is a list of the function for each auto-resetting fuse in
each drive.
• 1600 watt DC motor drive:
– F3: Failure will cause power loss of 24 Vdc at the I-O.
– F4/F5: Failure will cause power loss to the KCM CPU.
• 450 watt DC motor drive
– F3: Failure will cause power loss of 24 Vdc at the I-O.
• Vibratory Drive:
– F2: Failure will cause power loss of 24 Vdc at the I-O.
• Stepper drive-0000005987 only
– F2: Failure will cause power loss of 24 Vdc at the I-O.
– F1/F3: Failure will cause power loss to the KCM CPU.
• Stepper 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.

9.4.4 Replacing fuses

▲ Do not replace any fuse while under power.

▲ Wait 3 minutes after disconnecting KCM power prior to opening
the case.

1. Disconnect power from the KCM via approved lock-out/tag-out

procedures.
2. After waiting 3 minutes, open the KCM cover.
3. Identify the faulty fuse and replace with correct fuse.
4. Close cover on KCM and return to service.

Page 78 Docu-No.: 0490020605-EN Rev. 1.6.0

 Maintenance 9
KCM fuse replacement 9.4

9.4.5 1600 watt dc motor drive fuse location-0000002610

Following fuses are (5x20 mm, slow-blow) used:

F1/F2 -12.5AT, 5x20 mm, 250Vac fuse.
F1 F2
K1
SPDT
J5 J6

Fig. 9.3 Fuse location,

1600 W DC motor drive

9.4.6 450 watt dc motor drive fuse location-0000007405

J5 Following fuses are (5x20 mm, slow-blow) used:

F1/F2-6.3AT, 5x20 mm, 250Vac fuse.

F1

F2

J6
Fig. 9.4 Fuse location,
450 W DC motor drive

9.4.7 Vibratory drive fuse location-000000684

Following fuses are (5x20 mm, slow-blow) used:

Power
F1- 2.0AT, 5x20 mm, 250Vac fuse.

K1
SPDT

J5 J6

Fig. 9.5 Fuse location, vibratory drive

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 79

9 Maintenance
9.4 KCM fuse replacement

9.4.8 AC motor drive interface fuse location-000003413

Following fuses are (5x20 mm, slow-blow) used:

F1/F2-6.3AT, 5x20 mm, 250Vac fuse.
F1 F2
K1
SPDT
J5 J6

Fig. 9.6 Fuse location, AC interface

9.4.9 Stepper drive interface fuse location-0000005987

Following fuses are (5x20 mm, slow-blow) used:
F4-2.0AT, 5x20 mm, 250Vac fuse.
.
F4
Note:
K1
SPDT The HiPo and LoPo stepper have no replaceable fuses.

J5 J6

Fig. 9.7 Fuse location, Stepper Drive

Page 80 Docu-No.: 0490020605-EN Rev. 1.6.0

 Maintenance 9
KCM service connection 9.5

9.5 KCM service connection

The Config. serial data ports are service connections to the KCM. A
PC with K-Tron applications such as Loader, SmartConfig and
ParamStore are used with the KCM to upload new application pro-
grams, upload custom <KGR> data communications files and to
download entered operating parameters respectively.
 To access the Config port, merely open the KCM front cover. The
J11 Config DB-9 port is on the cpu pc board on the back of the front
DB-9 panel cover.
Config-
P1

J9

Fig. 9.8 KCM Config port on CPU pcb

1 5 Use a standard female to female DB-9 connector with a null modem

between the KCM Config port on the KCM CPU pcb and the PC.
This table provides wiring for the Config port connector-RS232.
6 9
2 = RxD, Receive data
3 = TxD, Transmit data
5 = Signal common
Note:
• A null modem cable is required for connection to a PC.
• The PC requires an RS232C serial port.
Fig. 9.9 Config port connections

9.5.1 Forcing the Config Port to UserIF protocol

Use this procedure to reset the Config Port to the UserIF protocol for
reading KCM menu and parameter data with a connected PC.
1. Power the KCM.
2. Using the S1 DIP switch on the KCM CPU pcb, place switches 6,
7, 8 in the "ON" position for at least two seconds.
3. KCM Config port will then become UserIF protocol configured.
4. Return switches 6, 7, and 8 to the "OFF" or original positions.

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 81

10 Troubleshooting
10.1 General information on fault detection

10 Troubleshooting

10.1 General information on fault detection

▲ 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.

10.1.1 Measuring motor power

Connect an external current/power measuring device only to the 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.
+ 5 Vdc
Com
Blue
10.1.2 Measure and adjust speed frequency signal
Red Yellow
The speed signal is a square-wave signal from 0 to 10.8 kHz/5 V DC.
Speed
Pick-up
The signal can be measured at the following locations:
• At the feeder: connect oscilloscope between common and signal.
0.125 mm
0.005 inch • At the KCM: connect oscilloscope between J2-4 (COM) and J2-2-
(signal).
Notes:
• If a scale interface pcb is used, connect to LK4-42 for common and
check the signal at LK-4 pins 47 and 48 for complementary
frequency signals. Amplitude of the waveform will be about 3.5 vdc.
• The gap between the pick-up gear and the face of the pick-up is
critical to feeder operation. If the gap is too large the waveform and
frequency from the sensor will not be correct. If the gap is too close,
pick-up damage will result. A piece of paper is a practical gapping
tool.
• Set pick-up and check the gap and the waveform.
• Normally the speed pick-up is located near the motor shaft of the
feeder drive motor.
Fig. 10.1 Speed pick-up adjustment

Page 82 Docu-No.: 0490020605-EN Rev. 1.6.0

 Troubleshooting 10
DC motor drive problems and solutions 10.2

10.2 DC motor drive problems and solutions

Note
• Before you change one of the programming variables, check the
parameter against standards.

Problem Possible Cause Remedy

Motor does not start. • No setpoint from KCM.  Enter setpoint at operating unit.
• Safety switch is active.  Check safety switch on the feeder
or its connection at KCM.
• Motor cable has been disconnected.  Check motor cables.
• Failed motor.  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 • Speed sensor has failed.  Check signal, replace sensor.
maximum speed. • If scale interface pc board (SIB) is  Check signal, if pick-up is OK, and
used, the SIB has failed. SIB is used, replace SIB.
• Setpoint is too high.  If signals are OK, replace KCM.
 Reduce setpoint.
Motor does not • Incorrect motor power setting.  Check programming.
achieve desired • Incorrect gear teeth setting.
speed.
Alv LED is <Off> • No AC power to drive  Check input power for proper
• Drive has failed connections.
 Replace drive.

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10 Troubleshooting
10.3 DC drive hex status codes

10.3 DC drive hex status codes

Notes:
• Failure modes occur on bits 7 to 15., excluding 9.
• These codes are displayed at the KCM interface.
Bit Function Hex Code

0 1 = Motor Run, 0 = Stop. 0001

1 1 = safety switch closed, 0 = open 0002
2 1 = Drive enable input closed, 0 = open 0004
1 = Bit 1 Input activated (low level). 0 = not
3 0008
activated, (high level)
1 = Bit 2 Input activated (low level). 0 = not
4 0010
activated, (high level)
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 1 = Safety relay failure 1000
13 1 = General motor failure 2000
14 1= Control-less running 4000
15 1 = EEPROM failure. 8000

Page 84 Docu-No.: 0490020605-EN Rev. 1.6.0

 Troubleshooting 10
Vibratory drive problems and solutions 10.4

10.4 Vibratory drive problems and solutions

Note
• Before you change one of the programming variables, check the
parameter against standards.

Problem Possible Cause Remedy

Vibratory does not • No setpoint from KCM.  Enter setpoint at operating unit.
start. • Safety switch is active.  Check safety switch on the feeder
• or its connection at KCM.
• Power cable is disconnected.  Check vibratory power cables.
• Failed drive unit.  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 • Displacement sensor has failed.  Check signal, replace sensor.
maximum • Setpoint is too high.  If signals are OK, replace KCM.
displacement.
 Reduce setpoint.
Tray displacement • Incorrect vibratory programming.  Check programming.
does not reach • Displacement sensor not set  Check displacement sensor.
desired value. correctly.
Alv LED is <Off> • No AC power to drive  Check input power for proper
• Drive has failed connections.
 Replace drive.

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10 Troubleshooting
10.5 Vibratory drive hex status codes

10.5 Vibratory drive hex status codes

Notes:
• Failure modes occur on bits 7 to 15., excluding 9.
• These codes are displayed at the KCM interface.
Bit Function Hex Code

0 1 = Motor Run. 0 = Stop. 0001

1 1 = safety switch closed. 0 = open. 0002
2 1 = Drive enable input closed. 0 = open. 0004
1 = Bit 1 Input activated (low level). 0 = not
3 0008
activated, (high level).
1 = Bit 2 Input activated (low level). 0 = not
4 0010
activated, (high level).
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
12 1 = Frequency limit 1000
13 1 = General drive failure. 2000
14 1 = Polarity error 4000
15 1 = EEPROM failure. 8000

Page 86 Docu-No.: 0490020605-EN Rev. 1.6.0

 Troubleshooting 10
Stepper drive problems and solutions 10.6

10.6 Stepper drive problems and solutions

Note
• Before you change one of the programming variables, check the
parameter against standards.

Fault Possible Cause Remedy

Motor does not run. • No setpoint from KCM.  Enter operating setpoint. Press
Alarm LED is <Off>. • No Drive Enable signal. <Start>.
• Safety switch is open.  Check for Drive Enable signal now.
• No AC power.  Check safety switch input.
 Enter setpoint at operating unit.
 Check safety switch on the feeder
or 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 does not run. • Motor cable fault.  Check motor cable and motor.
Alarm LED is <On>. • Motor short.  Check reason for motor overload
• Motor is overloaded. and correct.

Motor does not • Inadequate motor power  Check load on motor.

reach desired speed. • Setpoint is too high.  Verify motor power programming
• Motor speed not smooth. against label on stepper motor.
 Reduce setpoint.
Alarm LED indicates • Load is too high  Reduce motor load.
over temperature • Ambient temperature is too high  Reduce operating temperature.
Alv LED is <Off> • No AC power to stepper drive  Check input power for proper
• Stepper drive has failed connections.
 Replace stepper drive.
Alarm LED is • Various internal or external  See service specific information at
blinking a specified problems to the stepper drive are section 10.8.
count evident

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 87

10 Troubleshooting
10.7 Stepper drive hex status codes

10.7 Stepper drive hex status codes

Notes:
• Failure modes occur on bits 7 to 15., excluding 9.
• These codes are displayed at the KCM interface.
• These codes are for all stepper drives supported.
Bit Function Hex Code

0 1 = Motor Run. 0 = Stop. 0001

1 1 = safety switch closed. 0 = open. 0002
2 1 = Drive enable input closed. 0 = open. 0004
1 = Bit 1 Input activated (low level). 0 = not
3 0008
activated, (high level).
1 = Bit 2 Input activated (low level). 0 = not
4 0010
activated, (high level).
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 = Safety switch open. 1000
13 1 = General motor failure. 2000
14 Not used. 4000
15 1 = EEPROM failure. 8000

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 Troubleshooting 10
Stepper alarm LED flash sequence 10.8

10.8 Stepper alarm LED flash sequence

Alarm Description Number of Blinks

EEPROM failure • Invalid EEPROM data detected  1

upon power-up
Over temperature • Motor Drive IC indicates a thermal  2
warning. Temperature at motor
driver chips is > 145C. Clear fault
and re-start drive.
Reserved •  3
Serial master time- • No valid messages from the KCM  4
out. CPU in 10 seconds.
Safety switch open • Open safety switch result in a feeder  5
stoppage or the start command to be
ignored.
Zero speed failure^^ • Motor is being driven by the Stepper  6
but no encoder pulses are being
read.
Encoder failure^^ • Two channel encoder operation is  7
selected SW1 DIP position 4 = <1>.
and the motor is being driven by the
motor drive. No encoder pulses
received for channel A or B.
Motor rotation failure • Motor is being driven by the Stepper  8
but the encoder detects either a
jammed motor or reverse rotation.
High temperature • Temperature at drive is above 70  9
degrees C.

Notes:
• All alarms remain latched until the alarm is no longer present and
the alarm has been cleared by the serial master. Alarms1,2,4,6,7,
8,9 are cleared by the Alarm Clear message from the KCM CPU.
Alarm 5 is cleared only by the Stop command from the KCM CPU.
• Only Over Temperature (2), Serial Master Time-out (4) and Safety
Switch Open (5) alarms will cause the Stepper drive to stop the
motor. For all other alarms, the drive will try to run the motor.
• Blink sequence <9> is not used for stepper drives 0000001430 and
0000004568.

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 89

10 Troubleshooting
10.9 AC interface drive problems and solutions

10.9 AC interface drive problems and solutions

Note
• Before you change one of the programming variables, check the
parameter against standards.

Problem Possible Cause Remedy

Motor does not start. • No setpoint from KCM.  Enter setpoint at operating unit.
• Safety switch is active.  Check safety switch on the feeder
• Motor cable has been disconnected. or its connection at KCM.
• Failed motor.  Check motor cables.
• Contactor failed.  Replace motor.
• F1 or F2 fuses have failed.  Check for alarms that might stop
the machine.
• AC drive has failed.
 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 • Speed sensor has failed.  Check signal, replace sensor.
maximum speed. • If scale interface pc board (SIB) is  Check signal, if pick-up is OK, and
used, the SIB has failed. SIB is used, replace SIB.
• Setpoint is too high.  If signals are OK, replace KCM.
 Reduce setpoint.
Motor does not • Incorrect motor power setting.  Check programming.
achieve desired • Incorrect gear teeth setting.
speed.
• AC drive incorrectly programmed.
Alv LED is <Off> • No AC power to drive  Check input power for proper
• AC Interface Drive pcb has failed connections.
 Replace AC Interface drive.

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 Troubleshooting 10
AC drive interface hex status codes 10.10

10.10 AC drive interface hex status codes

Notes:
• Failure modes occur on bits 7 to 15., excluding 9.
• These codes are displayed at the KCM interface.
Bit Function Hex Code

0 1 = Motor Run. 0 = Stop. 0001

1 1 = safety switch closed. 0 = open. 0002
2 1 = Drive enable input closed. 0 = open. 0004
1 = Bit 1 Input activated (low level). 0 = not
3 0008
activated, (high level).
1 = Bit 2 Input activated (low level). 0 = not
4 0010
activated, (high level).
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
12 Not used. 1000
13 Not used. 2000
14 Not used. 4000
15 1 = EEPROM failure. 8000

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10 Troubleshooting
10.11 General KCM system alarms

10.11 General KCM system alarms

Notes:
• Additional alarms specific to each feeding application may be found
in the specific application programming manual.
• MDU references any type of KCM drive
• Alarm format: Alarm Number/HCU Alarm (if present)-Alarm Name
• See Programming manuals for specific process alarms.
Alarm Num- Alarm Cause Remedy

00 HARDWARE • KCM Hardware error. EEPROM  Check KCM CPU.

ERROR data is corrupt. For example, this  Clear alarm and try unit.
message will occur after updating or
changing firmware on the KCM.
01 KPROM MEM • The K-PROM cannot be accessed  Correctly insert K-PROM.
FAIL by the KCM CPU or checksum  Replace with known good K-
failed. PROM.
02 • Checksum error in kgr file area.  Verify K-PROM is properly
KPROM*KGR*FAIL installed.
 Replace K-PROM.
03 POWER GLITCH • Power dip detected. CPU did not  Verify AC mains are within
reset. specification,
 Replace drive pcb. (power supply)
04 KPROM WRITE • The K-Prom Write Counter exceeds  Check communication strategy.
COUNT 100'000 writes  Replace with known good K-
EXCEEDED • Some parameters are changing for PROM.
too many times.
05 INT CHAN FAIL • Internal channel has failed to  Check Internal Channel
communicate between the CPU and connections.
drive boards (also SFTs and HCU).  Replace either CPU or Drive pcb.
(also check SFTs and HCU if used)
06 WT PROC • SFT(s) failed.  Locate which SFT has failed on the
FAILURE • Serial communication to the load cell <SFTs> line in the <SCALE>
interrupted. Menu, <SFT> sub-menu.
• f = SFT internal failure.
communication OK.
• t = No communication from the SFT
to the controller board.
• ?= Not valid answer from SFT.
Table page 1 of 6

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 Troubleshooting 10
General KCM system alarms 10.11

Alarm Num- Alarm Cause Remedy

07 • Number of SFTs found during  Check <SFT REQUIRED> number

INCORRECTNUM.S polling does not equal that required. is valid. See <SCALE> menu,
FT <SFT> sub-menu.
 Check for all SFTs being
operational.
08 BAD SFT • SFT is showing an incorrect status.  Reset SFT´s. Replace SFT if
STATUS problem persists.
09 NO MDU FOUND • The KCM CPU did not find a motor  Check drive pcb LEDs for correct
drive on the internal channel on function.
power-up.  Check Internal channel
connections.
 Replace drive or CPU pcb.
10 MOTOR ALARM • The KCM CPU lost the motor drive  Check drive pcb LEDs for correct
on the internal channel while in function.
operation.  Check Internal channel
connections.
 Replace drive or CPU pcb.
11 MDU SERIAL • Motor drive has lost communication  Check Internal channel
TIMEOUT with the KCM CPU and then turns off connections.
all digital outputs and shuts of drive  Replace drive or CPU pcb.
power.
12 MDU THERMAL • Drive temperature has been  Reduce operating temperature
OVL exceeded > 75 deg C. Drive stops.
13 MDU SPEED • No speed feedback signal is present  Check speed pick-up for operation
DEV when motor is asked to run. and replace if necessary.
• Speed deviation from target > 5  Check speed pick-up wiring and
rpm power connections.
• Wrong motor voltage programmed.  Check programming.
 Replace drive.
 Check motor.
14 • Motor current limit is exceeded.  Reduce motor load.
MOTOR • Note:  Check motor power limit in the
OVERLOAD <MECHANICAL> menu,
• The Safety switch is not designed to
be used as a normal way of <MOTOR> sub-menu.
interlocking the KCM. It is used for  Review material/feeder selection.
safety control only.
15 • Safety relay failed to close contacts  Replace Drive pcb.
MDU SAFETY on power up and contacts remained
RELAY closed after power down.
Table page 2 of 6

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10 Troubleshooting
10.11 General KCM system alarms

Alarm Num- Alarm Cause Remedy

16 • Dual tach signals connected, one  Check tachometer-replace.

MOTOR/ENCDR failed.  Check motor brushes.
FAIL • Over-voltage on drive power supply.  Replace motor if required.
• Motor voltage applied but no speed  Replace KCM drive board.
feedback.
 Check for excessive line voltage.
• Drive temperature > 85 deg. C.
 Reduce operating temperature.
17 • Speed feedback but no motor  Replace drive board.
MDU voltage applied.
UNCONTROLLED
18 • EEPROM checksum failed.  Cycle power. If error persists,
MDU EEPROM replace drive pcb.
FAILED
19 MDU DRIVE • MDU drive pcb has failed. (vibratory  Exchange vibratory drive pcb.
FAILED drive only. Drive coil current too  Check drive coil for proper
high) impedance.
20 MDU POLARITY • Coil polarity is incorrect on the  Change the feedback coil polarity
vibratory drive. (Vibratory feeder by swapping leads at KCM.
only)
• Displacement frequency out of
range.
21 HCU REMOVED • HCU was removed.  Connect HCU at the KCM and
switch KCM On.
 Repoll SFT channel to re-connect
HCU.
 Clear NOVRAM if necessary.
22 HCU ALARM • HCU has an alarm.  See following alarms for trouble
shooting.
23/01 • EEPROM failed.  Clear alarm.
HCU EEPROM Replace EEPROM or HCU.
FAILED  Cycle power to the HCU.
24/02 • The controller's digital output driver  Replace HCU.
HCU DRIVER has detected a fault.  Latched.
FAILED
25/03 • Material is below the level of the  Refill or change supply hopper.
HCU supply hopper proximity sensor.  Check P17.
SUPP.HOPP.LOW • Sensor failed.  Check sensor or P23.
 Note: Alarm will automatically clear
when material is above sensor.
Table page 3 of 6

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 Troubleshooting 10
General KCM system alarms 10.11

Alarm Num- Alarm Cause Remedy

26/04 • The differential pressure across the  Clean or replace filter.

HCU D.P.ALARM filter is too high indicating a clogged  Check P24 and P16.
filter.
 Check P17
27/05 • If P20 Discharge Mode =01“Fill”  Check Parameter P25 Number of
HCU CYC.COUNT mode then: load cycles.
AL • Max. numbers of load cycle  Check conveying rate.
exceeded, because Buffer Hopper  Check Buffer hopper sensor.
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:  Check Parameter P25 Number of
• Discharge Request input has been load cycles.
on for more than the allowed load  Check conveying rate.
cycles. The Discharge Request
signal going inactive clears the load  Check discharge request signal.
cycle counter.
28/06 • Discharge valve has failed to either  Check sensor on the discharge
HCU DISCH VALVE open or close properly. This alarm is valve.
automatically disabled in P18  Check P26.
Operating Modes 03 and 04.

29/07 • Receiver is still full after discharge.  Check receiver. Material bridging in
HCU REV.FULL AL. • Receiver proximity switch too the receiver. Clean receiver.
sensitive adjusted or failed.  Check Receiver proximity switch or
P17.
30 • Protocol of KGR file does not match  Make corrections as necessary.
KLINK WRONG that required by the installed
KGR communication circuit card.
31 KLINK NO KGR • No KGR file loaded  Load KGR file with SmartConfig or
switch to <Built-IN> KGR file.
32 HPORT FAIL • Host communication pcb error.  Check communications pcb for
proper LED operation.
 Exchange communications pcb as
necessary.
Table page 4 of 6

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10 Troubleshooting
10.11 General KCM system alarms

Alarm Num- Alarm Cause Remedy

33 HPORT FAIL • Host communication pcb could not  No host communications pcb is
INIT be initialized. installed.
 Check host communications pcb
connections.
 Replace host communications pcb.
34 • Improper pcb installed in the host  Install correct host communications
HPORT ILLEGAL port location. pcb.
BD
35 KPORT FAIL • K-Port has failed  Replace K-Port comm pc card.
36 KPORT FAIL INIT • K-Port communication pcb could not  Replace K-Port comm pc card.
be initialized.
37 • Host communication pcb is installed  Check host communications pcb
KPORT ILLEGAL on the wrong port location-(K-Port). for proper mounting location.
BD
38 • One or more feeder parameters are  Correct KGR file.
KGR PARAM not correct for the specified feeder.  Use <Built-IN> KGR file.
ERROR
39 EXT IO FAIL • The MODBUS I-O connection has  Check connections to remote I-O
failed. device.
 Check remote I-O device wiring.
40 • Digital input on KCM selected for  Investigate the cause of this input
EXT ALR External Alarm is active. being active and correct.
ACTIVATED
41 INTERLOCK • Drive pcb Run Enable digital input is  Check the Drive pcb Run Enable
FAIL open during operation. digital input for proper function.
42 START • Start conditions not fulfilled.  Check status line.
IGNORED  Check for setpoint and re-enter if
necessary.
 Check all KCM digital inputs for
correct operation.
43 MASSFLOW • The current massflow is above the  Increase the alarm start delay time
HIGH tolerance entered in <ALARM> in the <ALARM> menu.
menu parameter <MF ERR+>.  Increase the tolerance <MF
ERR+> value.
 Check for proper feeding of
material.
 See if another alarm <DRIVE CMD
LO> is present.
Table page 5 of 6

Page 96 Docu-No.: 0490020605-EN Rev. 1.6.0

 Troubleshooting 10
General KCM system alarms 10.11

Alarm Num- Alarm Cause Remedy

44 MASSFLOW • The current massflow is below the  Increase the alarm start delay time
LOW tolerance entered in <ALARM> in the <ALARM> menu.
menu parameter <MF ERR->.  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 if another alarm <DRIVE CMD
HI> is present.
45 DRIVE CMD • Drive command has reached the  Reduce drive command.
CEILING limit <DC CEILING>  Increase Drive Command Ceiling.
See <MECHANICAL SETUP>,
<MOTOR> sub-menu.
46 DRIVE CMD • The drive command has exceed the  Check for proper feeding of
HIGH value <DRV CMD HI> Limit in the material.
<ALARM> menu.  Check for bridging in hopper
 Check for adequate product in
hopper
 Lower the operating setpoint <SP>.
 Increase the <DRV CMD HI> value
in the <ALARM> menu.
 Check for motor rotation.
 Replace KCM if drive has failed.
 Check motor.
 Check speed sensor.
47 DRIVE CMD • The drive command has dropped  Raise the operating setpoint <SP>.
LOW below the value <DRV CMD LO>  Increase the <DRV CMD LO>
Limit in the <ALARM> menu. value in the <ALARM> menu.
48 • DC motor brushes may be wearing  Motor brushes need inspection and
CHECK_MOTOR_B out and ready to fail. replacement if worn.
RUSHES  If brushes are OK, re-enter a
relevant brush life number in the
Performance sub-menu.
49 • It is set if the feeder was running  Check power supply
Reset while running before the power down or reset
occurred.
Table page 6 of 6

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 97

11 Optional Devices
11.1 Host communication circuit cards

11 Optional Devices

Options that can modify or extend the KCM’s performance are defined
here. Host communication circuit cards are described in manuals that
are identified in this section.

11.1 Host communication circuit cards

These circuit cards plug into the Host slot on the KCM CPU circuit
card. The host port is configured via the KSU-II SYSTEM menu or via
the PC connected to the Config port on the KCM.

Protocol Part Number Document Number

DeviceNet 0000005105 0590020609
ProfibusDP 0000005108 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

11.2 Encoder interface circuit card

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)
• Differential receiver pcb (0000006384) must be installed onto J2 on
the drive circuit card when the Scale Interface pcb interfaces to the
KCM. (Fig. 12.8)
• For a single differential speed input from the scale interface pcb,
bring into <SPD1 +/-> and select <Single input> for the tachometer
selection as shown in Fig. 12.9.
Fig. 11.1 Encoder interface photo

▲ The 0000006384 encoder interface functions with all drives except

the AC interface drive.

Page 98 Docu-No.: 0490020605-EN Rev. 1.6.0

 Optional Devices 11
Field power supply 11.3

11.3 Field power supply

In some select applications, a field wound DC motor is used. In that
instance, a KCM DC Field Supply is used. (part number 0000000639)
It is mounted near the motor. It is supplied with line power and the sup-
ply will output DC field power. For 115 Vac line, expect approximately
150 Vdc output. For 230 Vac line, expect about 300 Vdc output. These
values will change based upon line voltage, line frequency and field
loading as the DC output utilizes filter capacitors to minimize ripple.

Fig. 11.2 Field supply

The unit can be configured for either 115 Vac or 230 Vac single phase.
Two different modes of operation may be used.
• Mode 1: JP1 and JP2 are installed on the power supply. Field power
is present as soon as line power is applied to the power supply. No
connection to X3 is required.
• Mode 2: With JP1 and JP2 removed, and JP3 installed, control X3
when powered as shown in Fig. 12.17, and with switch S1 closed,
field power is available. When S1 opens, field power is removed
from the motor.
• See Fig. 12.17 for wiring details.
Note:
• The power supply uses two, 2 A, 5x20 mm Slo-Blo fuses.

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 99

11 Optional Devices
11.4 SFT expander circuit card

11.4 SFT expander circuit card

The SFT expander circuit card (part number 0000003411) is used on-
ly with the 450 watt dc drive when more than one SFT is to be con-
nected. 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

11.5 Daisy chain connector

The daisy chain connector permits easy cabling of K-Net connections

from one KCM to another without having to have 2 wires in any termi-
nal. point. This connector plugs into either K-Port 1 or K-Port 2.

Fig. 11.4 Daisy chain connector

Page 100 Docu-No.: 0490020605-EN Rev. 1.6.0

 Appendix 12
Cable length specifications 12.1

12 Appendix

12.1 Cable length specifications

12.1.1 DC motor cable lengths: 230 Vac

Motor Type Voltage Current Cable length for a Cable length for a
Rating Rating diameter of 1.5 mm2 or diameter of 4 mm2 or 12
16 AWG, in meters AWG, in meters

Lenze 55 W 180V 0.46A 300 300

Lenze 70 W 180V 0.7A 300 300
180V- 0.6A/
Bison 95/98 W 300 300
200V 0.75A
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
11.5A/
Baldor 2000/1600 W 200V 56/71 95/120
9.2A

12.1.2 DC motor cable lengths: 115Vac

Motor Voltage Current Cable length for a Cable length for a

Ratings Ratings diameter of 1.5 mm2 or diameter of 4 mm2 or 12
16AWG, in meters AWG, in meters

Lenze 70 W 90V 1.25A 264 300

Lenze 250 W 100V 3.5A 93 156
Stephan 370 W 90V 4.9A 65 111
Baldor 450 W 100V 5.4A 59 100
Grossenbacher 700 W 90V 9.5 33 56

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12 Appendix
12.1 Cable length specifications

12.1.3 Cable lengths for speed feedback signals

Notes:
• The Scale Interface pc board (SIB) pc board is located in a junction
box on the side of the feeder and is used when the KCM is not
mounted on the feeder.
• The cable must be fully shielded.
• Use the Scale Interface pc board (SIB) if more than 30 meters of
transmission distance between feeder and controls is required.

Pick-Up/Encoder Pick-up Type Cable length Cable length

without Line-Driver in with Line-Driver* in
SIB., in meters 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
US Digital HEDS 9100-H00 30 100
If motor coil and en- With encoder signals
coder signals are in in separate shielded
the same cable the cable.
signals must be indi-
vidually shielded.
See section 12.5.10
for more information.

Page 102 Docu-No.: 0490020605-EN Rev. 1.6.0

 Appendix 12
KCM I/O defaults 12.2

12.2 KCM I/O defaults

The following table shows the standard bit I/O assignment. If other
function are needed reassignment is possible with the operating unit.

12.2.1 Default KCM Programmable I-O table.

In/output Location LWF/LWB WBF SFM PID/VOL

CPU Input 1 J8-1 Start Start Bypass off Start

CPU Input 2 J8-2 Stop Stop Bypass on Stop
CPU Input 3 J8-3 ALS ALS ALS ALS
CPU Input 4 J8-4 None None None None
CPU Output 1 J8-6 Run Run Run Run
CPU Output 2 J8-7 Alarm Relay Alarm Relay Alarm Relay Alarm Relay
CPU Output 3 J8-8 ALS Out ALS Out ALS Out ALS Out
CPU Output 4 J8-9 Drive Enable Drive Enable Drive Enable 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 None
Drive Relay 1 J5-1/2/3 Feeder Run Feeder Run Drive enable Feeder Run
Drive Relay 2 J5-4/5/6 Refill Tare Bypass active Auto Mode
Drive Relay 3 J5-7/8 Alarm Alarm Alarm Alarm
Drive Input 1 J1-8 None None None None
Drive input 2 J1-11 None None None None

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12 Appendix
12.2 KCM I/O defaults

12.2.2 I-O function selection

Following the possible selection on the KSU-II operator interface for
the I/O assignment. Open I/O menu and select the desired sub-
menus.
Abbreviations:
• CONT = LWF, WBF, PID, VOL and SFM control (continuous)
• BATCH = LWB, WBB and SFB control (batch)
• LWF = loss-in-weigh feeder
• LWB = loss-in-weight batcher
• WBF = weigh belt feeder
• WBB = weigh belt 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

None None
All Setpoint All (Not XTR) Setpoint
All Massflow All CPU 0-10 kHz
All Drive Command All Extern
All Motor Speed XTR Hauloff
LWF/LWB/PID/SFM/SFB Feedfactor XTR XtrSetpt
WBF/WBB Prefeeder XTR XtrSpeed
WBF/WBB Beltloading XTR Pressure
WBF/WBB Belt Speed
LWB/WBB/SFB Batch%
LWB/WBB/SFB Batch Size
PID PVU Input
LWF/LWB Net Weight
SFM/SFB Net Chute
SFM/SFB Net Divert
WBF/WBB NetWeight1
WBF/WBB Netweight2
XTR FdrSetp
XTR Level

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 Appendix 12
KCM I/O defaults 12.2

For Digital output For Digital input

None None
All Run All Start
All Any Alarm All Stop
All Alr Relay All Interlock
All ALS Out All Run Enable
All Drive Ena All ALS Input
All (Not VOL/XTR) Grav Mode All Ack Alarm
XTR Auto Mode All Clr Alarm
All PSR Map All Start/Stop
All ASR Map All (Not VOL/XTR) VOL Mode
All Total Pulse XTR MAN Mode
LWF/LWB Refill All Local/External
LWF/LWB Refill Expired All Ratio/Direct
WBF/WBB Tare Run All External Alarm
WBF/WBB Prefeeder All Total Clr
SFM/SFB Bypass All Data Lock
SFM/SFB/LWF/LWB Blow-off LWF/LWB Refill Bypass
LWF/LWB Loader LWF/LWB Refill Command
LWF/LWB Hi/Low Gear LWF/LWB/WF/WB Empty
LWB/WBB/SFB Dribble All (Not XTR) Calibrate
LWB/WBB/SFB Batch Complete WBF/WBB Belt drift
XTR FDR Ena WBF/WBB Belt Index
WBF/WBB Dynamic Tare
SFM/SFB Bypass
SFM/SFB Normal FB
LWB/WBB/SFB BatchPause
LWF/LWB Loader Lvl
LWF/LWB Loader Ena

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12 Appendix
12.3 I-O function and KCM state indications

12.3 I-O function and KCM state indications

12.3.1 State indications

• RUN - Motor is running (speed feedback)
• DISA - Indicates the feeder is disabled and can not start.
Conditions are as follows:
– RUN ENABLE digital input is OFF. In this case, All START
commands are ignored. A start command is required after the
digital input is cleared. Pressing START will generate alarm 42 -
"Start Ignored". This function can be programmed to any digital
input. Run Enable input issues a STOP command when de-
energized.
– DRIVE ENABLE digital input is disabled. This digital input is
enable from JU1 on the Motor Drive board (jumper terminal 3 to
4 AND 5 to 6). If disabled, all START commands are ignored. A
start command is required after the digital input is cleared.
Pressing START will generate alarm 42 - "Start Ignored". This
input is predefined by JU1.
– DOWNSTREAM INTERLOCK digital input is active (ON). If a
START command is issued, “WAIT” is displayed. See “WAIT”
indication below. This function can be 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 DOWNSTREAM
INTERLOCK digital input is active. The start command is NOT
ignored and the feeder will run when the conditions are cleared.
• {blank} - If no status is displayed, the controller had a STOP
command and all other conditions are cleared.

Notes:
• A START and STOP command can be issued from the K-Tron
operator interface, Digital Input, or host communications.
• Run Enable, Drive Enable, and Alarm Shutdown inputs issue a
STOP command when activated. A Start command must be issued
AFTER the inputs are cleared for the feeder to run.
• In “Normal Mode“not energized = OFF, energized = ON
In “Inverse Mode“ON/OFF are reversed.
• Downstream Interlock requires an initial Start command. Toggling
this digital input does not issue a STOP command and therefore
does not require a Start command. The exception is if a Stop
command is issued, a new Start command is required. If state is

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 Appendix 12
I-O function and KCM state indications 12.3

DISA, start command is required. 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.

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12 Appendix
12.4 General KCM service variables

12.4 General KCM service variables

These variables may be accessed via the Service Menu on the KSU-
II, KSL or KSC. Additional service variables not shown here are de-
pendent upon application selected and are found in the specific pro-
gramming manual.

Variable Description
PreLoad MF=SP When set to <1> the MF value is preloaded with SP upon KCM starts or
large SP changes.
When set to <2> the MF will equal Setpoint even in Volumetric mode.

KLink Tx Delay Enable K-Link to delay TxD to prevent network overloads

Empty DC Value of drive command when emptying the feeder. Default is 70%.

Auto Span Limit Limit in actual range of the allowed span deviation from 1.000 to allow a
auto-span calculation to proceed. Default is 0.98-1.02 or an entry of
0.02.

Com1 Read Comm board K-Port 1 reads per second; <=100

Com1 Write Comm board K-Port 1 writes per second:<=10

Com1 Err Comm board K-Port 1 error counter:<= 1/hour

Com2 Read Comm board K-Port 2 reads per second:<=100

Com2 Write Comm board K-Port 2 writes per second:<=10

Com2 Err Comm board K-Port 2 error counter:<= 1/hour

Host Read Host channel reads per second: <=100

Host Write Host channel writes per second: <=10

Host Err Host channel error counter: <= 1/hour

IntCh Msgs Internal channel (SFT/MDU) messages per second

IntCh Err Internal channel (SFT/MDU) error counter

IntCh Load Internal channel (SFT/MDU) loading in percent: <= 50%

IntCh Node Internal channel (SFT/MDU) last failed node

IntCh Opcode Internal channel (SFT/MDU) last opcode

KpromWriteCount Counter for the write cycles to the Kprom

RefArrDevLimit LWF Only: Sets the maximum FF deviation allowed in the refill array. If
the FF deviation from Refill Complete to Refill Request is greater than
the RefArrDevLim, the limit is used, else the actual FF values are used.
Default is 30% deviation.

Modulation% LWF only: Shows the percent screw modulation used when <Modula-
tion> selected. When 0%, the modulation effect is zero.

Table page 1 of 2

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 Appendix 12
General KCM service variables 12.4

Variable Description
KCDR-K10S When set to <1> configures K-Port1 to function with a K-Commander-
KCDR, a separate K-Link unit (black box) or KDU using extended soft-
ware. When this entry is set to <0> K-Port1 returns to its normal function.
If <KPORT1 PROT> is set to <KSL> and this entry is set to <1> then K-
Port1 baud rate is selectable.

SWUpdateMode When set to <0>, it means the comm board and all slave devices are al-
lowed to use IAP.
When set to <1>, the KCM reload the comm board software on next pow-
er up, even if the s/w versions seem the same.
When set to <1> and an SFT REPOLL is executed, then the software of
all devices connected on the internal serial channel are reloaded regard-
less of if they have the same version as stored in the KCM.
When set to <2>, it inhibits all IAP function.

PertValueMode 0 = PertValue is displayed in Grams (Like SCM)

1 (default) = PertValue is displayed as a % of setpoint. With setpoint=0,
pertvalue is shown in Grams.

MFDispFilter2 This is the multiplier of the filter length of the second filter to the normal
filter. Higher number makes a more smooth indication. Default is 1,
means the two filters have the same time. Entering 0 turns that feature
off. No change to control, only displayed MF.

VolRate If set to other than <0>, this will add a variable <BULK DENSITY> to the
<PRODUCT CHANGE> menu. After a Auto FF calibration is done, this
value will display the volumetric capacity of the feeder.

ForceVibAlgo This 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.

RefillrepeatTime 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 pa-
rameter must be set to a non-zero value, such as 60 (seconds) and the
refill must be programmed to Auto Terminate. Then, when there is a refill
time out and the Net Weight is still below the refill request point, the refill
terminates (as normal), but also will start the AutoTerm Refill Repeat
Timer. When this AutoTerm Refill Repeat Timer expires, the refill cycle
starts over again automatically. This continues until the weight goes at
least above the refill request point.

Table page 2 of 2

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12 Appendix
12.5 KCM wiring examples

12.5 KCM wiring examples

12.5.1 System wiring examples

▲ The 450 watt DC motor drive and the 1600 watt DC motor drive are
wired in a similar manner but will be shown independently.
▲ As for all applications, refer to the wiring diagrams supplied for
your project as the official source for wiring your system.
▲ These wiring diagrams are provided as basic information 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.

12.5.2 KCM to KSU-II wiring at K-Port 1/2

KCM
K-Port 1 or 2 KSU II Primary Port

1 2 3 4 5 6
Vcc
1 2 3 4 5 6 7 8

COM

Tx+

Tx-

Rx+

Rx-
JP2

J1 or J2

Fig. 12.1 KCM to KSU-II wiring example

• If the KSU-II is more than 10 meters from the KCM, KSU-II power
must be supplied from an independent power supply.
• Either K-Port #1 or #2 may be used.
• Only one KSU-II may be powered from a single KCM.

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 Appendix 12
KCM wiring examples 12.5

12.5.3 KCM to KSL wiring at K-Port 1

• K-Port #1 is to be used only.

KSL-DB-9-RS485
KCM
1
K-Port 1
Vcc 2 Tx+

1 2 3 4 5 6 7 8
COM 3 Rx+

Tx+ 4
Tx- 5
Rx+
6 Tx-
Rx-
7 Rx-

8 COM

KCM K-Port KSL DB-9

2 8
3 3
4 7
5 2
6 6

Fig. 12.2 KCM to KSL wiring

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12 Appendix
12.5 KCM wiring examples

12.5.4 KCM to KSC wiring at K-Port 1- Digi card

• The wiring may be different for other RS485 serial communication
cards.
• K-Port #1 is to be used only.

Digi RS485
Serial

KSC-DB-9-RS485
KCM
1
K-Port 1
Vcc 2

1 2 3 4 5 6 7 8
COM 3

Tx+ 4
Tx-
5
Rx+
6 Rx+
Rx-
7 Rx-

8 Tx+

J1 9 Tx-

KCM K-Port KSC DB-9

2
3 6
4 7
5 8
6 9

Fig. 12.3 KCM to KSC wiring with Digi RS485 serial port

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 Appendix 12
KCM wiring examples 12.5

12.5.5 KCM to KSC wiring at K-Port 1- Moxa card

• The wiring may be different for other RS485 serial communication
cards.
• K-Port #1 is to be used only.

Moxa RS485
Serial

KSC-DB-9-RS485
KCM
1 Tx-
K-Port 1
Vcc 2 Tx+

1 2 3 4 5 6 7 8
COM 3 Rx+

Tx+ 4 Rx-
Tx-
5 COM
Rx+
6
Rx-
7

J1 9

KCM K-Port KSC DB-9

2 5
3 3
4 4
5 2
6 1

Fig. 12.4 KCM to KSC wiring with Moxa RS485 serial port

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12 Appendix
12.5 KCM wiring examples

12.5.6 KCM to KSC wiring at K-Port 1- K-Tron converter

• The wiring may be different for other RS485 serial communication
cards.
• K-Port #1 is to be used only.

9191-700550
RS 232 to RS422 Converter

DB-9-RS422
KCM
1
K-Port 1
Vcc 2 Tx+

1 2 3 4 5 6 7 8
COM 3 Rx+

Tx+ 4
Tx-
5
Rx+
6 Tx-
Rx-
7 Rx-

8 COM

J1 9

KCM K-Port Converter DB-9

2 8
3 3
4 7
5 2
6 6

Fig. 12.5 KCM to KSC wiring with interface 9191-700550 serial converter

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 Appendix 12
KCM wiring examples 12.5

12.5.7 KCM to WAGO I-O wiring at K-Port 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

WAGO-DB-9-RS485
KCM
1
K-Port 2
Vcc 2 Rx+

1 2 3 4 5 6 7 8
COM 3 Tx+

Tx+ 4
Tx-
5 COM
Rx+
6
Rx-
7 Rx-

8 Tx-

J2 9

KCM K-Port WAGO DB-9

2 5
3 2
4 7
5 3
6 8

Fig. 12.6 KCM to WAGO coupler wiring

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12 Appendix
12.5 KCM wiring examples

12.5.8 KCM without SIB board - dc motor - 0000002610

Typical system wiring diagram with a feeder mounted KCM.

• Not all terminal blocks are shown in this example.

SFT Gray
KCM
Pink 1600 W DC Drive
Green
Yellow
Speed
White Blue Sensor
Brown
Yellow Red
J8
6 5 4 3 2 1

6 5 4 3 2 1 J7 Com Sig +5Vdc

K4 J2
6 5 4 3 2 1DPDT
J4 4 3 2 1

J1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
J6

L1 N PE PE Mtr Mtr
Drive Enable Safety + -

DC Motor
Vac line in

Fig. 12.7 Feeder mounted KCM wiring example - 1600 W DC Drive

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 Appendix 12
KCM wiring examples 12.5

12.5.9 Remote KCM with SIB pcb at feeder

This is a feeder wiring example for a remote KCM with a feeder mount-
ed SIB circuit card for differential speed signal interfacing. (Fig. 12.8
and Fig. 12.9) The speed encoder interface is shown mounted to J2
in this example. (See Fig. 12.9).

9191-601650 SIB
LK-1-SFT1
Gray
+12 V 1
Pink
Com 2 See Note 1
Yel
Rx- 3
Grn SFT
Rx+ 4
Brn
Tx- 5
Wht
Tx+ 6

LK-1-SFT2
Gray
LK-4 +12 V 1
Pink
43 Com 2
Yel
44 Rx- 3
Grn SFT
45 Rx+ 4
46 Brn
Tx- 5
Wht
42 Tx+ 6

41
LK-2-SFT3
Gray
+12 V 1
Pink
KCM Com 2
Yel
1600 W DC Drive Rx- 3
Grn SFT
Rx+ 4
Brn
Tx- 5
Wht
LK-4 Tx+ 6
48
J8
47 LK-3
6 5 4 3 2 1 Blk or Blu
Com 21
Wht or Yel Speed
Sig 22
Pick-up
Red
6 5 4 3 2 1 J7 +5V 23

K4 J2
6 5 4 3 2 1DPDT
J4 4 3 2 1

J1

12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 J6
L1 N PE PE Mtr Mtr
+ -
Drive Enable Safety

DC Motor
Vac line in

Fig. 12.8 KCM using the SIB pcb example with differential receiver on J2

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12 Appendix
12.5 KCM wiring examples

Notes:
• Differential receiver-encoder interface pcb (0000006384) must be
installed onto J2 on the Drive circuit card when the Scale Interface
pcb interfaces to the KCM. (Fig. 12.9)
• Fig. 12.8 wiring shows the speed connection signals using the
encoder interface circuit card

KCM Drive Encoder Interface

0000006384

1 2 3 4
+5Vdc Spd 1 In +

1 2 3 4
+
Spd 1 In -
Enc A
- Spd 2 In +
Enc B

Com Spd 2 In -
+

J2 -

Fig. 12.9 Differential 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.

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 Appendix 12
KCM wiring examples 12.5

12.5.10 Stepper drive wiring example for 0000005987

• Not all terminal blocks are shown in this example.
• In the example shown the encoder and motor signals in the same
cable. This requires individually shield twisted pair with the signals
groups as shown and an overall shield.
• For >30 m an SIB board must be used and the motor and encoder
signals run in separate cables.
• Wire colors shown 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 12.6.5 for details.

SFT Gray
KCM
Pink Stepper Drive
Green
Yellow
White
Brown

J8
6 5 4 3 2 1
+5Vdc
SigB

SigA
Com

6 5 4 3 2 1 J7
K4 J2
6 5 4 3 2 1DPDT
J4 4 3 2 1

J1 J6
12 11 10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1

L1 N PE PE
PH2+

PH1+
PH2-

PH1-

Drive Enable Safety

White/Yellow

White/Green

White/Black

Vac line in
White/Red

Green
White
Black
Red

Dual
Stepper Channel
Motor Encoder

Fig. 12.10 KCM stepper drive field wiring example

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12 Appendix
12.5 KCM wiring examples

12.5.11 Encoder Line Driver Board

• For cable length > 2 m the Encoder Line Driver Board 0000020276
is installed at the stepper motor.

+5VDC +5VDC
1 2 3 4
J1 J2
CHB 5 5 CHB
+5VDC 4 4 +5VDC
CHA 3 3 CHA
INDEX 2 2 INDEX
COMMON 1 11 10 9 8 1 COMMON

CON5 CON5

Fig. 12.11 Encoder Line Driver Board

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 Appendix 12
KCM wiring examples 12.5

12.5.12 Vibratory feeder wiring example - 0000000684

• Not all terminal blocks are shown in this example.

SFT Gray
KCM
Pink Vibratory Drive
Green
Yellow
White
Brown

J8
6 5 4 3 2 1

6 5 4 3 2 1 J7
K4
6 5 4 3 2 1DPDT
J4

J1 J2 J6
12 11 10 9 8 7 6 5 4 3 2 1 2 1 8 7 6 5 4 3 2 1

L1 N PE PE

Drive Enable Safety

Coil Coil-
+

Displacement
FB Coil
Vac line in
Vibratory
Tray Coil

Fig. 12.12 KCM vibratory drive field wiring example

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12 Appendix
12.5 KCM wiring examples

12.5.13 AC drive wiring example - 0000003413

• Not all terminal blocks are shown in this example.
• There are a number of ways to wire the AC drive. The example
above shows an NPN 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.

NPN
KCM Speed
AC Drive Sensor

Sig
+5Vdc

Com

J2
4 3 2 1
Iout(-)
Iout(+)
Setpoint
to
10 9 8 7 6 5 4 3 2 1 J9 Remote
Drive

12 11 10 9 8 7 6 5 4 3 2 1 J1 8 7 6 5 4 3 2 1 J6

L1 N PE PE L1 L2

Drive Enable Safety

Motor
Contactor

Vac line in CR

Fig. 12.13 KCM AC interface wiring example

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 Appendix 12
KCM wiring examples 12.5

12.5.14 450 watt DC drive wiring example - 0000007405

• Not all terminal blocks are shown in this example.

SFT

Yellow
Green

Brown
White
Grey

Pink
J2 +5Vdc Sig

4 3 2 1
1 2 3 4 5 6 J4 Speed
Sensor

Com
J1

12 11 10 9 8 7 6 5 4 3 2 1
Safety

L1 Drive Enable
8 7 6 5 4 3 2 1

Vac line in
N
K4
DPDT
PE

PE

Mtr +

Mtr - KCM
DC Motor
J6 450 W DC Drive

Fig. 12.14 450 watt DC drive wiring example

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12 Appendix
12.5 KCM wiring examples

12.5.15 KCM interlock wiring example

This diagram is an example of how to connect multiple KCMs together
using the Bit Output and Bit Input control for an alarm interlock. When
any of the three KCMs goes into alarm, all shutdown. This assumes
that the KCM programming is proper.

K4
10 8 6 3DPDT
10 8 6 3 10 8 6 3
KCM #1-J8 KCM #2-J8 KCM #3-J8
Fig. 12.15 KCM interlock wiring for ALS

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>

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 Appendix 12
KCM wiring examples 12.5

12.5.16 Hi/Lo Auto gear external switching circuit

The following diagram shows how to safely wire the KCM for automat-
ic gear switching functions for the LWF/LWB application when a K2M
feeder with dual speed gearbox is used.

L1

High CR1
Gear

Drive
DC+
CR3 +
M
Drive
DC-
-

Low CR2
Gear

Fig. 12.16 HiLo gear selection wiring for KCM-LWF

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. 12.14
 Test function and re-connect DC motor wiring if screw speed
changes are reversed.

• CR1-CR3 are independent AC contactors with 15 A contacts

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12 Appendix
12.5 KCM wiring examples

12.5.17 Field wound DC motor wiring example

▲ Operation without field control:

JP3 and JP4 must be removed when JP1 and JP2 are installed in
the circuit. Removal of JP3 and JP4 removes the 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.
▲ Operation with field control:
JP3 and JP4 must be installed when JP1 and JP2 are removed
from the circuit. This enables the output circuit to be discharged
when using field control.

This diagram shows one potential way to wire the field supply if a field
wound DC motor is used.

X3

1 2
12 V

S1

F+ 1 2 3
F-
K4
PE
DPDT
X2
1 2 3 4

PE

Vac line in DC Motor

L1 Field
X1 Supply

Fig. 12.17 Field 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.

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 Appendix 12
KCM wiring examples 12.5

12.5.18 KCM to HCU wiring example

Typical system wiring diagram for interconnecting a pneumatic loader
using an HCU loader controller to the KCM.
• Refer to the HCU electronics manual for additional wiring
information.

KCM-SFT HCU-J1/J2

1 2 3 4 5 6 7
1 2 3 4 5 6
Pnk Wht

Yel Brn

Grn Grn

Brn Yel

Wht Pnk

Grd

Fig. 12.18 HCU wiring example

12.5.19 KCM to LSR wiring example

Typical system wiring diagram for interconnecting a pneumatic loader
using an LSR controller to the KCM.

• Refer to the LSR manual for additional wiring information.

KCM-SFT LSR -J1

1 2 3 4 5 6
1 2 3 4 5 6

Fig. 12.19 LSR wiring example

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12 Appendix
12.5 KCM wiring examples

12.5.20 KF2- to KCM Host 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.

AB KF2 Module
Comm board DB-25
Host Port-J1 1

1 2 3 4 5 6 7 8
COM 3

7
TxD
RxD

RS-232C

KCM K-Port KF2

2 7
7 3
8 2

Fig. 12.20 AB KF2 to KCM wiring example

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 Appendix 12
KCM wiring examples 12.5

12.5.21 BM-85 to KCM Host port wiring

This 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.

Modicon BM-85
Comm board DB-9P

Host Port-J1 1

1 2 3 4 5 6 7 8
COM 3

7
TxD
8
RxD

RS-232C 9

KCM K-Port BM-85

2 5
7 3
8 2

Fig. 12.21 Modicon BM-85 to KCM wiring example

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 129

12 Appendix
12.5 KCM wiring examples

12.5.22 Schematic of SIB board-9191601650

The Scale Interface pc board-SIB is used when the KCM is mounted
away from the feeder.
• Do not connect SFT power to LK-5
• Turn the DIP switch to <On> for all active SFT positions.

Note: if LK-5 is used, all poles of the DIP Switch must be open
LK-5
+12 Vdc SCM#1 1
+12 Vdc SCM#2 2
+12 Vdc SCM#3 3
4

SFT Disable Sw
S1 SFT # 1

S2 SFT # 2

T o Co nt roller S3 SFT # 3

LK-4 S4 SFT # 4

SFT # 3
41
+ 5 V dc
41 V reg LK-2 LK-1
42 1 1 + 1 1.3
Vdc
Com 42 2 2 Com
T x-
SFTT x- 43 3 3 Tx-
Tx + SFT # 1
SFT T x + 44 4 4 Tx +
Rx -
SFTRx- 45 5 5 Rx-
Rx +
SFT Rx + 46 6 6 Rx +
- + - + + 1 1.3
Spd + 47 1 1
Vdc
Tx Rx
Spd- 48 2 2 Com
U2
Sl i p + 2 6LS3 3
49 .
3 3 Tx-
26LS3 1 SFT # 2
Sl i p- 50 4 4 Tx +
U1 Yel Yel
A ux 1 51 5 5 Rx-

A ux 2 52 6 6 Rx +
J U- 2
A ux 3 53 GRD GRD SFT Cable Shields
Sli p Speed
A ux 4 54
+ 5 V dc Red
SFT # 4

J U- 1 GRD
28 27 26 25 23 24 21 23 22 21 LK-3
COM
+ 1 2 V dc
+ 5 V dc Auxiliary Bel tSl i p Mot or Speed

Fig. 12.22 SIB schematic

Page 130 Docu-No.: 0490020605-EN Rev. 1.6.0

 Appendix 12
KCM wiring examples 12.5

12.5.23 Belt slip wiring for WBF and WBB applications.

• See the WBB or WBF programming manual for specific
programming for belt slip operation.

Motor
Speed
Blue
Sensor

Yellow Red

Com Sig +5Vdc

J2
4 3 2 1
On Motor Drive pcb
Drum
Optical
Sensor
Brown White

Green
Fin- Fin+

J9
6 5 4 3 2 1
KCM CPU pcb

Fig. 12.23 Belt slip wiring example

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 131

12 Appendix
12.6 Summary of KCM I-O

12.6 Summary of KCM I-O

12.6.1 CPU I-O

# J1/J2 K-Port 1/2 J8 CPU Digital I-O J9 Analog/Freq J10 Alternate DC J11 Internal
channel, DC
power

1 Power(+24Vdc) +24 Vdc from

Dig In 1 Fin+, (0-10kHz) +14 to 40 Vdc
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 Ain+ (0-5/10 Vdc, TxD+, RS485
Common
0-20 mA)
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 132 Docu-No.: 0490020605-EN Rev. 1.6.0

 Appendix 12
Summary of KCM I-O 12.6

12.6.2 Common Drive I-O

These connections are common to all drive types. See later specific
sections for other drive connections.
# J1-Digital Inputs J3-Int Channel, PS 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

12.6.3 SFT Connections for all drives

• Only J4 is used on the 450 watt DC drive
• Not for PID or VOL applications

# J4/J7/J8 SFT

1 +12 Vdc @ 100mA

2 Common
3 TxD+ RS485
4 TxD- RS485
5 RxD+ RS485
6 RxD- RS485

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 133

12 Appendix
12.6 Summary of KCM I-O

12.6.4 Specific 450/1600 Watt DC Drive connections

# J2-Encoder J6-Line Power/
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

12.6.5 Specific Stepper Drive connections

# J2-Encoder J6-Line Power/ J6-Line Power/
Motor-0000005987 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 134 Docu-No.: 0490020605-EN Rev. 1.6.0

 Appendix 12
Summary of KCM I-O 12.6

12.6.6 Specific Vibratory Drive connections

# J2-Encoder J6-Line Power/
Motor

1 Displacement coil
Vib Coil -
feedback +
2 Displacement coil
Vib Coil +
feedback -
3 PE/GRD
4 PE/GRD
5 PE/GRD
6 Neutral
7 L2
8 L1

12.6.7 Specific AC Drive connections

# J2-Encoder J6-Line Power/ J9-Drive Interface
Motor

1 + 5 Vdc MDU L2 Power

I Out +
Control Relay NO
2 Frequency Input + MDU L1 Power
I Out -
Control Relay NO
3 Frequency Input - PE/GRD Freq Out +
4 Common PE/GRD Freq Out -
5 PE/GRD +2 4Vdc @ 0.2 A
6 Drive Ena Relay
Neutral
Common
7 Drive Ena Relay
L2
NO
8 Alarm Reset Relay
L1
Com
9 Alarm Reset Relay
NO
10 Common

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 135

12 Appendix
12.7 Declaration of Conformity KCM

12.7 Declaration of Conformity KCM

K-Tron (Schweiz) AG
Lenzhardweg 43/45
CH-5702 Niederlenz

KONFORMITÄTSERKLÄRUNG
DECLARATION OF CONFORMITY
DÉCLARATION DE CONFORMITÉ
Wir erklären hiermit, dass:
We declare herewith, that:
Nous déclarons ci-après que:

Typ / type: Kennzeichnung / marking / marquage:

KCM K-Tron Control Module II 3D Ex tD A22 IP65 T65°C

Tamb. = -20...+50°C
K-Tron 0590024903 B

konform ist / sind mit den Bestimmungen der unten genannten EG-Richtlinien. Folgende EG-Richtlinien
und harmonisierte Normen wurden angewendet:
is / are in conformity with the provisions of the below listed EC-Directives. The following EC-Directives
and harmonized standards have been applied:
est / sont conforme aux dispositions des Directives CE suivantes. Les Directives CE suivants et les
normes harmonisées ont été appliquées:

EG-Richtlinien / EC-Directives / Directives CE Normen / Standards / Normes

94/9/EG: Geräte und Schutzsysteme zur EN 1127-1:2007
bestimmungsgemässen Verwendung in EN 61241-0:2006
explosionsgefährdeten Bereichen EN 61241-1:2004
94/9/EC: Equipment and protective systems
intended for use in potentially explosive
atmospheres
94/9/CE: Appareils et les systèmes de
protection destinés à être utilisés en atmosphères
explosibles
2006/95/EG: Niederspannungs-Richtlinie EN 61010-1:2001
2006/95/EC: Low Voltage Directive
2006/95/EG: Directive Basse Tension
2004/108/EG: EMV-Richtlinie EN 61000-6-2:2005
2004/108/EC: EMC-Directive EN 61000-6-4:2007
2004/108/CE: Compatibilité Électromagnétique

Die technische Dokumentation ist vollständig vorhanden. Dokumentationsverantwortlicher ist Andreas

Rykart, LeiterEngineering.
The technical documentation is complete. Responsible for documentation is Andreas Rykart, Head of the
Engineering Department.
La documentation technique est complète. Le responsable de la documentation est Andreas Rykart,
Directeur Engineering.

Niederlenz, 10.08.2009

Andreas Rykart Gerhard Wirz

Engineering / Engineering Geschäftsführer / Managing director

Form 0990000207 A DE / EN / FR
Doc 0590000222 C; KS-OFF-0037335C.DOC

Page 136 Docu-No.: 0490020605-EN Rev. 1.6.0

 Appendix 12
Declaration of Conformity KCM SS 12.8

12.8 Declaration of Conformity KCM SS

K-Tron (Schweiz) AG
Lenzhardweg 43/45
CH-5702 Niederlenz

KONFORMITÄTSERKLÄRUNG
DECLARATION OF CONFORMITY
DÉCLARATION DE CONFORMITÉ
Wir erklären hiermit, dass:
We declare herewith, that:
Nous déclarons ci-après que:

Typ / type: Kennzeichnung / marking / marquage:

KCM K-Tron Control Module II 3D Ex tD A22 IP65 T65°C
Stainless Steel Tamb. = -20...+40°C
K-Tron 0990021903 A

konform ist / sind mit den Bestimmungen der unten genannten EG-Richtlinien. Folgende EG-Richtlinien
und harmonisierte Normen wurden angewendet:
is / are in conformity with the provisions of the below listed EC-Directives. The following EC-Directives
and harmonized standards have been applied:
est / sont conforme aux dispositions des Directives CE suivantes. Les Directives CE suivants et les
normes harmonisées ont été appliquées:

EG-Richtlinien / EC-Directives / Directives CE Normen / Standards / Normes

94/9/EG: Geräte und Schutzsysteme zur EN 1127-1:2007
bestimmungsgemässen Verwendung in EN 61241-0:2006
explosionsgefährdeten Bereichen EN 61241-1:2004
94/9/EC: Equipment and protective systems
intended for use in potentially explosive
atmospheres
94/9/CE: Appareils et les systèmes de
protection destinés à être utilisés en atmosphères
explosibles
2006/95/EG: Niederspannungs-Richtlinie EN 61010-1:2001
2006/95/EC: Low Voltage Directive
2006/95/EG: Directive Basse Tension
2004/108/EG: EMV-Richtlinie EN 61000-6-2:2005
2004/108/EC: EMC-Directive EN 61000-6-4:2007
2004/108/CE: Compatibilité Électromagnétique

Die technische Dokumentation ist vollständig vorhanden. Dokumentationsverantwortlicher ist Andreas

Rykart, LeiterEngineering.
The technical documentation is complete. Responsible for documentation is Andreas Rykart, Head of the
Engineering Department.
La documentation technique est complète. Le responsable de la documentation est Andreas Rykart,
Directeur Engineering.

Niederlenz, 10.08.2009

Andreas Rykart Gerhard Wirz

Engineering / Engineering Geschäftsführer / Managing director

Form 0990000207 A DE / EN / FR
Doc 0990021904 A; KS-OFF-0037334A.DOC

Docu-No.: 0490020605-EN Rev. 1.6.0 Page 137

12 Appendix
12.8 Declaration of Conformity KCM SS

Page 138 Docu-No.: 0490020605-EN Rev. 1.6.0

 Chapter 7:
Comm
Documentation
This Chapter Does
NOT Apply To This
Manual.
 Chapter 8:
Utilities
Documentation
This Chapter Does
NOT Apply To This
Manual.
 Chapter 9:
Reference
Documentation
 8502
Grounding, Shielding and Wiring Practices

Grounding, Shielding and

General Wiring Practices
for K-Tron Products

Rev: Produced by the K-Tron Institute

8502
Grounding, Shielding and Wiring Practices

No part of this publication may be reproduced or transmitted in any form or by any

means electronic or mechanical including photocopy, facsimile or computer generated
distribution without written permission from the K-Tron Institute. All translation
rights are reserved by the K-Tron Institute .

Rev: Produced by the K-Tron Institute

 8502
Grounding, Shielding and Wiring Practices

Table of Contents

Topic See Page

Grounding and Shielding and General Wiring 1
Practices for K-Tron Equipment
Overview 1
Concepts of Grounding and Shielding 2
Grounding Principles 3
Shielding Principles 7
Summary of Noise Reduction Techniques 9
General Wiring Principles 12
References 18
Index 19

Rev: Produced by the K-Tron Institute

 8502.1
Grounding, Shielding and Wiring Practices

Grounding and Shielding and General Wiring

Practices for K-Tron Equipment

Overview

Introduction This section gives the rules for grounding K-Tron electronic equipment.
Failure to provide adequate grounding can result in random equipment
failure or disruption of operation. Human injury can also result. Also
covered are techniques for shielding signal cables. Recommended
general wiring principles are also presented.

In this chapter
Topic See Page
Concepts of Grounding and Shielding 2
Grounding Principles 3
Shielding Principles 7
Summary of Noise Reduction Techniques 9
General Wiring Principles 12
References 18

Rev: Produced by the K-Tron Institute

8502.2
Grounding, Shielding and Wiring Practices

Concepts of Grounding and Shielding

Introduction Grounding and shielding techniques specified in this document are to

insure stable and predictable operation of your K-Tron equipment. The
purpose of grounding is to prevent personnel injury if a person comes
in contact with an electronic or electrical device. Good grounding also
prevents circulating currents from occurring which can result in signal
disruption. Shielding can help prevent interference from disrupting
machine operation. To be successful when sending high speed data
signals a long distance, care is required in grounding and shielding of
signal cables.

Electrical and Interference signals are generated in different ways and can enter
magnetic electronic circuits through the power lines, the input signal lines or the
interference signal output lines. In addition, interference can be capacitively -
electro-static coupling, magnetically coupled to closed loops in the
circuit or electro-magnetically coupled to wires that act as antennas.
Any of these situations can cause interference to be coupled from one
circuit to another. Finally, signal currents can couple to other circuit
parts through voltage drops on signal ground lines or power supply
lines.

In control systems, careful grounding and signal shielding are key in

preventing interference from causing operational problems and
downtime.

Rev: Produced by the K-Tron Institute

 8502.3
Grounding, Shielding and Wiring Practices

Grounding Principles

Introduction Proper grounding of equipment will prevent electrical shock and

personnel injury and help prevent interference from causing
operational problems with your K-Tron equipment.

Power line It is imperative for safety reasons to be sure that no voltage difference
grounding exists between various components of the feeder system. It is the case in
many plants where the ground connector is at differing potential
around the plant. When you install a feeding machine, the frame of that
feeder must be at the same potential as the chassis of the control system
in your control panel. The best way to insure that is to bring the ground
of each machine and control to a common ground point which then
goes to your "ground farm" or ground plane.

Continued on next page

Rev: Produced by the K-Tron Institute

8502.4
Grounding, Shielding and Wiring Practices

Grounding Principles, Continued

Power line
grounding
con't

Machine
Controls

Frame Grd Chassis Grd

Common
Ground
Point

Use braided conductors for this ground connection rather than smaller
gages of wire. In some cases, a flat, flexible copper strap for a ground
connection in an area of high levels of RFI is a good choice. Use
stranded wire for the connections as solid wire may fatigue and break
without you knowing it. Resistances to ground should be less than 0.5
ohms from any source.

Connections to feeding machines, and controls for ground are to be

made at the provided connection point for ground. The signal common
is not ground and should only be connect to ground if specified on the
wiring documentation. If process or signal common is to be connected
to ground, it must only be done at one point preferably at the common
ground point.

A special note; if water is present in the equipment area, it is suggested

that ground fault breakers be employed on power mains to prevent low
level ground fault currents, which will not cause a regular fuse or
circuit breaker to trip from injuring or killing operating personnel.

Continued on next page

Rev: Produced by the K-Tron Institute

 8502.5
Grounding, Shielding and Wiring Practices

Grounding Principles, Continued

Multiple In practical situations, it is necessary to tie differing grounds together.

grounds We have hardware grounds, which are described above, noisy grounds
that come from relays, motor drives and so forth and signal grounds
that come from low energy circuits such as signal buffers and so forth.

When you have this situation, use the following graphic to picture how
the grounds should be connected.

Noisy Grounds Hardware Grounds

Signal Grounds
( Relays, Motors ( Chassis, Racks
(Low level circuits)
and Drives) and Cabinets)

Ground Plane

Continued on next page

Rev: Produced by the K-Tron Institute

8502.6
Grounding, Shielding and Wiring Practices

Grounding Principles, Continued

A few If the installation does not provide a good ground connection to the
grounding panel or rack system or cabinet, provide a solid ground per the above
rules graphic. Do not rely on sliding drawers, hinges and other movable
connections to secure a solid ground. Hardware grounds made by
intimate contact such as welding or brazing or soldering are better than
those made by hardware of bolts and screws because galvanic reactions
can take place if materials are of a different valence. If you use crimp
connections, use a Mil std. crimper rather than the hardware store
variety. You will get better results.

If you have to use mechanical connections, be sure that the underlying

surface is conductive and is protected by a conductive finish that will
not degrade over time. Improperly made connections may work well in
a new installation but will be sources of trouble later on and then will
be extremely difficult to locate.

Rev: Produced by the K-Tron Institute

 8502.7
Grounding, Shielding and Wiring Practices

Shielding Principles

Introduction Shielding seems to be an art to all of us who are involved with dealing
with interference at low energy levels. We will give some clues as to
what to do.

Grounding the
shield The best approach is to ground the shield of the signal cable at the
controller(indicator) end not the transducer end. The rule is ; if the
signal source is ungrounded, connect the shield at the controls(receiver)
end, but if the source common is at ground and the controls(receiving
end) is not, connect the shield at the source. That means for a speed
pick-up signal, the shield of the cable in which the signal is sent to the
controller is grounded only at the controller(receiving end). This
eliminates circulating currents that can result if case grounds at either
end are at differing potentials. A graphic example is below. Note that
the sending cable is grounded at the Scale Interface pc board junction
box. Note that the source or speed pick-up is not grounded. The speed
pick-up source is floating above ground but the controller's common
may be grounded. This approach is most common with K-Tron
equipment is the first case and the same holds true for the SFT and DFT
weight sensors.

If for some reason, the transducer is grounded and the receiving end is
not, then the reverse holds true. Connect the shield at the grounded
end.
Connection
at Controls

Scale Interface
pc at machine
Speed
Pick-up

When coming through the Scale Interface Pc Junction box, be sure that
the box is securely grounded.

Continued on next page

Rev: Produced by the K-Tron Institute

8502.8
Grounding, Shielding and Wiring Practices

Shielding Principles , Continued

Shield The shield used in cables for transmission of data signals should be foil
requirements under braid. Braid does not give the high level of shielding by itself
that foil will provide. But together, configured in this manner, they give
the best level of shielding for all frequencies. The best choice in signal
cable is one that has twisted pairs that are individually foil shielded
and with a drain wire for shield connection.

Shielding There are many pitfalls. Watch out for these things in your installation.
pitfalls Don't install cabling near RF installations, sources of EMI such as arc
welders and motor controllers, sources of magnetic interference such as
large power transformers, or near sources of inductive spiking. The
vibrating wire transducer, like many low energy transducers, can be
subject to these high level energy sources. Vibrating wire sensing is a
low energy system. Only a few µvolts are present in the vibrating wire
and in some cases, RF interference may corrupt the oscillation of the
wire. It is best to key your radios near to the weight sensors to verify
they do not respond to the RFI being radiated. Doing this test prior to
placing the equipment into production permits additional interference
resolution to be incorporated if found to be necessary thus preventing
operational surprises while in production.

Also, bear in mind that pigtail shield terminations can also act as
antennas at short wavelengths. These are to be avoided.

Shielding rule The K-Tron Shielding Rule: Only ground the shield at the signal
receiving end, not the transducer end. Be sure that this connection is
also brought to the common ground point.

Special If high frequency data is being sent using coaxial cable, grounding is
shielding required at both ends. This is clearly different than the requirements for
situations low frequency situations.

Rev: Produced by the K-Tron Institute

 8502.9
Grounding, Shielding and Wiring Practices

Summary of Noise Reduction Techniques

Introduction This list is from Henry Ott's book as mentioned in the references list at
the end of the chapter. It is a checklist for your use. Those ideas that
have an asterisk are low or free in cost and should be regularly used.

Note: Some of these recommendations relate to equipment design and

are already incorporated into your K-Tron equipment. However these
same ideas can be used when you are designing interface electronics to
connect to the K-Tron control system.

Suppressing Enclose noise sources in a shielded enclosure

noise at its Filter all leads leaving a noisy environment
source Limit pulse rise times
Relay coils should be provided with some form of surge damping
Twist noisy leads together*
Shield and twist noisy leads
Ground both ends of shield used to suppress radiated interference

Continued on next page

Rev: Produced by the K-Tron Institute

8502.10
Grounding, Shielding and Wiring Practices

Summary of Noise Reduction Techniques, Continued

Eliminating Twist low-level signal leads*

noise coupling Place low-level leads near chassis
Twist and shield signal leads- coaxial cable should be used above 100
kHz
Shielded cables used to protect low frequency, low level signal leads
should be grounded at one end only however if coaxial cable is
used, the shield is grounded at both ends
Insulate shield on signal leads
When low-level signal leads and noisy leads are in the same
connector- not recommended by the way- separate them and
place ground leads between them*
Carry shield on signal leads through connections on a separate pin
Avoid common ground leads between high and low level
equipment*
Keep hardware and circuit grounds separate
Keep grounds as short as possible*
Use conductive coatings in place of non-conductive coatings for
protection of metallic surfaces
Separate noisy and quiet leads*
Ground low frequency (<100kHz), low level circuits at one point
only*
( high frequency and digital logic grounds are an exception)
Avoid questionable or accidental grounds
For sensitive equipment, operate source and load balanced to ground
Place sensitive equipment in a shielded enclosure
Filter or de-couple any leads entering enclosures containing sensitive
equipment
Keep the length of sensitive leads as short as possible*
Use low impedance power distribution lines
Avoid ground loops in low frequency , low level circuits*
Don't run signal and power lines parallel, cross at right angles*
Don't run signal and power lines in the same conduit or raceway
To eliminate ground loops, consider using one or more of the
following:
^ Isolation transformers
^ Common-mode chokes
^ Optical couplers
^ Differential amplifiers
^ Guarded amplifiers
^ Balanced circuits
^ Hybrid grounds

Continued on next page

Rev: Produced by the K-Tron Institute

 8502.11
Grounding, Shielding and Wiring Practices

Summary of Noise Reduction Techniques, Continued

Reducing Use only necessary bandwidth

noise at the Use frequency selected filters when applicable
receiver Provide proper power supply de-coupling
Bypass electrolytic capacitors with small high frequency capacitors
Separate signal, noisy and hardware grounds*
Use shielded enclosures
With tubular capacitors, connect the outside foil to ground*

Controlling Minimize ground inductance by using a ground plane or ground

emissions in grid
digital system Locate de-coupling capacitors next to each IC in the system
design Use the smallest value de-coupling capacitor that will do the job
Use a bulk de-coupling capacitor to recharge the individual IC de-
coupling capacitors
Clock signal loops areas should be kept as close to zero as possible
All cables should be treated to minimize their common mode current
All unused inputs on logic gates should be connected to either power
or ground
I-O drivers should be located near where the cables leave the system
Use the lowest clock frequency and slowest rise time that will do the
job
Keep clock circuits and leads away from I-O cables

Rev: Produced by the K-Tron Institute

8502.12
Grounding, Shielding and Wiring Practices

General Wiring Principles

Introduction This section gives your our preferences for wiring the K-Tron feeder
systems.

Color coding The following is the recommended color code for power wiring in the
for power K-Tron systems.
wiring
Signal Name Colors for USA Colors for Europe
AC Line -Hot Black Black
AC Line- Neutral White Light blue
Ground Green Yellow/Green
Motor DC + Not defined Not defined
Motor DC- Not defined Not defined
Motor Ground Green Yellow/Green
Low Level Power AC Yellow Red
Low Level Power Green Yellow/Green
Grounds

Continued on next page

Rev: Produced by the K-Tron Institute

 8502.13
Grounding, Shielding and Wiring Practices

General Wiring Principles, Continued

Controls The following chart is recommended for power wiring to K-Tron low
power wiring energy controls. Some examples of which are shown below. Colors are
shown for USA applications.

Device Wire Size Specifics

KDU 20 AWG, L1- black
(0.51 sq. mm), copper L2 - white
stranded, 105 C
Grd - green
rating, 600Vac
K10CU Control Rack 20 AWG, L1- black
(0.51 sq. mm) copper L2 - white
stranded, 105 C
Grd - green
rating, 600Vac
K10S CU Control 20 AWG, AC- yellow
Rack (0.51 sq. mm) copper AC- yellow
stranded, 105 C
Grd- green
rating, 600Vac

Note: this is 24 Vac

input.
K-Commander Wired with supplied L1- black
cord with same basic L2 - white
wire specifications as
Grd - green
above
Converters of various 20-22 AWG, L1- black
types, low energy (0.51-0.32 sq. mm) L2 - white
copper stranded, 105
Grd - green
C rating, 600Vac

Continued on next page

Rev: Produced by the K-Tron Institute

8502.14
Grounding, Shielding and Wiring Practices

General Wiring Principles, Continued

Power wire Power wiring is size critical. It is recommended that approximately 700
sizing for cir mils per amp be the conservative criteria for wire sizing for all
motor and power applications. For recommended runs of cable the following chart
motor drive
is satisfactory for those applications that use the MDU Motor Drive
system for
Unit. This chart if for US applications and meets American Insurance
USA
Association recommendations. For short distances, <50 ft, you can use
16 AWG in place of 14 AWG and 12 AWG in place of 10AWG.

Motor Rating Drive Rating Wire Gage to Motor

and Drive Unit
1/4 hp at 90 Vdc 6 amp at 115 Vac 14 AWG
1/2 hp at 90 Vdc 6 amp at 115 Vac 14 AWG
3/4 hp at 90 Vdc 15 amp at 115 Vac 10 AWG
1/4 hp at 180 Vdc 6 amp at 230 Vac 14 AWG
1/2 hp at 180 Vdc 6 amp at 230 Vac 14 AWG
3/4 hp at 180 Vdc 6 amp at 230 Vac 14 AWG
1 hp at 180 Vdc 6 amp at 230 Vac 14 AWG
1.5 hp at 180 Vdc 15 amp at 230 Vac 10 AWG
2 hp at 180 Vdc 15 amp at 230 Vac 10 AWG

Continued on next page

Rev: Produced by the K-Tron Institute

 8502.15
Grounding, Shielding and Wiring Practices

General Wiring Principles, Continued

Power wire Power wiring is size critical. It is recommended that approximately 0.35
sizing for sq. mm per amp be the conservative criteria for wire sizing for all
motor and power applications. For recommended runs of cable the following chart
motor drive
is satisfactory for those applications that use the MDU Motor Drive
system for
Unit. This chart if for European applications. Motor ratings are in kW.
Europe

Motor Rating Drive Rating Wire Gage to Motor

and Drive Unit
0.2 kW at 90 Vdc 6 amp at 115 Vac 1.85 sq. mm
0.4 kW at 90 Vdc 6 amp at 115 Vac 1.85 sq. mm
0.6 kW at 90 Vdc 15 amp at 115 Vac 5.2 sq. mm
0.2 kW at 180 Vdc 6 amp at 230 Vac 1.85 sq. mm
0.4 kW at 180 Vdc 6 amp at 230 Vac 1.85 sq. mm
0.6 kW at 180 Vdc 6 amp at 230 Vac 1.85 sq. mm
0.8 kW at 180 Vdc 6 amp at 230 Vac 1.85 sq. mm
1.1 kW at 180 Vdc 15 amp at 230 Vac 5.2 sq. mm
1.5 kW at 180 Vdc 15 amp at 230 Vac 5.2 sq. mm

Other power The following is a listing of cable specifications for power wiring
cable
specifications
Description Specification
Wire make-up Stranded cable with 30 AWG
(0.05 sq. mm) copper wire used for
stranding of the cable. Solid copper
wire can be used in wire troughs if
no wire movement is expected.
Insulation PVC, 105 degree C rating
Voltage rating 600 Vac recommended

Continued on next page

Rev: Produced by the K-Tron Institute

8502.16
Grounding, Shielding and Wiring Practices

General Wiring Principles, Continued

Data cables The quality of the data cable you use in the K-Tron installation may
have an impact upon the reliability of the operation of the equipment.
Below is a specification table for recommended data cables used for
feeder to controls connections and module to module data connections.

Description Specification
Wire make-up 20-22 AWG ( 0.51-0.32 sq. mm)
stranded copper wire, in wire
pairs. Each pair is twisted.
Shielding with a foil shield and
braid plus a common drain wire is
required. Stranding is done with 30
AWG (0.05 sq. mm) wire using 7
strands.
Insulation 105 degrees C or greater is
recommended
Capacitance mid-capacitance values are
recommended as the data interface
is usually RS485.
Voltage rating 300 Vac is recommended
Color In each pair, it is recommended for
recommendations easy troubleshooting that a
primary color and a the same color
with a contrasting stripe be
employed in each shielded pair.
Using multiple black is not a good
idea.

Continued on next page

Rev: Produced by the K-Tron Institute

 8502.17
Grounding, Shielding and Wiring Practices

General Wiring Principles, Continued

Other wiring The following are ideas that, if implemented, can minimize interference
suggestions in your plant.

Idea Action Item

1 Twist all power wiring with 1 twist per in. (25mm) of length
2 Always have 1 meter of spacing between power and signal
cables
3 Always cross power and signal cables at right angles, Never
run signal and power cables parallel to each other.
4 Never run power and signal wires in the same conduit or
raceway
5 Be sure that all grounds are truly secure
6 Always run signal cables in a grounded conduit. Do not
allow cable shield to touch conduit.

Rev: Produced by the K-Tron Institute

8502.18
Grounding, Shielding and Wiring Practices

References

Bibliography 1 ] The Art of Electronics, P. Horowitz and W. Hill, 1989, Cambridge

University Press, pp455-470.

2 ] Noise Reduction Techniques in Electronic Systems, H. Ott, 1988,

Wiley and Sons, pp 425

3 ] Electronics Engineers' Handbook, Donald Fink and Donald

Christiansen, Mc Graw Hill, pp 6-16

Rev: Produced by the K-Tron Institute

 8502.19
Grounding, Shielding and Wiring Practices

Index

A few grounding rules 6

antennas 2
circulating currents 2, 7
coaxial cable 8
Color coding for power wiring 12
common ground point 3, 8
Controlling emissions in digital system design 11
Controls power wiring 13
Data cables 16
differing potentials 7
Electrical and magnetic interference 2
electro-magnetically coupled 2
electro-static coupling 2
Eliminating noise coupling 10
"ground farm" 3
ground fault breakers 4
ground fault currents 4
ground plane 3
Grounding and shielding techniques 2
Grounding the shield 7
hardware grounds 5
If you have to use mechanical connections, be sure that the underlying
surface is conductive and is protected by a conductive finish that will
not degrade over time. Improperly made connections may work well in
a new installation but will be sources o 6
magnetically coupled 2
Mil std. crimper 6
Multiple grounds 5
noisy grounds 5
Other power cable specifications 15
Other wiring suggestions 17
Power line grounding 3
Power wire sizing for motor and motor drive system for Europe 15
Power wire sizing for motor and motor drive system for USA 14
preventing interference 2
process or signal common 4

Continued on next page

Rev: Produced by the K-Tron Institute

8502.20
Grounding, Shielding and Wiring Practices

Index, Continued

Reducing noise at the receiver 11

Resistances to ground 4
RF installations 8
sending high speed data signals 2
Shield requirements 8
Shielding 8
signal disruption 2
signal grounds 5
sources of EMI 8
sources of magnetic interference 8
Special shielding situations 8
Suppressing noise at its source 9
voltage drops 2

Rev: Produced by the K-Tron Institute

 8501
Proper Handling of Electronic Components

How to Correctly Handle

and Protect Sensitive
Electronic Components
and Assemblies

Rev: Produced by the K-Tron Institute

8501
Proper Handling of Electronic Components

No part of this publication may be reproduced or transmitted in any form or by any

means electronic or mechanical including photocopy, facsimile or computer generated
distribution without written permission from the K-Tron Institute. All translation
rights are reserved by the K-Tron Institute . The K-Tron Institute has made every effort
to ensure the accuracy and validity of this document. However, errors and omissions
may have occurred. If an error or omission is found, please contact the K-Tron Institute
at (609)589-0500.

Rev: Produced by the K-Tron Institute

 8501.1
Proper Handling of Electronic Components

Proper Handling of Electronic Components and

Assemblies

Overview

Introduction This chapter introduces the concepts for proper handling of electronic
assemblies. We will cover static damage issues. We will also provide
rules for carrying electronic assemblies about, and the problems of pc
board removal under power.

In this chapter
Topic See Page
Concepts of Static and its Damage Possibilities 2
Controlling Static Damage 3
Other Damage Issues 5
Index 6

Rev: Produced by the K-Tron Institute

8501.2
Proper Handling of Electronic Components

Concepts of Static and its Damage Possibilities

Concepts of Static electricity is caused by the attraction of a charged insulator and a

static conductive metal component coming in contact with one another. We
electricity have all been at home on a day with low humidity, walked across the
carpet and touched a doorknob. What happened? The small spark that
you saw or the jolt that you felt was static electricity. The voltage that
you saw or felt may have been more than 10,000 volts.

This same situation can result in physical damage to electronic

components. An electrical shock of only 50 volts may damage an
electronic circuit. In order to prevent or minimize damage to sensitive
electronic components, use of a wrist strap is required.

Concept of It is possible to cause what is referred to as incipient failure in an

incipient electronic component. This means that you have caused a failure but
failure the device is not totally failed. If a device fails for no apparent reason, it
means that it was likely damaged by poor handling some time prior,
maybe as long as 6 months ago.

To prevent failures from happening down the road, use proper

handling techniques for electronic components.

Rev: Produced by the K-Tron Institute

 8501.3
Proper Handling of Electronic Components

Controlling Static Damage

The use of the The wrist strap that is grounded will prevent damage to the electronic
wrist strap components when you handle them. The wrist strap, which is
grounded at one end, is worn on the user's wrist.

The following procedure describes how to use the grounding wrist

strap.

Step Action
1 Insure Velcro wrist strap is attached to the ground wire as
shown below

BLACK GROUND PAD

GROUNDING
LUG
VELCRO STRAP BUTTON
CONNECTOR

GROUND
WIRE

2 Place the Velcro strap around your wrist similar to a watch.

Note: Make sure the black ground pad is toward your skin
on the inside of your wrist
3 Tighten the strap and secure with the Velcro end.
4 Attach the ground wire to the frame of the equipment you
will be working with using the supplied nut and bolt.

Wrist strap Always secure the ground strap as described before picking up any
rule printed circuit boards

Continued on next page

Rev: Produced by the K-Tron Institute

8501.4
Proper Handling of Electronic Components

Controlling Static Damage, Continued

Checking Wrist straps can fail and then need to be replaced. To check a wrist
anti-static strap, touch a digital voltmeters probe to the conductive patch of the
wrist strap strap and the other probe to the terminal end which is attached to
ground. The resistance must be less equal to or less than 1,000,000 ohms
and greater than 47,000 ohms. If the resistance is greater than 1 meg
ohm, replace the wrist strap.

Rule: Replace wrist strap if end to end resistance is greater than 1 meg
ohm.

Grounding of The maximum resistance from the wrist strap ground connector to
wrist strap earth ground must be less than 100 ohms. Check to your system
ground.

Giving an You are grounded with your wrist strap. You hand the electronic
electronic device to a friend who is not grounded. What happens? You probably
component or damaged the device.
pc board to a
friend
Rule: All persons who handle sensitive electronic components must be
grounded with a wrist strap to the same ground plane.

Rev: Produced by the K-Tron Institute

 8501.5
Proper Handling of Electronic Components

Other Damage Issues

Preventing It is wrong to plug in and unplug electronic components when power is

surge damage applied. Power surges occur when this happens that can result in
circuit failure. These spikes of energy result in damage to sensitive
MOS devices used in current electronic technologies.

Rule: Always remove power before removing circuit boards from a

chassis.

Storage of If you store electronic components, particularly circuit boards, be sure

electronic that they are stored in anti-static bags. These bags prevent static
components damage. You can also handle the boards in the bags without special
precaution. To remove a board from a bag, you must be grounded by
wrist strap. Don't place the unprotected board (out of the bag) on a
plastic top table. Lay the board on an approved grounded mat or use a
piece of cardboard. Remember, certain circuit boards have batteries and
those batteries can be damaged if the board is laid on a metal top table.

Rule: To store electronic circuit boards, keep them in anti-static bags.

Handling Most electronic chassis can be handled without use of a wrist strap and
electronic can be placed on a metal table unless otherwise advised. However,
chassis high energy electricity can damage these devices. Never weld around
these devices or generate sparks from line power in their vicinity.

Rule: Never weld near an electronic control chassis.

Rev: Produced by the K-Tron Institute

8501.6
Proper Handling of Electronic Components

Index

Checking anti-static wrist strap 4

Concept of incipient failure 2
Concepts of static electricity 2
Giving an electronic component or pc board to a friend 4
ground plane 4
Grounding of wrist strap 4
Handling electronic chassis 5
Preventing surge damage 5
Static electricity is caused by 2
Storage of electronic components 5
The use of the wrist strap 3
Wrist strap rule 3

Rev: Produced by the K-Tron Institute

 Pricing Information Sheet
K-Tron Service, Parts Repairs and Training

K-Tron designs and manufactures equipment for long, reliable

operation. Like any precision device, your K-Tron equipment will
function best when it is installed, serviced and repaired by
factory-trained experts. All services are optional and may be
arranged by contacting the factory or your local K-Tron
representative.
Factory trained K-Tron technicians are strategically located
throughout the U.S. and many countries around the world.

Field Service
K-Tron provides three forms of field service: (1) Start-up Service,
technician. Technicians are on call 24 hours a day to answer
(2) Preventative Maintenance Service and (3) Emergency or
your questions. You may also use the hotline to place an
Field Repair Service. All services are available on demand at
emergency parts order.
our published hourly rates, plus parts and expenses.
Parts
Service Prices: K-Tron replacement parts meet the same high standards of
$111.00 per hour manufacture as your original K-Tron equipment. A list of recom-
$167.00 per hour overtime mended spare parts is provided to you whenever you purchase
$223.00 per hour Sundays and holidays K-Tron equipment. These are the essential parts that experience
plus transportation and living expenses shows, you should keep on hand to avoid costly shutdowns.

Travel Time Prices (door-to-door): Standard delivery time for in-stock parts is typically 24 hours.
$ 87.00 per hour Emergency delivery is also available at an additional cost to
$131.00 per hour overtime cover shipping and handling. Overnight delivery service is
$175.00 per hour Sundays and holidays available for $107. Airport counter-to-counter same day delivery
is $350 weekdays, $600 holidays and weekends. Same day
Travel Expenses: door-to-door is subject to location. Consult factory for same day
This includes all travel related out of pocket expenses incurred courier delivery cost, which typically runs $350-$1000.
during the service visit. These expenses will be itemized on the
invoice. K-Tron’s policy is $30 per diem for meals and $.585 per Repairs
mile. If the local area living expense is greater than the per Often factory repairs are more economical than field trouble-
diem amount, K-Tron will invoice for the amount of the meals. shooting and service. Typical repairs involve small items such as
Copies of all travel receipts are available upon request. circuit boards. Complete reconditioning of feeders and upgrad-
ing of scales can also be accomplished in the K-Tron factory.
Should you require our services, we will provide a factory trained
service engineer to service the equipment. K-Tron will provide Standard repairs are accomplished in three weeks and are billed
the purchaser with a written report following the visit, giving for time and materials per item. Labor is priced at $100 per hour.
details of the work carried out, parts replaced and consumable A 36-hour Rush program is available for a fee of $400 per time
materials used, together with any recommendations or com- and materials. Your repaired item will be shipped air express
ments. within 36-hours after receipt in our shop. A 72-hour Rush
program is available for a fee of $300 plus time and materials.
Fixed Price Start-up and Fixed Price Preventative Maintenance For many of our common repairs we have a standard repairs list.
services are also available at significant savings. Please
consult factory to request a quote for these services. Training Services & Tools
With the steadily increasing capabilities of K-Tron’s advanced
Telephone Support feeders and microprocessor-based control systems, operator and
Experienced and specially trained technicians are available to maintenance training has never been more important. The
answer your questions by phone. K-Tron’s telephone support K-Tron Institute of Technology (KIT) provides basic and advanced
technicians make extensive use of simulators to identify and training for volumetric and gravimetric feeder equipment and
understand your exact problem. Often speedy solutions can be controls, including operating and maintenance procedures.
found while you are still on the phone. We have found Classes are held regularily at the K-Tron Institute Training Center
telephone support especially effective for customers who have in Pitman, NJ. On-site training at your plant is also available.
sent their maintenance people to classes at the K-Tron Institute
The K-Tron Institute also offers tools and software to help you
of Technology and also when they maintain the recommended
optimize your feeder performance. Visit our website at :
level of K-Tron spare parts.
ktron.com/training_institute.
In North America call the Technical Assistance Hotline at 856-
For more information on the K-Tron Institute please call (856)
589-9083 during normal business hours (Eastern time zone).
256-3267.
Calling the same number after hours, on holidays and weekends
will get you to our answering service who will page a service

Distribution Date: Replaces: 02900000503 EN

July 29, 2008 January 16, 2008
 Pricing Information Sheet
K-Tron Service, Parts Repairs and Training

Purchaser Responsibility K-Tron Liability

The purchaser agrees to maintain and make freely available K-Tron liability is limited to the original purchase price of the
to the service engineer a record of all breakdowns and K-Tron product. The foregoing warranty is in lieu of all other
stoppages occurring on the equipment, together with a warranties or guarantees expressed or implied and of all other
record of all maintenance carried out. obligations or liabilities on the part of K-Tron whether in contract
or in tort. Under no circumstances will K-Tron be responsible
The purchaser will notify K-Tron before the visit of the site for any consequential or contingent damages due to errors in
safety regulations and procedures which the service engi- weighing.
neer is to observe. This includes any required pretesting,
facial hair restrictions or secrecy agreements. Terms
Customers with approved open accounts can use purchase
The purchaser will give the service engineer free and safe order numbers with net 30 day payment terms. POs are
access to the equipment. In the event that access to the required prior to the arrival of the service engineer. We accept
equipment is denied through no fault of the service engineer, Visa, Mastercard and American Express. For customers without
or for reasons entirely beyond his control, then the purchaser an account or credit card; payment in advance is required.
will reimburse K-Tron at the specified rates.
Nothing contained in this agreement shall be deemed to vary or
The purchaser will designate a “maintenance coordinator” as modify the rights or obligations of either party under any existing
the person who is appointed by the purchaser to coordinate agreements or contracts between them. Nothing contained in
all aspects of this service visit and is assumed to have the this agreement in any way invalidates or replaces the guaran-
authorization to request additional work to be performed. tees or warranties made by any supplier with respect to new
The purchases is also responsible to provide a knowledge- equipment.
able person to assist the service engineer in describing the
exact operation of the equipment and any process control
interfaces to a host system or auxillary equipment.

All electrical equipment furnished under this contract shall

conform to the latest applicable standards of the National
Electrical Code as recommended by the National Fire
Protection Association. However, when state, country,
municipal or local power company electrical codes may take
precedence, it shall be brought to the specific attention of
K-Tron for proper consideration. Electrical equipment for use
in Canada shall be manufactured under Canadian Standards
Association recommendations, but again, where provincial,
municipal, or local power company electrical and safety
conditions differ, it must be brought to the specific attention
of K-Tron.

K-Tron service engineers do not belong to a labor union

organization. The purchaser will make any arrangements
required with the local unions for the service engineer to
work on the equipment.

K-Tron America
Routes 55 & 553
Pitman, NJ 08071
Phone (856) 589-0500
Fax (856) 589-8113
www.ktron.com

Covered by Patents in the U.S.A. and Foreign Countries. Specifications subject to Change Without Notice. Printed in the U.S.A. 0290000503 EN
 4022
LWB Control Theory for KCM

K-Tron Loss-in-Weight
Batch (LWB) Control in the
SmartConnex II System
(KCM)
KCM SW version 1.4 and earlier

Rev: Produced by the K-Tron Institute

4022
LWB Control Theory for KCM

Rev: Produced by the K-Tron Institute

 4022
LWB Control Theory for KCM

“No part of this publication may be reproduced or transmitted in any form or by any
means electronic or mechanical including photocopy, facsimile or computer generated
distribution without written permission from the K-Tron Institute. All translation
rights are reserved by the K-Tron Institute . The K-Tron Institute has made every effort
to ensure the accuracy and validity of this document. However, errors and omissions
may have occurred. If an error or omission is found, please contact the K-Tron Institute
at (856)256-3267.

Information in this manual is correct as of the date of publication. K-Tron assumes no

responsibility for damages resulting from misuse of the equipment or negligence on the
part of operating personnel.”

Rev: Produced by the K-Tron Institute

4022
LWB Control Theory for KCM

Table of Contents

Loss-in-Weight Batch Control for the SmartConnex II System............................................. 1

Overview ............................................................................................................................... 1
LWB Control Theory of Operation.................................................................................... 2
Mechanical Disturbances (PERT) ...................................................................................... 7
Feedfactor.............................................................................................................................. 9
Index ............................................................................................................................................ 11

Rev: Produced by the K-Tron Institute

 4022.1
LWB Control Theory for KCM

Loss-in-Weight Batch Control for the SmartConnex II

System
Overview

Intro
This section discusses how the control system works in loss-in-weight
batch systems using the SmartConnex II(KCM)architecture.

Definitions
Please use the following definitions.

Abbrev. Function
FF Feedfactor in weight units/time – Like massflow

Feedfactor represents the feedrate capacity of the

batcher when the drive command is at 100%. It is
the rated capacity of the discharge device
FT Time in seconds the unit is in Fast run mode

FT = BT-DT
DT Time in seconds the unit is in Dribble run mode
PT Preact, in motor speed feedback pulses (which can
be converted to time) is the result of two preact
values. Preact1 comes between the Fast and the
Dribble cycle to ensure that the batch time is met.
Preact2 is the interval after Dribble that ensures the
batch weight target will be met. With vibratory
equipment, drive command pulses are used.
BT Total batch time in seconds
FM Material fed in Fast mode
DM Material fed in Dribble mode
PM Material fed during Preact. This is a learned value
that comes from running the process.
TM Total material fed during delivery
BZ Batch size setpoint
BW Batch Weight at any point in time
DC Actual drive command

Rev: Produced by the K-Tron Institute

4022.2
LWB Control Theory for KCM

LWB Control Theory of Operation

Intro
This section will discuss the details of how the LWB controller controls
during the batch sequence.

LWB operation
This is a discussion of batch operation. The focus is on Gravimetric
control where batch time and feedfactor are updated after each batch
complete.

To have the system deliver the desired quantity of material in the Batch
Time, it is necessary to first perform a Feedfactor calibration so that a
viable average Feedfactor (FF) is available for use in the batch time
calculations.

The delivered batch weight is constantly being compared to setpoint

and when the batch weight comes to a value represented by FM, the
unit will switch to Dribble mode and then when the Actual Batch
Weight –BW- reaches the Batch Setpoint, the unit will stop.

Here are a few formulas that will develop the theory.

FT ≈ BT – DT, the batching time (in seconds) during the fast cycle.

The quantity of material that will be delivered during the cycle is:

TM = FM + DM + PM

Therefore, the material delivered during each portion is as follows;

FM = FF*FT*(DC/100)/k,
DM = FF*DT*(DC/100)/k
PM = is estimated based upon past experience in material delivery

The factor “DC/100” is the de-rating value for the actual drive
command selected.

Where k = 3600 if the FF time unit is hours and 60 if the FF time unit is
minutes.

Continued on next page

Rev: Produced by the K-Tron Institute

 4022.3
LWB Control Theory for KCM

LWB Control Theory of Operation, Continued

LWB operation, con’t

Since PT is unknown at the beginning, the first batch time value may be
slightly larger than the Batch Time setpoint. But the actual batch weight
should still be near the setpoint. Until the amount of material that
comes from the batch ending period is known, the dribble time cannot
be reduced so that the batch time and batch weight will not overrun.

Certain situations arise when in Gravimetric control. When the drive

command value is changed by the operator, this action automatically
changes the batch time.

Likewise, when the fast Drive Command is changed, the Total Batch
time changes. When the Dribble Drive Command changes, the Batch
Time or Fast Drive Command changes. When the Dribble Time is
changed, the Batch Time or Fast Drive Command changes. These last
two conditions are based upon operator preference.

Operator preference is defined as whichever parameter was last

changed by the operator: Batch Time or Fast Drive Command, the other
parameter will change while trying to keep the operator entered value
fixed.

When the Batch Time changes, the Fast Drive Command will change.

This is based upon the premise of

FF = (MF/DC)*100%

where MF is the current massflow and DC is the drive command used

to achieve that massflow value.

Continued on next page

Rev: Produced by the K-Tron Institute

4022.4
LWB Control Theory for KCM

LWB Control Theory of Operation, Continued

Some rules
These are a few rules that are imposed on LWB control when in
Gravimetric control.

• Increasing Dribble Time increases Fast Drive Command

• Changing Feedfactor changes Fast Drive Command
• Increasing Batch Setpoint increases Fast Drive Command
• Feedfactor and Batch Time or Fast Drive Command updates or
changes after each batch based upon operator preference as
defined earlier.

The following diagrams give a clue as to what happens at various

points in the batch cycle. The stop period before commencing the batch
must be stable so that an accurate weight start reference point can be
determined. At the end of the batch, the same request for stable weight
also occurs before the final batch weight is posted and a batch complete
is given.

Continued on next page

Rev: Produced by the K-Tron Institute

 4022.5
LWB Control Theory for KCM

LWB Control Theory of Operation, Continued

Diagrams of operation

Dribble Drive
Batch Weight Delivered Command Stop

Fast Drive Command

Stop

Batch Time - seconds

In the following diagram, the bulk of the material is delivered during

the fast cycle. The dribble cycle must be long enough and at a low
enough drive command to minimize weight overshoot.

Fast Drive Command

Drive Command -%

Dribble Drive
Command

Stop Stop

Batch Time - seconds

Continued on next page

Rev: Produced by the K-Tron Institute

4022.6
LWB Control Theory for KCM

LWB Control Theory of Operation, Continued

Diagrams of operation, con’t

In this exaggerated view, there is a slight overshoot that will be learned

by the controller to adjust the final cut-off point for dribble.

Dribble Drive
Command Stop

magnified view at
completion
Batch Weight Delivered

Fast Drive Command

over feed due

to inertia and
system
dynamics

Stop

Batch Time - seconds

Rev: Produced by the K-Tron Institute

 4022.7
LWB Control Theory for KCM

Mechanical Disturbances (PERT)

Intro

This section discusses the issues of mechanical disturbances.

PERT
When vibration disturbances exist at the batcher location, the
control system will announce this using the message of PERT. This
message represents a perturbation or disturbance caused by excessive
mechanical noise to the weighing system.

What happens
when the
system is in
PERT?
When the system is frequently in a condition of PERT, certain variables
that would normally be updated during normal gravimetric operation
are not being updated. The following table indicates which parameters
are being updated or controlled and which ones are not when the
Adaptive Tuning is 'ON' and the system is in a condition of PERT.

Variable Condition during PERT

Displayed Mass Flow Remains at its current value
Feed Factor Average unchanged

Continued on next page

Rev: Produced by the K-Tron Institute

4022.8
LWB Control Theory for KCM

Mechanical Disturbances (PERT), Continued

Reducing
occurrence of
PERT
Ideally when the problem of excessive mechanical vibrations exists, the
solution would be to isolate the batcher from the vibration disturbances.

Possible reasons for PERT message are:

√ Poor installation of K-Tron batcher

All K-Tron batchers come equipped with rubber shock mounts to
help isolate mechanical noise. They must be installed.

√ Rigid connections at batcher

Caution must also be taken to maintain flexible connections at the
entrance and output of material flow to the K-Tron batcher.

√ Leaking refill valve

The refill valve should completely close when not in refill.

In some conditions where the mechanical disturbances are excessive

and cannot be resolved mechanically, you may need to manually tune
the control system. It is always suggested that everything be done to isolate
vibration noise from the K-Tron feeding system.

Rev: Produced by the K-Tron Institute

 4022.9
LWB Control Theory for KCM

Feedfactor

Intro
This section describes the Feedfactor calculation and how it is used in
the K-Tron Loss-in-Weight batch control model.

Feedfactor
calculation
The feedfactor is defined as the relationship between the output
massflow and the drive command . This value is used in both mass and
volumetric control modes to determine the drive command. The current
feedfactor is the estimated massflow (in engineering units) at 100%
drive command. The actual calculation is:

Feed Factor = (Mass Flow/Drive Command)*100

Where drive command is in % of reading and mass flow is taken at that

value of drive command.

Feedfactor is simply the feedrate capacity of the batcher.

And therefore:

Max Batch setpoint = (FeedFactor/k)*Batch time sec or

Minimum Batch time sec =k* (Batch Setpoint)/FeedFactor

Where k = 3600 ( FF in hour units) or 60 ( FF in minute units)

When is
feedfactor
calculated?
The feedfactor is calculated during gravimetric (mass) mode and is
updated while the batch is running. Therefore, any changes in the
material handling characteristics or density of the material will be
reflected in the feedfactor value. At batch complete, the newly
calculated feedfactor will update batch parameters, either Batch Time or
Fast Drive Command is changed by the software. The last of either of
these two values entered by the user is retained.

Continued on next page

Rev: Produced by the K-Tron Institute

4022.10
LWB Control Theory for KCM

Feedfactor, Continued

What does the

feedfactor tell
us?
What does feed factor tell us? While the units of feed factor are not
displayed but are inherently the units of mass flow, clearly, it gives us
the full scale estimated flow rate capacity of the batcher with the
material being metered. It also tells us what feedrates might be
achieved and what rates probably cannot be achieved. With this
information and the desired batch time, we can uncover the probable
maximum batch delivery value. Variations in feed factor over a period
of time give us an idea of what is happening to the flow ability and
density of the product being metered.

If a material was metered and its feedfactor was less than the desired
value to deliver the batch setpoint in the desired time, what does that
tell us to do about the mechanical components of the batcher? This
situation shows the value of using Feed Factor Calibration as a starting
point when feeding new materials.

What does
preact 1 and
preact 2 mean?
Preact 1 is the number of motor speed pulses in three parts total. They
are (1) number of pulses in the transition from fast to dribble, (2) pulses
in dribble, and (3) pulses in the transition from dribble to stop.
The primary reason for preact 1 is to get the batch time and dribble time
correct.

Preact 2 is the number of motor speed pulses in only the transition from
drib to stop. The reason for preact 2 is to get the batch as accurate (mass
accuracy) as possible.

Typical values could be preact1=6000 preact2=300

Rev: Produced by the K-Tron Institute

 4022.11
LWB Control Theory for KCM

Index

Definitions, 1 Feedfactor calculation, 9

Feedfactor calculation, 9 LWB operation, 2
Messages Some rules, 4
PERT, 7 What does the feedfactor tell us?, 10
Servicing What happens when the system is in PERT?, 7
Reducing occurrence of PERT, 8 When is feedfactor calculated?, 9
Theory What does the feedfactor tell us ?, 10
Diagrams of operation, 5 When is feedfactor calculated, 9

Rev: Produced by the K-Tron Institute

Chapter 10:
Spare Parts
 85
KCM Spare Parts List

K-TRON SPARE PARTS LIST FOR

KCM

Rev. B
 85
KCM Spare Parts List

Table of Contents

Overview ....................................................................................................................................................................1
Components................................................................................................................................................................2
Overview ...............................................................................................................................................................2
Cover Assembly ....................................................................................................................................................3
Cover with Keypad...........................................................................................................................................3
Cover with status LED .....................................................................................................................................4
Power Board Assembly .........................................................................................................................................5
Fuses.................................................................................................................................................................6
Optional Components.................................................................................................................................................7
K-Port Communication Board...............................................................................................................................7
Strain Relief and Hole Plugs .................................................................................................................................7
K-Prom (0000001744) ..........................................................................................................................................8
SFT Expander Board (Part Number 0000003411 KCM 3X SFT Board) .............................................................8
Daisey Chain Connector........................................................................................................................................8
Encoder Interface Card (Part Number 0000006384).............................................................................................8
Host Interface ........................................................................................................................................................9
Field Wound DC Motor Supply (PN 0000000639) ..............................................................................................9
Software....................................................................................................................................................................10
PC Software.........................................................................................................................................................10
Reference Documentation ........................................................................................................................................11

Note:

This document is general information related to K-Tron Equipment and should be used in conjunction with the K-
Tron Engineering Specifcation Sheets provided with the equipment. This document may not contain information
and pricing for custom or “project level” parts. Many of the options listed in is manual may not be currently on
your feeder, but can be added if required.

To assist in selecting spare parts to stock onsite, the following Capital Letter codes are used and apply to all Spare
Part Manuals:
A Critical Mechanical Item
B Critical Electrical Item
C Recommended Part be inspected and replacement if worn during Preventitive Maintenance
Program every 9000 runtime hours or every 2 years which ever is first.

All notes in lower case are defined in later sections and only apply to this manual

Rev. B
 85.1
KCM Spare Parts List

KCM
Overview
The KCM is a part of the Smart Connex family of multifunctional controller for K-Tron equipment. The KCM
includes hardware and software to control a single feeder. The SCM Enclosure is a Nema 4/IP-65 and is designed
for field mounting and in most cases will be mounted on the feeder with short connections to feeder SFTs, and
velocity sensors.

Depending on the options selected, the KCM may include a motor drive, Host Communications daughter board,
Internal Channel Board and expandable I/O Modules.

KCM is avalible with an intergrated Keypad and Display or only status LEDs. The status LED version requires
an external operator interface. The KCM with intergrated Keypad and Display can be used a stand-alone system
or intergrated with a external display.

KCM with Keypad and Display

KCM with Status LED

Rev. B
85.2
KCM Spare Parts List

Components

Overview
The KCM Assembly consists of two items. The CPU and Cover Aseembly is avalible with Keypad and Display
and LED status indicators. The Motor Drive assembly consists of the lower housing and a feedr module drive
board.

The Complete assembly consists for selecting the Cover and Motor Drive. The hinge hardware and
interconnection cable is included with the Cover Assembly. Option K-Tron Interface (K-Bus) and Host
communcaition boards are optional and must the listed separately.

1 CPU Board
2 Motor Power Board
3 K-Port COmmuncation Board
4 Host Communcation Interface
5 K-Prom

Rev. B
 85.3
KCM Spare Parts List

Cover Assembly
The Cover includes the bezel, laminaite, and CPU board with software. The KCM was two Cover Assemblied.
Option K-

Cover with Keypad

Seq Part Number Eng. Description Qty Note

0000004041 Entire Assembly B,a,b
* Includes K-Prom Board (0000001744)

Individual Components
1 000002618 Bezel 1
2 000002457 Laminate 1
5 0000003660 Gasket 1 C
6 0000004038 SealScrew, Captive M5 x 16 4
8 0000001741 CPU Bpoard 1 B
9 0000004040 VF Display 1 B
12 0000004393 Gound Wire 1
0000001744 K-Prom 1 Not Shown
Notes
a Optional K-Port Communication Board, SFT expander, or Host Communcation boards are not
listed. These boards are shown in the section on Optional Components.
b Includes empty K-Prom Board (0000001744). If replacing existing board, transfer the K-Prom
from the orginal board to retain programming.

Rev. B
85.4
KCM Spare Parts List

Cover with status LED

Seq Part Number Eng. Description Qty Note

0000004042 Entire Assembly B,a,b
* Includes K-Prom Board (0000001744)
Individual Components
1 0000002619 Bezel 1
2 0000004037 Bushing 2
3 0000003660 Gasket 1 C
4 0000004038 SealScrew, Captive M5 x 16 4
5 0000001741 CPU Board 1 B
8 0000002608 LED Status Board 1 B
9 0000002851 Laminate 1
10 0000004393 Gound Wire 1
-- 0000001744 K-Prom 1 Not Shown

Notes
a Optional K-Port Communication Board, SFT expander, or Host Communcation boards are not
listed. These boards are shown in the section on Optional Components.
b Includes empty K-Prom Board (0000001744). If replacing existing board, transfer the K-Prom
from the orginal board to retain programming.

Rev. B
 85.5
KCM Spare Parts List

Power Board Assembly

The Power Board includes lower housing and Motor Drive Boards

Power Board Assembly Board Notes

Part Number Part Number
450 Watt DC Motor 0000004179 0000007405 B; Max 450 Watt Motor at 180
VDC or Max 225 Motor Watt at
90 VDC
1600 Watt DC Motor 0000004180 0000002610 B; Max 1600 Watt at 180 VDC,
or Max 800 Watt at 90 VDC
Vibratory Drive 0000004324 0000000684 B, K1, K2, K3
AC Motor Interface 0000004323 0000003413 B; No motor drive provided,
only interface to external drive
Stepper Motor (60 Watt) 0000004178 0000004178 B; 24 VDC at 2.5 Amps
Stepper Motor (40 Watt) 0000001430 B; 24 VDC at 1.5 Amps
Stepper Motor (120 Watt) 0000005987 B; 48 VDC at programmable 1.5
or 2.5 amps

Rev. B
85.6
KCM Spare Parts List

Fuses
There are 2 fuses mounted on the Power pc board. The location for each board is shown
below

0000002610 1600 Watt DC Motor Drive

F1/F2 9289611150 Fuse 5x20 12.5 Amp

0000007405 450 Watt DC Motor Drive

F1/F2 9289611090 Fuse 5x20 6.3A

0000000684 Vibratory Drive

F 9289611020 Fuse 5x20 2A

0000003413 AC Motor Interface

F1/F2 9289611090 Fuse 5x20 6.3A

0000005987 Stepper Motor Drive

F4 9289611020 Fuse 5x20 2A

Rev. B
 85.7
KCM Spare Parts List

Optional Components

The following items are also avalible for the KCM.

K-Port Communication Board

The option allows the KCM to communicate with external K-Tron Interfaces or expansion I/O. Part Number
0000001737.

Strain Relief and Hole Plugs

The SCM uses the following strain relief to protect and seal the entry points for the cabling.

Part Number Eng. Description Qty Note

9114000530 BSHG SHLD PG9 5-7MM ID STL *
9114000370 BSHG SHLD PG9 7-10MM ID STL *

Hole Plug and O-Ring

0000004130 Hole Plug M16 11
0000004131 O-Ring M16 Hole Plug 11
0000004126 Hole Plug M20 3
0000004127 O-Ring M20 Hole Plug 3
0000004132 Hole Plug 1/8 BSP 2

Rev. B
 85.8
KCM Spare Parts List

K-Prom (0000001744)
The KCM uses the K-Prom board to store all feeder configuration data. If the CPU board is replaced the existing
K-Prom should be moved to the new controller and all configuration data will be restored. Please consult K-Tron
technical support if moving a K-Prom to a CPU board with different version of software

SFT Expander Board (Part Number 0000003411 KCM 3X SFT Board)

This board is used the 450 Watt DC Motor drive board. This allows easy wiring of three SFTs to the existing
terminal connections.

Daisey Chain Connector

This connector fits the K-Port Connection and allows daisey chaining of devices.

Encoder Interface Card (Part Number 0000006384)

Differental Speed signals from a Scale Interface Board are converter to single ended inputs for KCM drive boards.

Rev. B
 85.9
KCM Spare Parts List

Host Interface
These boards are used in the Host Interface slot to provide the KCM with communication abilites to other devices.

Part Number Eng. Description Note

0000005108 KCM, PROFIBUS DB MODULE
0000005105 KCM, DEVICENET MODULE
0000005107 KCM, MODBUS PLUS MODULE
0000005106 KCM, ETHERNET IP MODULE
0000005108 KCM, PROFIBUS DB MODULE
0000001737 KCM COMMUNIKATIONS BOARD RS232/RS485 Host
Interface

Field Wound DC Motor Supply (PN 0000000639)

This device is used for the Supply for Field Wound (non-permentent magnet) DC Motors. THis is the board only
to replace unit provide in external junction box.

Rev. B
85.10
KCM Spare Parts List

Software

PC Software
This section lists the PC software available for the SCM. This software requires PC with a RS232 Com Port to
interface to the SCM controller.

Part Number Eng. Description Note

0031700080 DISK FA SCM LOADER UTILITY p
0019700610 S/W PC K-LCD/K-LINK r
Notes:

Description
p This only includes the loader program LOADER.EXE
(SW PN 9700 20970). This disc does NOT include the
latest software. See next section of application
software information.
r This disc contains the PC software required to
configure and install the host communications.
9700202300 KGRSEND.EXE
9700201040 KLCONFIG.EXE
9700201420 MODBUS.EXE
9700201240 ABCONFIG.EXE
9700201400 TESTAB.EXE
9700201340 SIECONFIG.EXE
9700201410 SIEMEMS.EXE

Rev. B
 85.11
KCM Spare Parts List

Reference Documentation

Part Number Eng. Description

DCS8501 Handling Electronics
DCS8502 Proper Grounding Connections

0490020605 KCM Electronics

DCS7507 Smart Link Data Variables
DCS414 Smart Connex Feeding Overview
DCS4010 LWF Control SmartConnex
DCS4011 PID Control SmartConnex
DCS4012 LWB Control SmartConnex
DCS4010 WBF Control SmartConnex

0590020609 DeviceNet Host Interface

0590020607 Proibus DP Host Interface
0590020608 Modbus Plus Host Interface
0590020610 Ethernet/IP or Ethernet/Modbus Host Interface
0490020605 Modbus RTU or Allan Brday DF1 Host Interface

Rev. B
 79-EN
KT20 Feeding Module Spare Parts Manual

K-Tron Spare Parts List for

KT20 Feeding Module

Rev. D
 79-EN
KT20 Feeding Module Spare Parts Manual

Table of Contents

Overview............................................................................................................................................................... 1
Gearbox................................................................................................................................................................. 2
Gearbox Assemblies ........................................................................................................................................ 2
Gearbox Components....................................................................................................................................... 3
Screw and Tube..................................................................................................................................................... 7
Twin Screws .................................................................................................................................................... 7
Discharge Tubes ............................................................................................................................................ 10
Flexes and Caps ............................................................................................................................................. 12
Screw Drive Motors............................................................................................................................................ 13
Motor Brushes................................................................................................................................................ 13
KCL Motor .................................................................................................................................................... 14
Speed Pickup Retrofits................................................................................................................................... 15
Horizontal Agitator ............................................................................................................................................. 16
Feeding Bowl ...................................................................................................................................................... 17
Special Options ................................................................................................................................................... 18
Hinge Kit........................................................................................................................................................ 18
Inline Reducer................................................................................................................................................ 19
Reference Documentation................................................................................................................................... 20

Note:

This document is general information related to K-Tron Equipment and should be used in conjunction with the
K-Tron Engineering Specifcation Sheets provided with the equipment. This document may not contain
information and pricing for custom or “project level” parts. Many of the options listed in is manual may not be
currently on your feeder, but can be added if required.

For Price and Availability information, please refer to the Spare Part Price List or contact your local K-Tron
representative or office for details.

To assist in selecting spare parts to stock onsite, the following Capital Letter codes are used and apply to all
Spare Part Manuals:
A Critical Mechanical Item
B Critical Electrical Item
C Recommended Part be inspected and replacement if worn during Preventitive Maintenance
Program every 9000 runtime hours or every 2 years which ever is first.

All notes in lower case are defined in later sections and only apply to this manual.

Rev. D
 79.1
KT20 Feeding Module Spare Parts Manual

KT20 Feeding Module

Overview
The KT20 screw feeder module is designed to handle a wide range of feeding applications. This module
consists for several sections. This is manual is for a K-T20 or KCL-T20, but does NOT include the K2-T20 or
the KML-T20.

The feeding module consists of the following components:

A Gearbox
B Feeder Bowl (12 liter chown)
C Horizontal Agitator
D Feeding Screws
E Discharge Tubes (Vertical Discharge shown)
F Motor
G Scale (KCL – D5 Scale Show, other configuration is with KSFT shown below)
H Options (Pressure Balance Discharge Shown)

Rev. D
79.2
KT20 Feeding Module Spare Parts Manual

Gearbox

The gearbox provides a connection between the motor and the feeding screws and optional horizontal
agitators.

This Gearbox is available for NEMA or IEC motors. NEMA motor mounting bolts are inserted from the
inside of the gearbox and threaded into the motor. The IEC version motors are mounted with the bolts passing
through the motor flange and threaded into the gearbox casting. Most feeders manufactured in North America
have NEMA Motors.

K-Tron offers several reductions as shown below:

Gearbox Reduction Screw Speed @

2000 Motor RPM
A 2.68:1 746
B 5.60:1 375
C 12.95 154

Gearbox Assemblies
The gearbox assembly does not include the motor, motor housing, agitator bearing, or agitator drive gear
assembly. These gearboxes ship with Oil and a shipping cap. Gearbox holds 120 ml of MobilGear 634

The Shipping cap should be removed and replaced with a breather plug.

Seq Part Number Eng. Description Qty Note

0213000150 T20 SA GRBX RED A 2.68:1 *B 1
0213000160 T20 SA GRBX RED B 5.60:1 *B 1
0213000170 T20 SA GRBX RED C 12.95:1 1

Rev. D
 79.3
KT20 Feeding Module Spare Parts Manual

Gearbox Components
This section reviews the individual components of the gearbox.

Cross Sectional View of the Gearbox

(Shown without Horizontal Agitator Gear)

Rev. D
79.4
KT20 Feeding Module Spare Parts Manual

Seq Part Number Eng. Description Qty Note

5.10 9522303030 T20 INTERMEDIATE GEAR SHAFT 1
5.11 SPACER * d, Size to fit
9522303070 T20 GEARBOX SPACER 1 d
9522303080 T20 GEARBOX SPACER 1 d
9522303090 T20 GEARBOX SPACER 1 d
5.12 9359401490 M8X155 SCREW 2
5.13 9438700110 KEY 5X5X25 D6885A STL 2 9438-40130
5.14 9114000190 BUSHING 2 9114-40005
5.15 9522-30299 SCREW DRIVE SHAFT PAIR 1 e
5.16 9522309280 T-20 OILITE BEARING 2
5.17 9303000650 CRESCENT RING # 5103-62 2 9359-42614
5.18 9324000070 FLOROCARBON SEAL #AR600226 2 9324-40070
5.19 9324000010 GSKT SCR FDR T20 SILICON WHT 1 f , 9578-26890
5.20 9324300010 GASKET TO T20 GEARBOX 1
5.21 9524400000 OIL BREATHER PLUG 1 Sightglass
5.22 9107000050 BEARING 12/28/8 #6001 STEEL 1 9107-40001
5.23 9522303060 T20 GEARBOX SPACER 1 d
5.24 9703-40001 SPACER 1 g
5.25 9522000190 T20 GEARBOX SPACER 1 9522-26344
5.26 9620000060 OIL BREATHER PLUG 1 Installed onsite
5.27 9522303000 T20 PINION GEAR 1
5.28 9522303050 T20 GEARBOX SPACER 1
5.29 WORM GEAR DRIVE SET *
9338000340 WORM GEAR SET T20 ''A'' 2.68:1 1 9522-30295
9338000350 WORM GEAR SET T20 ''A'' 5.60:1 1 9522-30296
9338000360 WORM GEAR SET T20 ''A'' 12.95:1 1 9522-30297
5.31 9107000050 BEARING 12/28/8 #6001 STEEL 1 9107-40001
5.39 9324000060 SEAL 14/30X7 T20 1 9324-41006
5.40 9324000050 T-20 GEARBOX SEAL 12X28X7 1 9324-41005
5.41 SUPPORT BEARING ASSEMBLY
9107000070 BRG 10/30/9 FAG 7200-BTVP 1 9107-40001
9303000020 SNAP RING 30 INTL DIN 472 1
9107000030 INNER RING 10/14X13 1
5.42 9107001030 BRG BALL 6000 2RS 10X26X8 1 9107-40000
5.59 9303000010 SNAP RING 28 INTL DIN472 1 9359-42220
5.60 9338000030 T/20 PINION GEAR 1
5.72 9170000020 MOBIL GEAR OIL SHC 634 120ml 9790-40004

Notes:
d Spacer Dimensions: P/N Outside Inside Thickness
Dia (mm) Dia (mm) (mm)
952230306 25.9 14 1.5
952230307 27.9 19 0.13
952230308 27.9 19 0.20
952230309 27.9 19 0.25
e Screw Drive Shafts – Must be order together
9522003810 T20 SCREW DRIVE SHAFT R/H
9522003820 T20 SCREW DRIVE SHAFT L/H
f This seal is WHITE SILCONE. For high abrasive applications, BLACK VITON is available;
P/N 958530413
g Items 23 and 24 replaces 9703000090 DISC SPRING 25.8/19.3X0.3 K3*D

Rev. D
 79.5
KT20 Feeding Module Spare Parts Manual

Optional Horizontal Agitator Support

Back Cover For Horizontal Agitator

Rev. D
79.6
KT20 Feeding Module Spare Parts Manual

Seq Part Number Eng. Description Qty Note

5.07 9585701280 COV DRIVE AGIT KCLKT20
5.08 9512711600 PLATE DRIVE AGIT GRY KCLKT20 1
5.43 9303000130 CAMLOCK LATCH 51L1-1-1AA 1
5.45 9522263430 WSHR BACK-UP D16X30X2 2 d
5.46 9303700200 RET RING BORE 42MM DIA D472 ZP 2
5.47 9324000110 T20 SEAL 20X36X8 BEARING HOUS 2
5.48 9324000120 SPCR RND 36ODX26IDX3 T20 1
5.49 9324000080 T20 DELRIN SEAL BRG HOUS. 1
5.50 9324000020 GSKT RND 42.5ODX25IDX6 T20 1
5.51 9107700150 BRG BALL 20/42 X 12 2-SEALS 2
5.53 9522272400 NUT CAP M6X20 1
5.54 9324000020 GSKT RND 42.5ODX25IDX6 T20 1
5.55 9522303030 T20 INTERMEDIATE GEAR SHAFT 1 d
5.56 9338000000 GEAR AGIT SCREW FEEDER T20 1
5.57 9438000000 KEY 5X5X16LG DIN 6885 1
5.58 9522000230 T20 SPACER 1
5.67 9359005510 SCR HEX M8X1.25X155 D931ST 1
5.68 9620700230 PIPE PLUG THD PG9 BRASS NP 1
5.69 9585001970 PLUG DOME 3/8 NYLON BLK 1

Notes:
d Agitator Shaft without snap rings (item 5.45) use Shaft Part Number 9522000110

Rev. D
 79.7
KT20 Feeding Module Spare Parts Manual

Screw and Tube

Twin Screws
Twin-screw feeders have two screws make up the metering device that transports the material from the hopper
to the process. The material fills the gap between the screws and between the screws and tube wall and is then
pushed through the tube.

Twin screws are designated by their type and pitch and length. The three basic types of twin screws are
concave (B), auger (C), and spirals (A). The concave and auger screws are closed flight. The spirals are an
open flight style of screws. Special screw configurations are available for handling difficult powders.

Coarse Pitch is often referred to as Profile A or Profile 1. Fine Pitch is often referred to as Profile B or Profile
2. For concave screws, Pitch is measured between two flights. For Spiral and Augers, Pitch is measured
between neighboring flights.

Rev. D
79.8
KT20 Feeding Module Spare Parts Manual

Screws with outboard bearing have a bearing support extension. This extension is 4.9 inches and is in addition
to the total length (TL) listed for the screws. Outboard bearing screws require a Tube with outboard bearings.

Screw Nomenclature

Code Description
SCR Screw
OB Includes Outboard Bearing Support
CC Concave Course
CF Concave Fine
AC Auger Course
AF Auger Fine
SC Spiral Course
SF Spiral Fine
20MM Screw Diameter is approx. 20 millimeters
STD Standard Length Screw
E50 Extended 50 mm passed standard length
TL Total Length of screw in inches not
including the outboard bearing support

Rev. D
 79.9
KT20 Feeding Module Spare Parts Manual

All Dimensions are in MM

Part Number Eng. Description TL Dia Pitch Note
Concave / Twin Screws:
9528701950 SCR SET 20MM CC STD KT20 252 20 20 s
9528701960 SCR SET 18.5MM CF STD KT20 252 18.5 10.9 s
9528702030 SCR SET 20MM CC E50 KT20 302 20 20 s
9528702040 SCR SET 18.5MM CF E50 KT20 302 18.5 10.9 s
9528702130 SCR SET 18.5MM P3 STD KT20 252 18.5 5.5 s
9528702270 SCR SET 18.5MM P3 E50 KT20 302 18.5 5.5 s
Auger / Closed Flight Screws:
9528701970 SCR SET 20MM AC STD KT20 252 20 27 s
9528701980 SCR SET 20MM AF STD KT20 252 20 7 s
9528702050 SCR SET 20MM AC E50 KT20 302 20 27 s
9528702060 SCR SET 20MM AF E50 KT20 302 20 7 s
Reduced Dia Auger / Closed Flight Screws:
9528702010 SCR SET 12MM AC STD KT20 255 12 20 s
9528702020 SCR SET 12MM AF STD KT20 255 12 10 s
9528702090 SCR SET 12MM AC E50 KT20 305 12 20 s
9528702100 SCR SET 12MM AF E50 KT20 305 12 10 s
Spiral / Open Flight Screws:
9528701990 SCR SET 20MM SC STD KT20 255 20 16 s
9528702000 SCR SET 20MM SF STD KT20 255 20 10 s
9528702070 SCR SET 20MM SC E50 KT20 305 20 16 s
9528702080 SCR SET 20MM SF E50 KT20 305 20 10 s
Screw Seal
9324000010 GSKT SCR FDR T20 SILICON WHT

Notes: (Rev A)
s Sold as a set of two screws. Order Quantity is 1
t Sold as individual screws, but 2 screws required. Order Quantity is 2

Rev. D
79.10
KT20 Feeding Module Spare Parts Manual

Discharge Tubes

Glassbeaded tubes are standard for volumetric feeders and for loss in weight feeders. Electropolished tubes can
also be supplied if required. The Discharge Tube length must match the length of the screw and diameter.
Extended screws may require discharge tubes with outboard bearing support. The standard tube length is 73
mm for both the Horizontal and Vertical Tubes. The vertical discharge outlet is 60mm in Diameter adds to the
overall length. The Tube length to the centerline of the vertical discharge is 88 mm.

Rev. D
 79.11
KT20 Feeding Module Spare Parts Manual

Tube Nomenclature

Code Description
V Vertical Discharge
GBO Glassbead Finish
EPL ElectroPolish Finish
OB Includes Outboard Bearing Housing
SW Sanitary welds on tube
STD Standard Length Screw
E100 Extended 100 mm passed standard length
TL Total Length of tube is only the Horizontal
section and does NOT include the vertical
discharge section

Part Number Eng. Description TL ID Cap Note

(mm) (mm) Dia
Horizontal Discharge – EPL Finish
9497701170 TUBE DISCH H STD EPL KT20 73 22 --
9497701180 TUBE DISCH H E50 EPL KT20 123 22 ---
Horizontal Discharge – GBO Finish
9497701270 TUBE DISCH H STD GBO KT20 73 22 --
9497701280 TUBE DISCH H E50 GBO KT20 123 22 ---
Horizontal Discharge – #4 Finish
9497701210 TUBE DISCH H STD #4 KT20 73 22 --
Vertical Discharge – EPL Finish
9512711320 TUBE DISCH V STD EPL KT20 73 22 60
9512711330 TUBE DISCH V E50 EPL KT20 123 22 60 CL=138
Vertical Discharge – GBO Finish
9512712940 TUBE DISCH V STD GBO KT20 73 22 60
9512712950 TUBE DISCH V E50 GBO KT20 123 22 60 CL=138

Rev. D
79.12
KT20 Feeding Module Spare Parts Manual

Flexes and Caps

Part Number Description Qty Qty Qty Note

Vert Press Horz
Dsch Bal Dsch

Discharge Tube Flex

8901700160 KIT FLEX CONN 2.37'' KCLKT20 1 2 0 C

Discharge Tube Cap

9585407220 COV DISCH TUBE 60.3 (2.37'')ID 1 1 0 C

Rev. D
 79.13
KT20 Feeding Module Spare Parts Manual

Screw Drive Motors

The screw drive motor is used to control the speed of the feeding module. The screw drive consists of three
components.

• DC Motor
• Motor Coupling
• Coupling Sleeve

Part Number Description Brush Note

Screw motors
HorsePower Armature Rating Model Number B
9473700600 450 Watt 100 VDC SD 33-2331Z134G1 B
9473700610 450 Watt 200 VDC SD 33-2331Z190G1 M1 B
9473000790 1/2HP 90 VDC SD M3,M4 B
9473410010 1/2HP 180 VDC SD M1 B
9473001400 1/2HP 90 VDC CD M5 B
9473000480 1/2HP 180 VDC CD M2 B
9473000890 1/2HP 90 VDC XP FGE0213 M6 B
9473000520 1/2HP 180 VDC XP FGE0262 M7 B
Motor Coupling and Sleeve
9226000090 CPLG HUB 5/8 BORE T35/S200 1 Mtr
9226000100 COUPLING SLEEVE 1 C
9226000060 T20/21 HUB CPLNG 10MM BORE 1 Gbx

Motor Brushes
Motor Brushes must be match to the motor vendor specifications. Please call the Parts Department with the
Motor Manufacture and Model number for the proper brushes. Commonly used brushes are listed below.

Seq Part Number Eng. Description Qty Note

M1 9473700510 MOT ACCES BRUSH 180V BALDOR 2 Baldor
M2 9473000380 MOTOR ACCES BRUSHES #YP00492 2 PacSci
M3 9473002160 MOTOR ACCES BRUSH #BP5011T01 2 Baldor
M4 9473000310 MOTOR ACCES BRUSH #5000-5032 2 Electrol
M5 9473000370 MOTOR ACCES BRUSHES #YP00494 2 PacSci
M6 9473000300 MOTOR ACCES BRUSHES #YP00507 2 PacSci
M7 9473000000 MOTOR ACCES BRUSHES #YP00508 2 PacSci

Rev. D
79.14
KT20 Feeding Module Spare Parts Manual

KCL Motor
The Lab Line or KCL feeders have a special motor configuration. This configuration does not use the Speed
pickup and housing, but has the speed feedback integral to the motor.

The KCLT20 has two motors. One motor has an integral 5:1 gear head for lower federates.

Part Number Eng. Description

0833700350 KIT MOT 124W 5:1 RDCN KCLKT20
0833700360 KIT MOTOR 95W KCLKT20
Motor with Speed pickup Only
0000000083 MOTOR DC 124W 180V BALDOR 10:1
0000000833 MOTOR DC 124W 5:1 RDCN 180V

Note:
• Kits include motor, adapter flange, coupling and mounting hardware
• Both these motors are manufactured by BALDOR. If replacing any other motor manufacturer,
the KIT is required. This is not a direct replacement and may require removing the existing
speed pickup assembly.
• The KCL motor is only designed for a C-Gearbox.

Rev. D
 79.15
KT20 Feeding Module Spare Parts Manual

Speed Pickup Retrofits

K-Tron uses speed pickups from two suppliers, AeroFlex and Jaquet. Additional, K-Tron will add quick
connectors to the end of the cables, which creates a combination of part numbers. The Aeroflex speed pickup
has limited availability and is replaced by the Jaquet.

P/N 0123000250 DET MAG SPEED PU W300/600 *D

Uses P/N 924400000 DET MAG SPEED PICK-UP (shown with Molex Connector)
AeroFlex B12L-5CT

P/N 0000000237 DET MAG SPEED PICKUP W/CONN

Uses P/N 9244700110 DET MAG SPEED PICKUP K2 with Connector added
JAQUET FTG 1088.00 EX. This is a direct replacement for 9244000040

The Jaquet Pickup is available with a variety of terminations on the wires.

Part Number Graphic Representation Notes

9244700110 Pickup with bare
wire terminations.

0000000237 Used on
retrofits the SCM Controls and
0123000250 K10S control
9244000440 systems
9244700130 Used with K10S and
directly replaces Hardware Controls
0123000250

9244700160 Extended leads with

bare wire ends. Used
in some Hazardous
locations. (Mostly

Rev. D
79.16
KT20 Feeding Module Spare Parts Manual

with K2 Feeders)
Horizontal Agitator

T20 feeders have a removable horizontal agitator to aid material flow in the feed hopper section

3 2

Seq Part Number Eng. Description Qty Note

1 9512711530 RETAINER AGIT KCLKT20 1
2 9522704780 AGIT 2 BLADE HDN EPL KT20 1 u
9522704790 AGIT 2 BLADE HDN #4 KT20 * u
9512715060 AGIT 2 BLADE EPL KCLKT20 *
9512711650 AGIT 2 BLADE #4 KCLKT20 *
9512712800 AGIT 4 BLADE KCLKT20 *
9512712830 AGIT 4 BLADE #4 KCLKT20 *
9512714520 AGIT 4 BLADE #8 SW KCLKT20 *
3 9512000940 T20 AGITATOR BOLT ZINC PLTD. 1

Notes:
u Made with harden steel. Do not use with food, pharma, or corrosive materials

Rev. D
 79.17
KT20 Feeding Module Spare Parts Manual

Feeding Bowl

T20 feeding bowl is available in different metal finishes and two sizes (5L or 12L) The feeding bowl to
attached to the extension hopper using a V-Clamp and gasket as show below.

Part Number Eng. Description Qty Note

T20 Feeding Bowl 1

9512712920 HPPR FDR AG 5L GBO/2B SW KT20
9512713110 HPPR FDR 5L EPL SW KT20
9512713130 HPPR FDR 5L #4 O/I SW KT20
9512713150 HPPR FDR 12L GBO/2B SW KT20
9512909290 HPPR FDR 12L EPL SW KT20
9512713160 HPPR FDR 12L GBO/#4 SW KT20
V-Clamp and Gasket
9219700240 V-CLAMP HPPR FDR SST K2M 1 C
9522701350 NUT V-CLAMP HPPR K2M 1
9303001010 LATCH T-BOLT #10-32 1
9324700440 GSKT RND HPPR K2 1 C

Rev. D
79.18
KT20 Feeding Module Spare Parts Manual

Special Options

Hinge Kit
This hinge kit is available for extension hoppers with hinge bracket.
Consult Factory for Part Numbers

Rev. D
 79.19
KT20 Feeding Module Spare Parts Manual

Inline Reducer
A 4:1 inline reducer can be added to the T20 line feeders.

Seq Part Number Eng. Description Qty Note

INLINE REDUCER
601 9682400010 T20 REDUCER 4:1 1 h
602 9359004600 SCR SOC M6X1X90 D912 STLZP 1
603 9512713360 FRAME SPRT MOT 4:1 GRA KCVKT20 1
604 9512713370 SPRT MOTOR 4:1 GBO KCVKT20
605 9359009390 NUT HEX M10X1 D439 STLZP

h Motor Must be NEMA 56C Frame

Rev. D
79.20
KT20 Feeding Module Spare Parts Manual

Reference Documentation
The following documentation applies to the K2 feeder

Part Eng. Description

Number
DCS4518 User Manual for KCVT20
DCS401 Basics of Feeding
DCS42 K2 Small Hopper Spare Part List

Rev. D
 31
Spare Parts List Manual Guide

K-Tron America
Recommended Spare Part Guide and Pricing

This document is general information related to K-Tron Equipment and should be used in conjunction
with the K-Tron Engineering Specification Sheets provided with the equipment. This document may
not contain information and pricing for custom or “project level” parts. Many of the options listed in
this manual may not be currently on your feeder, but can be added if required.

To assist in selecting spare parts to stock onsite, the following codes may be listed at NOTES:

A Critical Mechanical Item

B Critical Electrical Item
C Recommended part to be inspected and replaced if worn during Preventative
Maintenance Program every 9000 runtime hours or every 2 years which ever is first.

All notes in lower case defined in that section of the manual.

All prices are UNIT price (in US$), FOB Pitman, NJ. We can accept Visa/MasterCard/American
Express, Purchase Order from customers with open accounts, or electronic fund transfers.

For further information or to place an order, please contact:

K-Tron America, Inc.

Customer Service Group
Routes 55 & 553
PO Box 888
Pitman NJ 08071
Tel: 856-589-0500
Fax: 856-256-3232
Email: support@ktron.com

Rev. A Price subject to change without notice

Price effective 2/1/2005
 Chapter 11
Aux. Equip.
This Chapter Does
NOT Apply To This
Manual.