K-Tron KCM Docu. Inc. Stops

TECHNICAL INSTRUCTION KCM Protocol

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

0590020612-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 able to eliminate eliminate the the cause of the alarm alarm displays? displays?



Have you modified part of the system, product or operating mode?



Have you tried to remedy the fault in accordance accord ance 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 that have sequences sequences you have to to follow. 

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.: 0590020612-EN Date:2005/09/02 Original: 0290020608-EN KIT Project No: 241

“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 with respect to the Company's equipment. Except as otherwise expressly provided by K-Tron in any such document, document, K-TRON MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NOR ANY OTHER WARRANTY, WARRANTY, EXPRESS EXPRESS OR IMPLIED, IMPLIED, WITH RESPECT TO THE EQUIPMENT.” EQUIPMENT.” If an error or ommission is found, please contact: [email protected].

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 able to eliminate eliminate the the cause of the alarm alarm displays? displays?



Have you modified part of the system, product or operating mode?



Have you tried to remedy the fault in accordance accord ance 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 that have sequences sequences you have to to follow. 

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.: 0590020612-EN Date:2005/09/02 Original: 0290020608-EN KIT Project No: 241

“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 with respect to the Company's equipment. Except as otherwise expressly provided by K-Tron in any such document, document, K-TRON MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NOR ANY OTHER WARRANTY, WARRANTY, EXPRESS EXPRESS OR IMPLIED, IMPLIED, WITH RESPECT TO THE EQUIPMENT.” EQUIPMENT.” If an error or ommission is found, please contact: [email protected].

Table of Contents 1

Safe Safety ty Notes Notes ..... ........ ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ..... ..... ..... 1

1.1 1.1.1 1.1.1

Safety Safety symbol symbol definitio definitions ns ........ ............ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ....... ..... 1 Related Related safety/elec safety/electrica tricall icons icons ........ ............ ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ....... ..... .. 1

1.2

Proper Proper use ....... ........... ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ....... ....... ....... ... 2

1.3

Organiza Organization tional al measure measures s ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ........ ...... .. 2

1.4

Operato Operatorr respons responsibilit ibilities ies ......... ............. ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........2 ....2

1.5

SafetySafety-con conscio scious us operatio operation n ....... ............ ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ......... ......... ........ ........ ........ ......... .........3 ....3

1.6

Safety Safety devices devices ........ ............ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ....... ... 3

1.7

High voltage voltage ..... ......... ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ....... ....... ....... ... 3

1.8

Addition Additional al equipme equipment nt ........ ............ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ....... ...... ... 4

1.9

Removal Removal from service service ...... .......... ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ .......4 ...4

1.10

Customer Customer service service and and repairs repairs ........ ............ ........ ........ ........ ......... ......... ........ ........ ........ ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ...... .. 4

1.11

Warranty Warranty ........ ............ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ....... ....... .........4 .....4

1.12 1.12.1

Applied Applied safety safety signs signs and and placard placards s ......... ............. ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ....... 4 Selected safety signs on machines ......................... ...................................... .......................... ......................... ........................ ..................... ......... 4

2

Data Data Str Struc uctu ture res, s, For Forma mats ts and and Dat Data a Type Types s for for Smar SmartC tCon onne nexx-II II .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....5 ..5

2.1

Overview Overview ......... ............. ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ....... ....... ........5 ....5

2.2 2.2.1 2.2.1 2.2.2 2.2.2

Data descripti descriptions ons ......... ............. ........ ........ ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ........ ........ ........ ........ ........ ......... ......... ....... ........6 .....6 Data types types ......... ............. ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ....... ....... ........ ...... .. 6 Applica Application tion types types ......... ............. ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ......... ......... ........ ........ ........ ......... ........ ....... ........6 ....6

2.3 2.3.1 2.3.1 2.3.2 2.3.2 2.3.3 2.3.3 2.3.4 2.3.4 2.3.5 2.3.5 2.3.6 2.3.6 2.3.7 2.3.7 2.3.8 2.3.8 2.3.9 2.3.9 2.3.10 2.3.11 2.3.12 2.3.13 2.3.14 2.3.15 2.3.16

Data and formats formats .......... ............... ......... ........ ........ ........ ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ........ ........ ........ ......... ......... ....... ...... ... 7 KCM global global variable variables: s: Process Process ........ ............ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ......... ......... ........ ....... ...7 7 KCM global variables: variables: Alarms ........ ............ ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ........ ........ ........ ......... ......... ........ ...... .. 8 KCM global global variables: variables: Scale Scale parameter parameters s ........ ............ ........ ........ ........ ........ ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ...... .. 9 KCM global global variables: variables: Digital Digital I-O ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ......... ......... ........ ...... 10 KCM global global variable variables: s: Analog I-O ......... ............. ........ ......... ......... ........ ........ ........ ......... ......... ........ ......... ......... ........ ........ ........ ......... ......... ........11 ....11 KCM global global variable variables: s: Modbus Modbus I-O ........ ............ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ........11 ....11 KCM global global variable variables: s: HCU Loader Loader Params Params .......... .............. ........ ........ ........ ........ ........ ......... ......... ........ ........ ......... ......... ......... .........12 ....12 HcuSelP HcuSelParam aramNum Num Definitions Definitions ........ ............ ......... ......... ........ ........ ........ ......... ......... ........ ........ ......... ......... ........ ......... ......... ........ ......... ......... ........ ...... 12 KCM global global variable variables: s: Communica Communication tions s ........ ............ ........ ........ ........ ......... ......... ........ ......... ......... ........ ........ ........ ......... ......... ........ ........14 ....14 KCM global variables: Miscellaneous Miscellaneous ....................... ................................... ......................... ......................... ......................... ................... ...... 14 KCM variables: LWF ........................ ..................................... ......................... ......................... .......................... ......................... ......................... .................. .....16 16 KCM variables: LWB ........................ ..................................... .......................... .......................... ......................... ........................ ......................... .................. .....18 18 KCM variables: PID ................................ ............................................ ........................ ........................ ......................... .......................... ...................... ............ ... 21 KCM variables: SFM ........................ ..................................... ......................... ......................... .......................... ......................... ......................... .................. .....22 22 KCM variables: VOL ...................... .................................. ......................... .......................... .......................... ......................... ........................ .................... ........24 24 KCM variables: WBF .............................. ........................................... ......................... ........................ ......................... .......................... ...................... ........... .. 24

2.4

Service Service variable variable index index ..... ......... ........ ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ........ ........ ......... ......... ........ ...... .. 25

3

I-O I-O Funct Functio ions ns ..... ........ ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ......26 ...26

3.1 3.1.1

Global Global I-O function functions s for all applicat applications ions ........... ............... ......... ......... ........ ........ ........ ......... ......... ........ ......... ......... ........ ........ ........ ......... ....... 26 Global digital inputs ........................ ..................................... .......................... ......................... ......................... ......................... ......................... ................... ...... 26

3.1.2 3.1.3 3.1.4

Global analog setpoint input .............................................................................................26 Global digital outputs ........................................................................................................27 Global analog outputs ....................................................................................................... 27

3.2 3.2.1 3.2.2 3.2.3 3.2.4

LWF I-O ............................................................................................................................28 LWF digital inputs .............................................................................................................28 LWF analog setpoint input ................................................................................................28 LWF digital outputs ...........................................................................................................28 LWF analog outputs ..........................................................................................................29

3.3 3.3.1 3.3.2 3.3.3 3.3.4

WBF I-O ............................................................................................................................29 WBF digital inputs .............................................................................................................29 WBF analog setpoint input ................................................................................................29 WBF digital outputs ........................................................................................................... 29 WBF analog outputs ......................................................................................................... 30

3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5

PID I-O ..............................................................................................................................30 PID digital inputs ...............................................................................................................30 PID analog setpoint input .................................................................................................. 30 PID analog process input ..................................................................................................30 PID digital outputs .............................................................................................................30 PID analog outputs ...........................................................................................................31

3.5 3.5.1 3.5.2 3.5.3 3.5.4

VOL I-O .............................................................................................................................31 VOL digital inputs ..............................................................................................................31 VOL analog setpoint input ................................................................................................. 31 VOL digital outputs ............................................................................................................ 31 VOL analog outputs ..........................................................................................................31

3.6 3.6.1 3.6.2 3.6.3 3.6.4

SFM I-O ............................................................................................................................32 SFM digital inputs .............................................................................................................32 SFM analog setpoint input ................................................................................................32 SFM digital outputs ...........................................................................................................32 SFM analog outputs ..........................................................................................................32

3.7 3.7.1 3.7.2 3.7.3 3.7.4

LWB I-O ............................................................................................................................33 LWB digital inputs ............................................................................................................. 33 LWB analog batch setpoint input ......................................................................................33 LWB digital outputs ...........................................................................................................33 LWB analog outputs ..........................................................................................................34

4

Command Functions ...................................................................................................... 35

4.1

Overview ...........................................................................................................................35

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8

Command tables for action functions ................................................................................35 Global command table ......................................................................................................35 HCU Loader command table ............................................................................................35 LWF command table ......................................................................................................... 36 WBF command table ........................................................................................................36 PID command table ..........................................................................................................36 VOL command table ......................................................................................................... 36 LWB command table ......................................................................................................... 37 SFM command table ......................................................................................................... 37

5 5.0.1

Condensed Process Status Variables ..........................................................................38 Introduction .......................................................................................................................38

5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7

Condensed process status variable table .........................................................................38 Condensed global process status variable table .............................................................. 38 Condensed LWF process status table .............................................................................. 39 Condensed WBF process status table ............................................................................. 39 Condensed PID process status table ............................................................................... 40 Condensed VOL process status table .............................................................................. 40 Condensed LWB process status table ..............................................................................40 Condensed SFM process status table .............................................................................. 41

6 6.0.1

Expanded Process Status Word - PSW ........................................................................ 42 Introduction ....................................................................................................................... 42

6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7

Expanded PSW tables ......................................................................................................42 PSW word mapping .......................................................................................................... 42 Global PSW Map .............................................................................................................. 42 LWF PSW Map ................................................................................................................. 44 WBF PSW Map ................................................................................................................. 44 PID and VOL PSW Map ...................................................................................................44 SFM PSW Map ................................................................................................................. 45 LWB PSW Map ................................................................................................................. 45

7 7.0.1 7.0.2

Alarm Status Variables-ASW ......................................................................................... 46 Introduction ....................................................................................................................... 46 ASW word mapping .......................................................................................................... 46

7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7

Alarm status word tables-ASW ......................................................................................... 47 Global ASW alarm status table ......................................................................................... 47 LWF alarm status definitions ............................................................................................ 50 VOL alarm status definitions ............................................................................................. 50 WBF alarm status definitions ............................................................................................51 LWB alarm status definitions ............................................................................................ 51 PID alarm status definitions ..............................................................................................52 SFM alarm status definitions ............................................................................................ 52

8 8.0.1

Condensed Alarm Status Words-ASR .......................................................................... 53 Introduction ....................................................................................................................... 53

8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.1.7

Tables of condensed alarm status words .........................................................................53 Global ASW condensed alarm status table ...................................................................... 53 LWF condensed alarm status definitions ..........................................................................54 VOL condensed alarm status definitions ..........................................................................54 WBF condensed alarm status definitions .........................................................................54 LWB condensed alarm status definitions .......................................................................... 55 PID condensed alarm status definitions ...........................................................................55 SFM alarm status definitions ............................................................................................ 55

9 9.0.1

KSL Line Functions ........................................................................................................56 Introduction ....................................................................................................................... 56

9.1 9.1.1 9.1.2

KSL line variable listing ..................................................................................................... 56 KSL numeric parameters .................................................................................................. 56 KSL line command table ...................................................................................................57

10

KCM Built-In *.kgr Files ..................................................................................................58

10.1

Protocols supported ..........................................................................................................58

10.2

Communication settings ....................................................................................................59

10.3 10.3.1 10.3.2 10.3.3 10.3.4 10.3.5 10.3.6 10.3.7

Variable locations and mapping ........................................................................................60 Floating point reads from the KCM ...................................................................................60 Condensed process status and alarm status reads ..........................................................61 Heartbeat, single word read ..............................................................................................62 Single word writes for control ............................................................................................62 Command register ............................................................................................................62 Command functions ..........................................................................................................63 Floating point writes to the KCM .......................................................................................64

11

Index .................................................................................................................................65

Safety Notes Safety symbol definitions

1

1 1.1

Safety Notes

Installation, commissioning and programming of the specified equipment should only be undertaken by qualified personnel.

1.1



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 indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate personal injury.



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.

CAUTION

!

!

!

CAUTION

WARNING

DANGER

Safety symbol definitions

1.1.1

Related safety/electrical icons

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

1 1.2

Safety Notes Proper use

1.2

Proper use



Only operate the KCM in conjunction with the feeder equipment from K-Tron.



Only operate the KCM in accordance with the specified technical data.



Do not operate where there is a risk of explosion.



Do not use the equipment in a manner not intended by the manufacturer.

1.3

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.



Always keep the metering device operating instructions within easy reach. Ensure that they are always complete and legible.

1.4

Operator responsibilities



Ensure that only qualified and trained personnel work with the KCM.



Establish personnel responsibilities for operation and maintenance.



Ensure that personnel have read and understood the operat ing 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.

Safety Notes Safety-conscious operation

1.5



1 1.5

Safety-conscious operation

Any changes (including changes to operational behavior) which affect safety must be immediately reported to the responsible member of staff.



Perform all operations with safety in mind.



Do not make any internal adjustments to the KCM while the feeder is in operation.

1.6

Safety devices



The electrical safety devices must not be altered. This increases the danger of accidents.



Never operate the KCM 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 10 seconds to lapse prior to opening the enclosure. This ensures safe discharge of high voltage components.

1.7

High voltage

Warning! Danger!

!

DANGER



High voltage of 230 Vac may be present on the line power cables of the KCM.



Switch off the power to the KCM for 3 minutes before:

– any disassembly, maintenance and repair work – replacing the motor.  Only qualified electricians may work on the KCM. 

Protect the KCM against moisture entrance.

1 1.8

Safety Notes Additional equipment

1.8



Modifications to the KCM are prohibited.



The operator is responsible for complying with all safety regulations related to operation with the feeding equipment.

1.9

!

CAUTION

Additional equipment

Removal from service



Disconnect the KCM from the power supply before removal from service.



The operator is responsible for the proper removal of the KCM from service.

1.10



Customer service and repairs

The KCM may only be repaired by

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

1.11



Warranty

See project specifications and sales agreements for warranty information.

1.12

Applied safety signs and placards

1.12.1

Selected safety signs on machines

Fig. 1.1

Power applied sign

Data Structures, Formats and Data Types for SmartConnex-II Overview

2

2 2.1

Data Structures, Formats and Data Types for SmartConnex-II

This document presents the numeric and digital data that is available via the KCM Smart K-Link connectivity function. The KSL needs to be at ver. 4 software.

2.1

Overview

Two sections are presented. The first section presents a summary table of the variables that may be selected in Smart K-Link and the second shows the index settings used when binary or bit data is selec ted. Command, Alarm and Process Status functions fit this later category. Please use the following notation when using these variables. Data Type: Numeric - Float, Strings or Integer Data Types, Digital - Bit Arrays Typically used variables: Marked in Bold typeface. For PLC register assignments, use: Float, string, bit array: 2 registers Integer: 1 register Access information:’R’ means Smart K-Link output only,’R/W’ means the variable is both an input and output value. Units of time are generally in seconds unless otherwise specified. Using string data may require setting of an ASCII data block in the PLC. Then select ASCII in the Poll Record Table. It is recommended to use floating point rather than integer math. This will eliminate the need for scaling.

2 2.2

Data Structures, Formats and Data Types for SmartConnex-II Data descriptions

2.2

Data descriptions

There are different types of data that can be exchanged amount devices. This will help you to identify them. 2.2.1

Data types

Data types are broken into three major categories: ·Commands ·Status ·Variable or process data Commands are requests for an action to be taken by the controller. These mnemonics begin with the letter ’C’. Status information is a report on the operating condition of the controller. These values can be bit mapped or brought back as full 16 bit arrays for a total of 256 bits. What is left is the process data or such things as setpoint and massflow. For clarification of mnemonics, use this list. 2.2.2 Application

Application types

Function

LWF

Loss-in-Weight Feeder

WBF

Weigh Belt Feeder

PID

Proportional, Integral, Derivative Controller

LWB

Loss-in-Weight Batch Feeder

SFM

Smart Flow Meter Controller

VOL

Volumetric feeder controller

Data Structures, Formats and Data Types for SmartConnex-II Data and formats

2.3

2 2.3

Data and formats

This section provides a listing of data that is passed from various applications to the supervisory control system. You will select them using the SmartConfig PC application when defining variables and their placement in the PLC memory map. This listing shows the variables for all machines where applicable. 2.3.1

Name

ActualTemperature

KCM global variables: Process

Units

Type

R or R/W

Description

deg C

float

R

Internal temperature of the KCM.

binary

R

32 bit definition of the KCM operating status.

CondProcStat DriveCommand

percent

float

R

Value of operating drive command from the controller.

GrossWeight

weight

float

R

Weight on the scale.

GrossWeight2

weight

float

R

Weight on the secondary weighing device on a WBF or SFM.

integer

R

Integer value that increments to 9999 then rolls over and resumes the count. Indicates basic operation of the KCM.

HeartBeat

Massflow

rate

float

R

Output of the feeder in weight/time units.

MotorPower

watts

float

R

Actual power used by the motor.

MotorSpeed

rpm

float

R

Current motor speed.

NetWeight

weight

float

R

GrossWeight-TareWeight.

NetWeight2

weight

float

R

GrossWeight2-TareWeight2.

Setpoint

rate/ weight

float

R/W

Target operation of the feeder.

TareWeight

weight

float

R/W

Weight of feeder on scale.

TareWeight2

weight

float

R/W

Weight of feeder on the secondary scale.

Totalizer

weight

float

R/W

Accumulative weight delivery of the feeder.

2 2.3


2.3.2

Name

AlarmDelay

KCM global variables: Alarms

Units

Type

R or R/W

Description

seconds

integer

R/W

Time, in seconds, for the alarm to persist before a hard alarm can occur.

integer

R/W

Alarm action:

AlarmMode

Ignore = 0, Alarm immediate = 1, Alarm timed = 2, Alarm Stop immediate = 3, Alarm Stop timed = 4 AlarmNumber

integer

R/W

Number of the actual alarm- see ASR list.

integer

R/W

Time, in seconds, upon machine start-up when the process alarms are suppressed.

AlarmStat[16]

binary

R

Alarm status, see alarm status listing.

CondAlarmStat

binary

R

Condensed alarm status, see listing.

AlarmStartupDel

seconds

DrvCmdHiLimit

percent

float

R/W

Limit for drive command for when drive command exceeds the value, an alarm occurs.

DrvCmdLoLimit

percent

float

R/W

Limit for drive command for when drive command fallls below the value, an alarm occurs.

MassflowHiLim

percent

float

R/W

Limit for massflow for when massflow exceeds the value, an alarm occurs.

MassflowLowLim

percent

float

R/W

Limit for massflow for when massflow falls below the value, an alarm occurs.

integer

R/W

When set, the stop bit clears alarms:

StpBitClrAl

0 = stop bit does not clear alarms 1 = stop bit will clear alarms


2.3.3

Name

Units

NumSFTReq

KCM global variables: Scale parameters

Type

R or R/W

Description

integer

R/W

Number of SFTs located at the feeder.

SampleTime

seconds

float

R/W

Sample time interval of weight sampling.

ScaleGrossRange

weight

float

R/W

Weight range of scale.

ScaleSpan

float

R/W

Span correction factor.

SelectedSFT

integer

R/W

Address of the viewed SFT.

SFTAddress

integer

R/W

SFT addressed? 0 = no, 1 = yes

SFTConfig

string

R

Shows operation of connected SFTs.

SftCutOff

Hz

float

R/W

SFT low pass filter.

SFTRawWeight

weight

float

R

Weight direct from SFT.

SFTStatus

binary

R

Operational condition of SFT.

SFTType

string

R

Shows SFT weight range.

2 2.3

2 2.3


2.3.4

Name

Units

KCM global variables: Digital I-O

Type

R or R/W

Description

DgInSelFun

integer

R/W

Selects function for the digital input.

DgInSelNum

integer

R/W

Selects the input to be used by number.

DgInSelPol

integer

R/W

Sets the polarity for the input: 0 = normal, 1 = inverse

DgInSelValue

integer

R

Shows the digital input state: 0 = off, 1 = on/active Note:

low voltage on input = active/on DgOutSelFun

integer

R/W

Selects function for the digital output.

DgOutSelMap

integer

R/W

Selects a specific output function to be mapped to a register.

DgOutSelNum

integer

R/W

Selects the output to be used by number.

DgOutSelValue

integer

R

Shows the digital output state: Output conducting = on Output not conductng = off


2.3.5

Name

KCM global variables: Analog I-O

Units

Type

AnInSelDB

percent

float

AnInSelMax

percent

float

AnInSelMin

percent

float

Scaling for the analog minimum value.

integer

Analog input source:

AnInSelSrc

2 2.3

R or R/W

Description

Deadband setting for this analog input. R/W

Scaling for the analog maximum value.

0 = CPU(0-10kHz), 1 = CPU(Analog), 2 = External AnInSelValue

percent

float

Actual value of the analog signal.

AnOutSelDB

percent

float

Deadband setting for this analog output.

integer

Analog output function select.

AnOutSelFun AnOutSelMax

percent

float

Scaling for the analog maximum value.

AnOutSelMin

percent

float

Scaling for the analog minimum value.

integer

Selection of the desired analog output for the KCM:

AnOutSelNum

CPU = 0, EXT1 = 1, EXT2 = 2, EXT3 = 3 AnOutSelValue

percent

integer

2.3.6

Name

Units

Actual value of the analog signal.

KCM global variables: Modbus I-O

Type

R or R/W

ExtIOBinding

integer

R/W

ExtIONodeSel

integer

R/W

ExtIOTypes

integer

R

ExtIOTypeSel

integer

R/W

Description

[0 to 3]

2 2.3


2.3.7

Name

Units

HcuActCycle

KCM global variables: HCU Loader Params

Type

R or R/W

Description

integer

R

Describes where in the loading cycle the HCU controller is. Motor Timer(1), Load Delay(2), Loading(3), Line Clear(4), Discharge Delay(5), Discharge(6).

HcuActTime

seconds

integer

R/W

Shows the active time for the specified cycle.

HcuCommand

integer

R/W

HCU command to: None(0), Run(1), Stop(2), Clear Alarms(3), or Discharge(4)

HcuSelParmNum

integer

R/W

Number of parameter loaded

HcuSelParmValue

float

R/W

Shows the parameter value for the parameter number selected

HcuStatus

integer

R

HCU status to: None(0), Alarm(1), RecFull(3), Buf Full(4), Comm Fail(5), OK(6)

2.3.8

HcuSelParamNum Definitions

Number

Description

1

Load Timer

2

Line Clear Timer

3

Discharge Timer

4

Filter Delay Timer

5

Filter Pulse Timer

6

Motor Timer

7

Load Delay Timer

8

Discharge Delay Timer

9

Receiver Proximity Sensor

10

Buffer Hopper Proximity Sensor

11

Supply Hopper Proximity Sensor

12

Remote Start Timer

13

Remote Stop Timer


Number

Description

14

Discharge Valve Switch

15

Differential Pressure Switch

16

Discharge Request Switch

17

Digital Input Set-Up (Xor Mask)

18

Operating Mode

19

Filter Clean Mode

20

Discharge Mode

21

Not used.

22

HCU Software Version

23

Supply Hopper Low Alarm Timer

24

Differential Pressure High Alarm Timer

25

Load Cycle Alarm Counter

26

Discharge Valve Alarm Timer

27

ON/OFF Counter

28

Run Time

29

Software Version of HSU

2 2.3

2 2.3


2.3.9

Name

Units

KCM global variables: Communications

Type

R or R/W

Description

ConfigBaud

integer

R/W

Baud rate for the KCM config port.

ConfigMode

integer

R/W

Sets the KCM config port function.

HostFile

integer

R/W

Sets whether the built-in or downloaded kgr file is used by the host function in the KCM.

HostProt

integer

R/W

Defines the host protocol to be used.

KPort1Baud

integer

R/W

Baud rate for K-Port1.

KPort1Prot

integer

R/W

Defines the protocol for K-Port1.

KPort2Baud

integer

R/W

Baud rate for K-Port2.

KPort2Prot

integer

R/W

Defines the protocol for K-Port2.

2.3.10

Name

Units

KCM global variables: Miscellaneous

Type

R or R/W

Description

AutoSpanLimit

integer

R/W

Sets the limit on auto span calculation using the auto-calibration function.

AuxBoardType

integer

R

Defines the aux board type.

CalibCorrel

percent

float

R

Variance of flow during the calibration cycle.

CalibCorrLimit

percent

float

R/W

Sets the limit for variance of flow during the calibration cycle without canceling activity.

CalibDriveCmd

percent

float

R/W

Drive command used during the auto-calibration cycle.

CalibMatFed

weight

float

R

Amount of weigh the controller states was delivered during the autocalibration cycle.

CalibTime

seconds

integer

R/W

Time for the auto-calibrate cycle.

CheckWeight

weight

float

R/W

Measured amount of product delivered during the autocalibration cycle.

ChkWEnum

integer

R

Subscroll listing showing calibration status codes.

ControlType

integer

R

Type of controller application used.


Name

Units

DeviceID

Type

R or R/W

Description

integer

R

KCM feeder type by a numeric code

2 2.3

LWF = 60, WBF = 61, SFM = 62, PID = 63, VOL = 64, LWB = 65 DgInFun[16]

integer

R/W

Function for the digital input selected.

DgInPol[16]

integer

R/W

Polarity of the input function selected.

DgOutFun[16]

integer

R/W

Function of the digital output selected.

DgOutMap[16]

integer

R/W

PSR or ASR map value of the selected digital output.

DgOutPol[16]

integer

R/W

Polarity of the output function selected.

DrvCmdCeiling

percent

integer

R/W

Sets the limit on how high drive command can go. It is a stop limit.

EmptyDC

percent

integer

R/W

The drive command used to empty the feeder.

integer

R/W

Defines the number of pulses per revolution of the primary velocity sensor.

float

R/W

Sets the totalizer increment.

integer

R/W

Sets the mode for setpoint control:

Encoder teeth ExternTotalInc

weight

FdrCtrMode

0 = local, 1 = ratio, 2 = direct, 3 = line1, 4 = line2, 5 = line3 up to 10 = line8 FeederAddress

integer

R

Address of the KCM.

FeederName

string

R/W

Name for the KCM. [14 bytes]

float

R

Time the feeder has been running in hours.

integer

R/W

Sets the type of application used.

integer

R/W

Built-in loader control, filter clear time.

GearReduction

float

R/W

Primary gear reduction for a feeder.

IDSetpoint

integer

FeederRunTime

hours

FeederType FltClearTime

msec.

Value for remembering pictures/graphics. Used by the KSC.

KLinkTxDelay

msec.

integer

R/W

Delays host transmissions to prevent network overloads.

MassflowFiltLen

seconds

integer

R/W

Display filter time constant.

binary

R

Operational status of the drive board. See document 0490020605 for details.

MDUStatus MaximumFlow

rate

float

R/W

Sets the limit for maximum flow.

MinimumFlow

rate

float

R/W

Sets the limit for minimum flow.

2 2.3


Name

Units

Type

R or R/W

Description

NominalPower

watts

integer

R/W

Sets the maximum motor power to be drawn.

NominalSpeed

rpm

integer

R/W

Sets the maximum, rated motor speed.

NominalVoltage

volts

integer

R/W

Sets the limit for DC voltage to the motor.

PreLoadMFeqSP

Hz

integer

R/W

SerVarSubscrl

integer

R/W

Number of the service variable selected.

SerVarValue

float

R/W

Value of the service variable selected.

float

R/W

The ratio setpoint value.

integer

R

Condition under which the KCM was last stopped.

float

R/W

Totalizer preload value. Use <0> to clear totalizer.

integer

R/W

Selects the units of operation:

SetpointRatio

percent

StoppedBy TotalizPreload

weight

Units

0 = kg/hr, 1 = kg/min, 2 = lb/hr, 3 = lb.min, 4 = metr ton/hr, 5 = en ton/hr, 6 = g/hr, 7 = g/min

2.3.11

Name

Units

KCM variables: LWF

Type

R or R/W

Description

AdaptGain

float

R/W

Learned gain value for LWF.

AdaptTuning

integer

R/W

Sets adaptive tune function: 0 = off, 1 = on

AveFeedFactor

rate

DensArray

float

R

Average feeding factor.

integer

R/W

Turns on the Refill/Density array: 0 = off, 1 = on

FeedFactAlrmLim

percent

float

R/W

Sets the bounds on good values of feedfactor.

FeedFactArray1

rate

float

R

Shows the feedfactor value in the lower portion of the Refill array.

FeedFactArray5

rate

float

R

Shows the feedfactor value in the middle portion of the Refill array.

FeedFactArray9

rate

float

R

Shows the feedfactor value in the upper portion of the Refill array.

Data Data Str Struct uctur ures es,, Form Format ats s and and Data Data Typ Types es for for Sma Smart rtCo Conn nnex ex-I -III Data an and fo formats

2 2.3

Name

Units

T y pe

R or R/W

Description

FltClearTime

msec.

integer

R/W


GearReductionLo

float

R/W

Sets the higher gear reduction/lowest speed for K2 feeders with dual speed gearboxes.

GearSwitch

integer

R/W

Turns on the dual speed control: 0 = high, 1 = low, 2 = auto high, 3 = auto low

InitialFeedFact

rate

LoadEna

float

R/W

Starting feedfactor

integer

R/W

Enables the built-in loader control: 0 = off, 1 = on

LoadMaxTime

seconds

integer

R/W

Sets the maximum load time for the built-in loader control.

LoadCloseTime

seconds

integer

R/W

Sets the valve close time for the built-in loader control.

LoadDischTime

seconds

integer

R/W

Sets the time for discharge for the built-in loader control.

LoadMotorTime

seconds

integer

R/W

Sets the motor run time for the built-in loader control.

integer

R/W

Turns on modulation:

Modulation

0 = off, 1 = on MotorCtrlGain

float

R/W

Motor gain set by user.

NetWtHighLimit

weight

float

R/W

Maximum high limit on net weight.

NetWtLowLimit

weight

float

R/W

Minimum low limit on net weight.

float

R

Actual pert value.

PertValue PostRefillDelay

seconds

integer

R/W

Sets the time for post refill function.

RefArrDevlimit

percent

float

R

Maximum allowed variance in feedfactor from empty to full points on the refill array curve.

RefillDelTime

seconds

integer

R/W

Time for refill to occur before an alarm.

integer

R/W

Turns on/off the automatic refill function:

RefillEna

0 = disabled, 1 = enabled, 2 = if running RefillLevelMax

weight

float

R/W

High weight level that turns off refill.

RefillLevelMin

weight

float

R/W

Low weight level that starts the refill.

integer

R/W

Sets the refill mode:

RefillMode

0 = Manual, 1 = Auto, 2 = AutoTerm

2 2.3 2.3

Data Data Stru Structu ctures res,, Format Formats s and and Data Data Type Types s for for Smart SmartCon Connex nex-II -II Data Data and and for form mats ats

Name

Units

Type

R or R/W

Description

ScrewSpeed

rpm

float

R

Displays screw RPM when Gear Reduction is set.

VibDisplSpan

float

R/W

Sets span for vibratory drive.

VibDispVal

float

R

Current vibratory displacement output.

VibKVNumber

integer

R/W

Sets the feeder type to KV1-KV3.

float

R/W

Maximum change allowed in Setpoint before the control behavior is executed execu ted on the vibratory calibration curve.

VibY0

float

R

Correction factor for vibratory feeder nonlinearity at 8% Drive Command.

VibY1

float

R


VibY2

float

R


VibY3

float

R


VibY4

float

R


VibY5

float

R


VibY6

float

R


VibSPChgLimit

percent

2.3. 2.3.12 12

Name

Units

KCM KCM vari variab able les: s: LWB LWB

Type

R or R/W

Description

AdaptGain AdaptGain

float

R/W

Learned gain value value for LWF LWF when adaptive tuning is active.

AdaptTuning AdaptTuning

integer

R/W

Sets adaptive adaptive tune tune to on/off: on/off: 0 = off, 1 = on

AveFeedFactor AveFeedFactor

rate

float

R

Current average average feeding feeding factor. factor.

BatCompMass

weight

float

R

Current batch weight delivered.

BatCompPerc

percent

float

R

Batch weight delivered in percent of setpoint.

Data Data Str Struct uctur ures es,, Form Format ats s and and Data Data Typ Types es for for Sma Smart rtCo Conn nnex ex-I -III Data an and fo formats

Name

Units

BatCount BatchTimeGrace

seconds

BatRefMode

2 2.3

T y pe

R or R/W

Description

integer

R

Number of batches delivered but does not increment for aborted batches.

integer

R/W

If this value plus the Maximum Batch Time is exceeded during batching, a batch time exceeded alarm will occur.

integer

R/W

Sets the refill mode type: 0 = undefined, 1 = refill after batch, 2 = pause batch to refill, 3 = refill while batching

BatSize

weight

BatState

float

R/W

Batch setpoint.

integer

R

State of batcher:

BatTime

seconds

integer

R/W

Batch time in seconds.

BatTolerance

percent

float

R/W

Sets batch tolerance for out of limit final batch value.

DribDC

percent

float

R/W

Drive command in dribble mode.

DribTime

sedonds

float

R/W

Time in dribble mode.

FastDC

percent

float

R/W

Drive command in normal mode.

FeedFactAlrmLim

percent

float

R/W

Sets the bounds on acceptable values of feedfactor.

FeedFactArray1

rate

float

R

Shows the feedfactor value in the lower portion of the Refill array.

FeedFactArray5

rate

float

R

Shows the feedfactor value in the middle portion of the Refill array.

FeedFactArray9

rate

float

R

Shows the feedfactor value in the upper portion of the Refill array.

FltClearTime

msec.

integer

R/W


GearReductionLo

float

R/W

Sets the higher gear reduction/lowest speed for K2 feeders with dual speed gearboxes.

GearSwitch

integer

R/W

Turns on the dual speed control: 0 = high, 1 = low, 2 = auto high, 3 = auto low

InitialFeedFact JogEna

rate

float

R/W

Starting feedfactor.

integer

R/W

Enables the jog function. 0 = off, 1 = on

LoadEna

integer

R/W

Enables the built-in loader control. 0 = off, 1 = on

2 2.3


Name

Units

Type

R or R/W

Description

LoadMaxTime

seconds

integer

R/W

Sets the maximum load time for the built-in loader control.

LoadCloseTime

seconds

integer

R/W

Sets the valve close time for the built-in loader control.

LoadDischTime

seconds

integer

R/W

Sets the time for discharge for the built-in loader control.

LoadMotorTime

seconds

integer

R/W

Sets the motor run time for the built-in loader control.

MaxBatSize

weight

float

R/W

Maximum allowable batch size.

integer

R/W

Turns on modulation:

Modulation

0 = off, 1 = on MotorCtrlGain

float

R/W

Motor gain as set by user.

NetWtHighLimit

weight

float

R/W

Maximum high limit allowed on net weight.

NetWtLowLimit

weight

float

R/W

Minimum low limit allowed on net weight.

float

R

Actual pert value.

integer

R/W

Sets the time for post refill function.

Preact1Pulses

integer

R/W

Preact value of motor encoder pulses from fast to dribble control.

Preact2Pulses

integer

R/W

Preact value of motor encoder pulses from dribble to stop.

PertValue PostRefillDelay

seconds

RefArrDevlimit

percent

float

R

Maximum allowed variance in feedfactor from empty to full points on the refill array curve.

RefillDelTime

seconds

integer

R/W

Time for refill to occur before an alarm

integer

R/W

Turns on/off the automatic refill function:

RefillEna

0 = disabled, 1 = enabled, 2 = if running RefillLevelMax

weight

float

R/W

High weight level that turns off refill.

RefillLevelMin

weight

float

R/W

Low weight level that starts the refill.

integer

R/W

Sets the refill mode:

RefillMode

0 = Manual, 1 = Auto, 2 = AutoTerm ScrewSpeed StableWtCnt

rpm

float

R

Displays screw RPM when Gear Reduction is set.

float

R/W

Number of stable weight readings after dribble that are required for batch complete.


Name

Type

R or R/W

Description

StopPert

float

R/W

The net weight deviation above which a PERT will be detected.

VibDisplSpan

float

R/W

Sets span for vibratory drive.

VibKVNumber

integer

R/W

Sets the feeder type to KV1-KV3.

float

R/W

Maximum change allowed in Setpoint before the control behavior is executed on the vibratory calibration curve.

VibY0

float

R


VibY1

float

R


VibY2

float

R


VibY3

float

R


VibY4

float

R


VibY5

float

R


VibY6

float

R


VibSPChgLimit

Units

2 2.3

percent

2.3.13

Name

KCM variables: PID

Units

Type

R or R/W

Description

AveFeedFactor

rate

float

R

Current value of feedfactor.

DerContribFreq

Hz

integer

R

Value of frequency component due to Derivative control.

DerivLimit

Hz

integer

R/W

Limit to the amount of derivative action allowed.

DerivTime

seconds

float

R/W

Derivative time interval.

FeedFactAlrmLim

percent

float

R/W

Sets the bounds on good values of feedfactor.

InitialFeedFact

rate

float

R/W

Starting feedfactor.

InputFiltLen

seconds

float

R/W

Process variable input filter.

2 2.3


Name

Units

Type

R or R/W

Description

IntContribFreq

Hz

integer

R

Value of frequency component due to Integral control.

IntegralTime

seconds

float

R/W

Integral time interval for control.

ProcessVariable

rate

float

R

Current process value.

PropContribFreq

Hz

integer

R

Value of frequency component due to proportional control.

PropGain

float

R/W

Amount of proportional gain applied to control.

PVinMax

float

R/W

Limit on process variable input-maximum.

PVinMin

float

R/W

Limit on process variable input-minimum.

PVInSelect

integer

R/W

Selects the type of process variable input.

SelfTune

integer

R/W

Turns on/off self tuning feature: 0 = off, 1 = on

TotalInhibit

integer

R/W

Turns on/off totalizer function: 0 = off, 1 = on

2.3.14

Name

Units

AutoReZero

KCM variables: SFM

Type

R or R/W

Description

integer

R/W

Turns on/off chute auto re-tare function: 0 = manual, 1 = auto

BlowOff

integer

R/W

Turns on/off blow-off function: 0 = off, 1 = on

BypassFunct

integer

R/W

Turns on/off Auto Bypass function: .0 = off, 1 = on

BypassInterval

float

R/W

Sets bypass valve operation interval.

BypassValve

integer

R/W

Turns on/off Bypass valve function: 0 = off, 1 = on

CalDC

percent

integer

R/W

Overall calibration drive command.

CalDC1

percent

integer

R/W

Calibration drive command at flow 1.

CalDC2

percent

integer

R/W


CalDC3

percent

integer

R/W



Name

Units

CalDev CalMassFlow

weight

CalStep

2 2.3

Type

R or R/W

Description

float

R

Deviation over the calibration range.

float

R

Amount of product delivered during calibration cycle.

integer

R/W

Cal step 1-3 taken.

ChuteAngle

degrees

float

R/W

Angle of chute to horizon.

ChuteLength

meters

float

R/W

Length of chute.

ChuteThresh

weight

float

R/W

Weight below which chute weight is considered <0>.

float

R/W

Span value for chute.

float

R/W

Derivative time for control.

float

R/W

Span value for divert.

ChuteWgtSpan DerivTime

seconds

DivertWgtSpan DivertThresh

weight

float

R/W

Weight below which divert weight is considered <0>.

IntegralTime

seconds

float

R/W


InternalFiltLen

seconds

float

R/W

Massflow filter value.

MaterialFact0

weight

float

R

A0 flow error correction factor.

MaterialFact1

weight

float

R


MaterialFact2

weight

float

R


MaxMFAlrmLim

rate

float

R/W

Upper limit on massflow.

MinMFAlrmLim

rate

float

R/W

Lower limit on massflow.

OverallSpan‘

float

R/W

Overall calibration factor.

PropGain

float

R/W

Amount of proportional gain applied to control.

2 2.3


2.3.15

KCM variables: VOL

Name

Units

Type

R or R/W

Description

Density

weight/ vol

float

R/W

Density of fed product that is entered for use in calibration.

CalWt1

weight

float

R/W

Calibration weight at Cal Drive Cmd 1.

CalWt2

weight

float

R/W

Calibration weight at Cal Drive Cmd 2.

CalDC1

percent

integer

R/W

Calibration drive command at step 1.

CalDC2

percent

integer

R/W

Calibration drive command at step 2.

Feedfactor

rate

float

R

Current value of feedfactor.

integer

R/W

Actuates power-on start function:

PowerOnStart

0 = off, 1 = on 2.3.16

Name

Units

BeltIdxEna

KCM variables: WBF

Type

R or R/W

Description

integer

R/W

Enables belt index function: 0 = off, 1 = on

BeltLength

meters

float

R/W

Length of belt.

BeltLoad

weight/ length

float

R

Beltloading value.

BeltLoadSetpt

weight/ length

float

R/W

Belt loading setpoint used for volumetric control.

BeltSlipAlrmLim

percent

float

R/W

Limit on belt slip.

BeltSlipValue

percent

float

R

Actual belt slippage.

BeltSpeed

m/min or ft/min

float

R

Actual belt speed.

DeckGap

meters

float

R/W

Distance between weigh bridges.

DriveDrumDiam

meters

float

R/W

Diameter of drive roller.

HiBeltLdAlrmLim

weight/ length

float

R/W

High belt loading alarm limit.

IntegralTime

seconds

float

R/W


LoBeltLdAlrmLim

weight/ length

float

R/W

Low belt loading alarm limit.

integer

R/W

Location, motor or roller for velocity sensor.

PickupPos

Data Structures, Formats and Data Types for SmartConnex-II Service variable index

2 2.4

Name

Units

Type

R or R/W

Description

PreFdrDist

meters

float

R/W

Distance of prefeeder to weigh bridge.

PreFdrTune

integer

R/W

Turns on Prefeeder autotune function.

PrefeedDCSpan

float

R/W

Spans the prefeeder drive command value to set belt loading.

TotalDeadBand

weight/ length

float

R/W

Sets the lower beltload that turns off the totalizer.

TransportDist

meters

float

R/W

Distance from weigh bridge to discharge.

WeighDeckLength

meters

float

R/W

Weigh bridge length.

2.4

Service variable index

This section presents service variable index information that is available on the KSU-II or KCM/KD. Go to the Machine Menu of the KSU-II or KCM/KD and to the Service Set-Up sub-menu.

Desc

Variable

PreLoad MF=SP

Preload MF value with SP upon KCM starts or SP changes

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%. LWB and LWF only.

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

Modulation%

Screw modulation-percent- amplitude, debug variable.

KCDR-K10S

When set to <1> configures K-Port 1 to function with a K-Commander or KDU using extended software. When set to <0> returns K-Port 1to normal function.

ReprogCommBd

When this variable is set to <1> and KCM power is cycled, automatic reprogramming of the comm board by the KCM will occur. This value is reset to <0> after the programming activity is complete.

3 3.1

I-O Functions Global I-O functions for all applications

3

I-O Functions

This section presents I-O mapping for KCM products with parameter code. These functions will be found in the I-O menu.

3.1

Global I-O functions for all applications

3.1.1

Global digital inputs

A true/on condition results in the desired action.

Name

Function List

None=0 Start=1 Stop=2 Interlock=3 Run Enable=4 ALS Input=5 Al. Ack=6 Al. Clr=7 Start/Stop=8 Vol Mode=9 Loc/Ext=10 Ratio/ Direct=11 External alarm=12 Totalizer Clear=13 Data Lock=14

3.1.2

Name

None=0 Setpoint=1

No function assigned. Start Machine Stop Machine Downstream interlock for temporary stop of machine. Run enable to stop and prohibit machine from starting. Alarm shutdown input Alarm Acknowledge Alarm Clear One-wire start stop. True = Start/False = Stop Force to volumetric mode if true. Local or external setpoint source. 1= Ext, 0=Local Ratio or direct mode.1=Direct, 0=Ratio Input for an external alarm. Input to clear totalizer. Input to lock data from being changed.

Global analog setpoint input

Function List

No function assigned. Feeder setpoint. = (10kHz/Max SP) x Actual SP or = (20ma/Max SP) x Actual SP

I-O Functions Global I-O functions for all applications

3.1.3

Global digital outputs

A true/on condition is the result.

Name

Function List

None=0 Feeder Run=1 Any Alarm=2 Hard Alarm Relay=3 ALS Output=4 Drive Ena=5 Mass Mode=6 PSR-Map=7 ASR-Map=8 Totalizer Pulse=9

3.1.4

Name

None=0 Setpoint=1 Massflow=2 Net Weight=3

No function assigned. Output is true if feeder is running Output is true for any alarm situation Relay output is true only for any hard alarm condition. Alarm shutdown output. Output is true when the Driver Enable line is active- drive should run. Output is true when feeder is in mass mode. Output is true when the selected PSR bit is true. See PSR mapping for LWF application.(Process Status) Output is true when the selected ASR bit is true. See ASR mapping for LWF application. (Alarm Status) Output for totalizer pulses.

Global analog outputs

Function List

No function assigned. Setpoint normalized to maximum rate. =(20ma/Max Setpoint) x Massflow Setpoint Massflow normalized to maximum rate. =(20ma/Max Setpoint) x Massflow Net Weight normalized to gross range. (This may also be NetWeight1 for a belt feeder or Chute Net Weight for the SFM.) =(20ma/Scale Range) x Netweight

3 3.1

3 3.2

I-O Functions LWF I-O

3.2

LWF I-O

This section presents I-O variables for Loss-in-Weight feeder applications. 3.2.1

LWF digital inputs

Add the following to the global digital input listing. A true/on condition results in the desired action. Name

Function List

Batch Pause=15 Empty=16 Ref Bypass=17 Ref Cmd=18 Calib=19 Loader Level=20 Loader Enable=21

3.2.2

Empty the feeder now Refill Bypass Refill Command (force refill) Starts the Auto Calibration routine. Loader is at its full level. Enables the loader function

LWF analog setpoint input

See global listing. 3.2.3

LWF digital outputs

Add the following to the global digital output listing. A true/on condition is the result. Name

Refill=10 Refill Expired=11 Loader=12 Blow-off=13 HiLoGear=14 Dribble=15 Batch Complete=16

Function List

Output is true when a refill is called for. Output is true when the refill time has expired and refill did not complete. Runs loader motor. Turns on blow off feature for loader. Selects either Hi or Lo gear function for K2 feeders. Dribble mode active Batch completed

I-O Functions WBF I-O

3.2.4

3 3.3

LWF analog outputs

Add the following to the global analog output listing. Name

Function List

Drive Cmd=4 Motor Speed=5 Feedfactor=6

3.3

Drive command. =(20ma/100%) x (%Drive Command) Motor speed normalized to maximum motor speed. = (20ma/Max motor rpm) x Actual motor speed Computed feedfactor as a function of the initial value. =(20ma/Initial Feedfactor) x Average Feedfactor

WBF I-O

This section presents I-O variables for Weigh Belt feeder applications. 3.3.1

WBF digital inputs

Add the following to the global digital input listing. A true/on condition results in the desired action.

Name

Function List

Empty=15 Empty the feeder now Belt Drift=16 Input for belt drift detection Belt Index=17 Belt index function input Dynamic A dynamic tare is to occur Tare=18

3.3.2

WBF analog setpoint input


WBF digital outputs

Add the following to the global digital output listing. A true/on condition is the result.

Name

Tare Run=10 Prefeeder Drive Enable=11

Function List

A dynamic tare is ongoing if true. Enable the prefeeder to run.

3 3.4

I-O Functions PID I-O

3.3.4

WBF analog outputs

Add the following to the global analog output listing.

Name

Function List

NW1=3 NW2=4 DriveCommand=5 Motor speed=6 Belt Load=7 Prefeeder=8

3.4

= (20mA/ScaleRange)*NetWeight 1 (Netweight on the primary weigh bridge) = (20mA/ScaleRange)*NetWeight 2 (Netweight on the secondary weigh bridge if used) = (20mA/100%) x Percent drive command = (20mA/Max Mot RPM) x Act Mot Speed Actual belt loading as a function of Belt Load SP. = (20ma/Belt Load SP) x Current belt loading Value of the prefeeder signal. For Soder feeder select Direct algorithm. = (20 ma)*(DrvCmd)*PrefeederSpan

PID I-O

This section presents I-O variables for PID applications. 3.4.1

PID digital inputs

Add the following to the global digital input listing. A true/on condition results in the desired action. Name

Function List

Calib=15

Starts the Auto Calibration routine.

3.4.2

PID analog setpoint input


PID analog process input

This entry is preset. 3.4.4

PID digital outputs

See global listing. A true/on condition is the result.

I-O Functions VOL I-O

3.4.5

3 3.5

PID analog outputs


Name

Function List

PVUInput=3 Drive Command=4 Motor Speed=5 Feedfactor=6

3.5

=(20mA/100%)xPVinput value percent of maximum = (20mA/100%) x Percent drive command = (20mA/Max Mot RPM) x Act Mot Speed Computed feedfactor as a function of the initial value. =(20ma/Initial Feedfactor) x Average Feedfactor

VOL I-O

This section presents I-O variables for VOL applications. 3.5.1

VOL digital inputs

Add the following to the global digital input listing A true/on condition results in the desired action.

Name

Function List

Calib=15

Starts the Auto Calibration routine.

3.5.2

VOL analog setpoint input


VOL digital outputs

See global listing. A true/on condition is the result. 3.5.4

VOL analog outputs


Name

Drive Command=3 Motor Speed=4

Function List

= (20mA/100%) x Percent drive command = (20mA/Max Mot RPM) x Act Mot Speed

3 3.6

I-O Functions SFM I-O

3.6

SFM I-O

This section presents I-O variables for SFM applications. 3.6.1

SFM digital inputs


Name

Function List

Bypass Fb=15 Normal Fb=16

Input from the Bypass valve position contact- Bypass position Input from the Bypass valve position contact- Normal position

3.6.2

SFM analog setpoint input

See global analog setpoint input list. 3.6.3

SFM digital outputs


Name

Function List

Bypass Valve=10 BlowOff=11

3.6.4

Bypass valve is in bypass mode if true Blowoff function is active if true

SFM analog outputs


Net Chute=3 Net Divert=4 DriveCommand=5 Motor speed=6 Feedfactor=7

Function List

Net weigh on the chute = (20mA/ScaleRange)*NetWeight_Chute Net weight on the divert channel = (20mA/ScaleRange)*NetWeight_Divert = (20mA/100%) x Percent drive command = (20mA/Max Mot RPM) x Act Mot Speed Computed feedfactor as a function of the initial value. =(20ma/Initial Feedfactor) x Average Feedfactor

I-O Functions LWB I-O

3.7

3 3.7

LWB I-O

This section presents I-O variables for Loss-in-Weight batch applications. 3.7.1

LWB digital inputs


Name

Function List

Ref. Bypass=11 Ref. Cmd=12 Ext. Al.=13 Pause=14 Empty15 FF Calibration=16

3.7.2

Refill Bypass Refill Command (force refill) Customer alarm from external source. If true, will force a batch pause If true, will initiate a empty function of the batch feeder If set to true, will initiate a feedfactor calibration routine.

LWB analog batch setpoint input

Name

Function List

Batch Size=1

3.7.3

Batch size setpoint. = (10kHz/Max Batch SP) x Actual Batch SP or = (20ma/Max Batch SP) x Actual Batch SP

LWB digital outputs


Name

Refill=10 Refill Expired=11 Loader Run=12 Blow-off=13 HiLoGear=14 Dribble=15 Batch Complete=16

Function List

Output is true when a refill is called for. Output is true when the refill time has expired and refill did not complete. Runs loader motor. Turns on blow off feature for loader. Selects either Hi or Lo gear function for K2 feeders. Output is true if the unit is in dribble mode Output is true if the unit has reached batch complete

3 3.7

I-O Functions LWB I-O

3.7.4

LWB analog outputs


Net Weight=1 Drive Command=2 Motor Speed=3 Feedfactor=4 Batch Size=5 Batch% Complete=6

Function List

Net Weight normalized to gross range. =(20ma/Scale Range) x Netweight = (20mA/100%) x Percent drive command = (20mA/Max Mot RPM) x Act Mot Speed Computed feedfactor as a function of the initial value. =(20ma/Initial Feedfactor) x Average Feedfactor Batch Size = (20ma/Max Batch Size) x Actual Batch Size Percentage of batch complete =(20ma/Batch Size) x Actual Amount Batched

Command Functions Overview

4

Command Functions

4.1

Overview

4 4.1

This section presents control and status functions for operation of the KCM system. Command functions are to be entered as alphanumeric values in Smart K-Link. They must be entered in upper case letters for a machine and in lower case letters for line function. For commands to be activated, a trigger will have to be provided at the PLC. This trigger can be a rising (HIT) or falling edge (LOT), a high (HI) or low (LO) level or an action on either transit ion (XOT). The (HIT) trigger is preferred for most situations.

4.2

Command tables for action functions

4.2.1

Global command table

Description

Mnemonic

Alarm acknowledge Alarm clear Stop Start Clear database invalid bit in PSR Stop and preserve alarms Clear totalizer Enable totalizer-PID only Disable totalizer-PID only

4.2.2

CALA CALC CSPC CSTC CDBI CSPA CTOC CTON CTOF

HCU Loader command table

Description

HCU Loader clear alarms HCU Loader Discharge to OFF HCU Loader Discharge to ON HCU Loader Run HCU Loader Stop

Mnemonic

CHCA CHDF CHDO CHRU CHST

4 4.2

Command Functions Command tables for action functions

4.2.3

LWF command table

Description

Mnemonic

Set MASS mode flag Set VOL. Mode flag Set tare values from gross weight Automatic feed factor calculation Empty feeder Refill start

4.2.4

CMAM CVOM CTAR CCFF CETY CCRF

WBF command table

Description

Mnemonic

Set MASS mode flag Set VOL. Mode flag Set static tare values from gross weight Dynamic belt tare Empty feeder Automatic feed factor calculation

4.2.5

CMAM CVOM CTAR CTR2 CETY CCFF

PID command table

Description

Mnemonic

Set MASS mode flag Set VOL. Mode flag Command ramp down of manual output Command ramp up of manual output

4.2.6

VOL command table

Use global commands only.

CMAM CVOM CMRD CMRU

Command Functions Command tables for action functions

4.2.7

LWB command table

Description

Mnemonic

Set MASS mode flag Set VOL. Mode flag Set tare values from gross weight Automatic feed factor calculation Clear batch count Pause batch run Empty feeder Refill start

4.2.8 Description

Set MASS mode flag Set VOL. Mode flag Tare chute & plate sft

CMAM CVOM CTAR CCFF CCBC CPAS CETY CCRF

SFM command table Mnemonic

CMAM CVOM CTAR

4 4.2

5 5.1

Condensed Process Status Variables Condensed process status variable table

5

Condensed Process Status Variables

5.0.1

Introduction

This section presents the process status variables that are presented for operational analysis. The variable that is read is a 32 bit (2 register value) with the mnemonic of . When the condition is present, the specific bit is set high.

5.1

Condensed process status variable table

Bit code is the bit location in the CondensedProcStatus word 5.1.1

Bit Code 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Condensed global process status variable table

Function

KSU-II or KCM/KD display is present Database invalid Alarm Shutdown Input active Disable Input active Line mode active Unused Auto calibration in progress CVAR – Examine changed variable Unused Machine running Drive Enabled Mass/Grav Mode Alarm relay active Alarm Shutdown output active Any hard alarm is present Any soft alarm is present - not timed out Unused Unused Unused Unused Unused Unused Unused Unused


Condensed global status variable table, con’t Bit Code 24 25 26 27 28 29 30 31

Function

KCM initialization complete Unused Unused Feeder emptying HCU loading Waiting to run Smart K-Link Initialization complete Pert function active

5.1.2

Condensed LWF process status table

Please see the global process status table for bits not shown here. Bit

Function

Code 8 16 18 19 20 21 22 23

Refill window set true Refill Time-out set Built-in Loader function enabled Ratio setpoint mode Direct setpoint mode Refill_Enabled Refill set to Auto mode Refill timer set on (KCM = always true)

5.1.3

Condensed WBF process status table

Please see the global process status table for bits not shown here.

Bit Code 8 19 20

Function

Dynamic tare active Ratio setpoint mode Direct setpoint mode

5 5.1

5 5.1


5.1.4

Condensed PID process status table


Bit Code 19 20

Function

Ratio setpoint mode Direct setpoint mode

5.1.5

Condensed VOL process status table


Bit Code 19 20

Function

Ratio setpoint mode Direct setpoint mode

5.1.6

Condensed LWB process status table


Bit Code 8 16 18 19 20 21 22 23 26

Function

Refill window set true Refill Time-out set Built-in Loader function enabled Paused Batch complete Refill_Enabled Refill set to Auto mode Refill timer set on (KCM = always true) Dribble active


5.1.7

Condensed SFM process status table

Please see the global process status table for bits not shown

Bit Code 18 19 20

Function

Refill Bypass enabled Ratio setpoint mode Direct setpoint mode

5 5.1

6 6.1

Expanded Process Status Word - PSW Expanded PSW tables

6

Expanded Process Status Word - PSW

6.0.1

Introduction

This list set is used for expanded PSW mapping for PSW bits 0-95. Many of these special bits can be mapped to a digital output. These bit functions are not used for Smart K-Link applications.

6.1

Expanded PSW tables

6.1.1

PSW word mapping

Here is a list that identifies the PSW word number with the Process ID code. Each PSW word is 32 bits long. The bit is set to TRUE at the condition specified.

Word Number

Bit Range

Word(0)

0-31

Word(1)

32-63

Word(2)

64-95

6.1.2

Global PSW Map

These process codes are common for all K-Tron machines. This is the bit number entered into the Smart K-Link PSW word configuration.

PSW(Process number)

Description

DB Initialized(0)

• Not used

CVAR(1)

• Not used

Run(2)

• Motor/machine running

Disa(3)

• Run disabled by Interlock input or run enable input

Ena(4)

• Drive output enabled

ALS_In(5)

• Alarm shutdown input active

ALS_Out(6)

• Alarm shutdown output active

AL_Rel(7)

• Alarm relay active

Hard_AL(8)

• Complement of AL_Rel

Soft_AL(9)

• On for any alarm present


PSW(Process number)

Description

Emptying(13)

• Machine is being emptied by Empty function

Wait(15)

• Feeder received a start command but is waiting

Start_OK(20)

• Start input will start feeder

HCU_Alarm(32)

• HCU loader alarm

HCU_Rec_Full(33)

• Loader receiver is full

HCU_Buf_Full(34)

• HCU alarm

HCU CommFail(35)

• HCU communication failure to CPU

HCU_Loading(36)

• HCU loading status

Hard_interlock(40)

• Drive (MDU) hard interlock input status

Interlock_In(41)

• Interlock input bit status

Enable_In(42)

• Run enable input bit status

Vol_Mode_In(46)

• Volumetric input bit status

Extern_In(47)

• Machine set for External SP bit input

Direct_In(48)

• Machine set for Direct SP bit input

Ext_Al_in(49)

• External alarm input bit active

Disp_Present(64)

• KCM/KD display present

CPU_Init_cpl(65)

• CPU initialization complete

Mass_mode(66)

• Unit in Grav mode

Calib(67)

• Currently running an auto calibrate routine

6 6.1

6 6.1


6.1.3

LWF PSW Map

Use these additional codes for all LWF machines.

PSW(Process number)

Description

Refill_Bypass_In(45)

• Refill bypass bit input is set for LWF

Gear_Sw_Out(51)

• Hi (Lo) gear switch output bit state

Blowoff_Out(52)

• Filter blowoff function output bit state

Pert(68)

• Unit in PERT condition

Refill(69)

• Feeder is refilling by automatic means

Ref_Timeout(70)

• Refill timer has expired

Loader_Full(75)

• Loader full input to control

Loading(76)

• Loader motor is running

Load_Ena(77)

• Loader is enabled to run

6.1.4

WBF PSW Map

Use these additional codes for all WBF machines.

PSW(Process number)

Description

Sec-Deck(14)

• Secondary weigh bridge is active

Prefeeder enabled(50)

• Prefeeder enable output bit state

BeltDrift(53)

• Belt drift has been detected

BeltIndex(54)

• Belt index function bit state

Dynamic tare ongoing(70)

• Dynamic tare is in progress

6.1.5

PID and VOL PSW Map

Use the global PSW map only.


6.1.6

SFM PSW Map

Use these additional codes for all SFM flowmeters.

PSW(Process number)

Description

BP-Open-In(43)

• Bypass valve open input bit status is true

BP-Close-In(44)

• Bypass valve close input bit status is true

Blowoff_Out(52)

• Filter blowoff function bit state.

Pert(68)


Bypass(69)

• Bypass output bit state

Unstable(71)

• Weight is unstable on SFM

6.1.7

LWB PSW Map

Use these additional codes for all LWB machines.

PSW(Process number)

Description

Pause(12)

• Batcher has paused.

Gear_Sw_Out(51)

• Hi (Lo) gear switch output enabled

Blowoff_Out(52)

• Filter blowoff bit state

Pert(68)


Refill(69)

• Feeder is refilling by automatic means

Ref_Timeout(70)


Loader_Full(75)

• Loader full input to control

Loading(76)

• Loader motor is running

Load_Ena(77)

• Loader is enabled to run

BatchComplete(78)

• Batch has completed

Dribble(79)

• Batcher is in dribble mode

6 6.1

7 6.1

Alarm Status Variables-ASW Expanded PSW tables

7

Alarm Status Variables-ASW

7.0.1

Introduction

This section presents the alarm status variables that provide feedback on all types of machine alarms. You have 95 bits of alarm reporting. If you wish to limit the register requirement you may bit map selected conditions or extract the 32 bit Condensed Alarm Status-ASR word in two registers. These are in the KCM. 7.0.2

ASW word mapping

Here is a list that identifies the ASW word number with the Alarm ID code. Each ASW word is 32 bits long

Word Number

Bit Range

Word(0)

0-31

Word(1)

32-63

Word(2)

64-95

Alarm Status Variables-ASW Alarm status word tables-ASW

7.1

Alarm status word tables-ASW

7.1.1

Global ASW alarm status table

7 7.1

These alarm codes are common for all K-Tron machines. This is the bit number entered into the Smart K-Link ASW word configuration. Note:

Some global entries will not be used for VOL and PID applications since SFTs are not employed.

ASR(Alarm number)

Description

K-Prom_Fail(1)

• Checksum error in parameter memory

K-Prom_Fail(2)

• Checksum error in kgr file area

Power_Glitch(3)

• Power dip detected. CPU did not reset

Int_Chan_Fail(5)

• Internal channel has failed to communicate between the CPU and drive pcbs

Gen_Weight_Fail(6)

• SFT(s) failed • Serial communication to the load cell interrupted • f = SFT internal failure. communication OK • t = No communication from the SFT to the controller board • ?= Not valid answer from SFT

Incorrect_Num_SFT (7)

• Number of SFTs found during polling does not match that required

Bad_SFT_Status(8)

• SFT is showing an incorrect status

No_MDU-Found(9)

• The drive pcb is not function with respect to the CPU pcb

MDU Failure(10)

• Motor drive has failed

MDU_Timeout(11)

• CPU pcb not communicating with the Drive pcb

MDU_Thermal(12)

• Drive temperature has exceeded deg C

MDU_Speed(13)

• No speed feedback signal is present when motor is asked to run

7 7.1


ASR(Alarm number)

Description

MDU_Current(14)

• Motor current limit is exceeded

MDU_SRelay(15)

• Safety relay disconnected while running

MDU_Motor(16)

• No current in motor leads when motor is supposed to run

MDU_Control(17)

• Drive problems

MDU_EEPROM(18)

• EEPROM checksum failed

MDU_Drive_Fail(19)

• MDU drive pcb has failed

MDU_Polarity(20)

• Coil polarity is incorrect on the vibratory drive (Vibratory feeder only)

HCU_Removed(21)

• HCU was removed

HCU_Alarm(22)

• HCU has an alarm

HCU_EEPROM(23)

• EEPROM failed

HCU_Driver(24)

• The controller's digital output driver has detected a fault

HCU_Supp_Hp(25)

• Material is below the level of the supply hopper proximity sensor • Sensor failed

HCU_Filter_DP(26)

• The differential pressure across the filter is too high indicating a clogged filter

HCU_CycCount(27)

If P20 Discharge Mode =01“Fill” mode then: • Max. numbers of load cycle exceeded, because Buffer Hopper Low input has been active (on) for more than the allowed load cycles. The Buffer Hopper Low signal going inactive clears the load cycle counter If P20 Discharge Mode =02 (LWF) mode then: • Discharge Request input has been on for more than the allowed load cycles. The Discharge Request signal going inactive clears the load cycle counter


ASR(Alarm number)

Description

HCU_DischVlv(28)

• Discharge valve has failed to either open or close properly. This alarm is automatically disabled in P18 Operating Modes 03 and 04

HCU_Rec_Full(29)

• Receiver is still full after discharge. • Receiver proximity switch too sensitive adjusted or failed

KLinkWrongFile(30)

• Protocol of KGR file does not match that required by the installed communication circuit card

KLink_No_File(31)

• No KGR file loaded

KLink_HPortFail(32)

• Host communication pcb error

KLink_HPortFail Init(33)

• Host communication pcb could not be initialized

KLink_HPort_IllegBd (34)

• Improper pcb installed in the host port location

KLink_KPort Fail(35)

• Check Host circuit card

KLink_KPortFail Init(36)

• Check Host circuit card

KLink_KPort_IllegBd (37)

• Host communication pcb is installed on the wrong port location-(K-Port)

KLink_BadKGR(38)

• One or more feeder parameters are not correct for the specified feeder

Ext_IO_Fail(39)

• The MODBUS I-O connection has failed

External Alarm(40)

• Digital input on KCM selected for External Alarm is active

Aux_interlock(41)

• Run Enable digital input has failed

Start_Ignored(42)

• Start conditions not fulfilled

MF-High(43)

• The current massflow is above the tolerance entered in menu parameter

MF_Low(44)

• The current massflow is below the tolerance entered in menu parameter

7 7.1

7 7.1


ASR(Alarm number)

Description

DC_Ceiling(45)

• Drive command has reached the limit

DC_High(46)

• The drive command has exceed the value Limit in the menu

DC_Low(47)

• The drive command has dropped below the value Limit in the menu

Check_Brush(48)

• DC motor brushes may be wearing out and ready to fail.

7.1.2

LWF alarm status definitions

Use these in addition to the global values.

ASR(Alarm number)

Description

FF_Alarm(52)

• Feedfactor is either zero or outside the Feedfactor alarm limit

Scale_Over(53)

• Scale is over its range

Scale_Under(54)

• Scale is reading under zero

Weight_High(55)

• Weight is above the High Limit

Weight_Low(56)

• Weight is below the Low Limit

Refill_Time(57)


Loader_Empty(58)

• Loader is empty

Low_Gain(61)

• Adaptive gain has dropped below 10, the value will be locked at 10 and a alarm will display.

7.1.3

VOL alarm status definitions

Use only the appropriate global values.


7.1.4

WBF alarm status definitions


ASR(Alarm number)

Description

Belt_Slip(52)

• Belt is slipping beyond the belt slip limit

Scale_Over(53)


Scale_Under(54)


Weight_High(55)

• Weight is above the High Belt Load Limit

Weight_Low(56)

• Weight is below the Low Belt Load Limit

Belt_Drift(57)

• The belt is drifting off the machine

Belt_Buildup(58)

• Belt is accumulating material beyond the limit.

7.1.5

LWB alarm status definitions


ASR(Alarm number)

Description

FF_Alarm(52)


Scale_Over(53)


Scale_Under(54)


Weight_High(55)

• Weight is above the High Limit

Weight_Low(56)

• Weight is below the Low Limit

Refill_Time(57)


Loader_Empty(58)

• Loader is empty

BatchTolerance(59)

• Batch tolerance limit has been exceeded

BatchTime2Hi(60)

• Batch time limit has been exceeded

7 7.1

7 7.1


7.1.6

PID alarm status definitions


ASR(Alarm number)

Description

FF_Alarm(52)


7.1.7

SFM alarm status definitions


ASR(Alarm number)

Description

Range_Div(53)

• Divert channel is over its range

Range_Chute(54)

• Chute channel is over its range

Over_Flow(55)

• Rate is above the maximum limit

NoFlow(56)

• No flow condition has been detected

Valve(57)

• Bypass valve has failed

Condensed Alarm Status Words-ASR Tables of condensed alarm status words

8 8.1

8

Condensed Alarm Status Words-ASR

8.0.1

Introduction

This section presents the various condensed alarm status words for those who only wish to import a maximum of 2 registers or alarm data. A list for each type of application will be presented here.

8.1

Tables of condensed alarm status words

8.1.1

Global ASW condensed alarm status table

These condensed alarm codes are common for all K-Tron machines. This is the bit number entered into the Smart K-Link ASW word configuration. A 32 bit word is used to describe the Condensed Alarm Status. Note:

Some global entries will not be used for VOL and PID applications since SFTs are not employed.

ASR(Alarm number)

Description

Ext_Alr(1)

• External Alarm active

DC_High, and DC_Ceiling(14)

• Either drive command has exceeded the high limit or tried to exceed the ceiling

DC_Low(15)

• Drive command has dropped below the Low DC limit

Num_SFT(19)

• Number of SFTs is incorrect

Internal_Channel_F ail(20)

• Internal channel on which the SFTs

Weight_Fail, Bad_SFT_Status (21)

• Weighing system failure

Hardware failure(22)

• All hardware and KPort or K-Link problems

MDU(23)

• Any related drive problem is identified here

Interlock(24)

• An interlock is active

Start_Ignored(25)

• A start input has been ignored

HCU problems(26)

• Any HCU problem is grouped here

8 8.1


8.1.2

LWF condensed alarm status definitions


ASR(Alarm number)

Description

FF_Alarm(0)

• Feed factor alarm active

Loader_Empty(3)

• Loader is empty of product

Weight_High(5)

• Weight is above the high limit

Weight_Low(8)

• Weight is below the low limit

Scale_Over(9)

• Scale is over-range

Scale_Under(10)

• Scale is under-range

Refill_Time(11)


MF_High(12)

• Massflow is above the high limit

MF_Low(13)

• Massflow is below the low limit

8.1.3

VOL condensed alarm status definitions

Use only the appropriate global values.

8.1.4

WBF condensed alarm status definitions


ASR(Alarm number)

Description

Belt_Slip or Belt_Drift(0)

• Either belt slippage or belt drift is the problem

Belt_Buildup(2)

• Belt has buildup that exceeds the limit

Hi_Belt_Load(8)

• Belt loading exceeds the limit

Scale_Over(9)


Scale_Under(10)


Lo_Belt_Load(11)

• Belt loading is below the limit


8.1.5

LWB condensed alarm status definitions


ASR(Alarm number)

Description

FF_Alarm(0)

• Feed factor alarm active

Loader_Empty(3)

• Loader is empty of product

BatchTime2High(4)

• Batch time has expired

Weight_High(5)

• Weight is above the high limit

Weight_Low(8)

• Weight is below the low limit

Scale_Over(9)


Scale_Under(10)


Refill_Time(11)


MF_High(12)

• Massflow is above the high limit

Batch_Tolerance(13)

• Batch is out of tolerance

8.1.6

PID condensed alarm status definitions


ASR(Alarm number)

Description

FF_Alarm(0)


8.1.7

SFM alarm status definitions


ASR(Alarm number)

Description

Range_Div(2)

• Divert channel is over its range

Range_Chute(5)

• Chute channel is over its range

NoFlow(8)

• No flow condition has been detected

Over_Flow(9)

• Rate is above the maximum limit

Valve(10)

• Bypass valve has failed

8 8.1

9 9.1

KSL Line Functions KSL line variable listing

9

KSL Line Functions

9.0.1

Introduction

This section shows the variables for KSL Line Function. The mnemonics are indicated by lower case characters.

9.1

KSL line variable listing

Note:

Access information:’R’ means Smart K-Link output only,’R/W’ means the variable is both an input and output value. 9.1.1

KSL numeric parameters

Here is a listing of KSL line variables.

Name

Units

Type

R or R/W

Description

LineBatchSize

weight

float

R/W

Total batch size of line – for batch applications only.

LineMaxBatchSize

weight

float

R/W

Maximum total batch size of line – for batch applications only.

LineMaxRate

rate

float

R/W

Full scale line massflow rate.

LineMassflow

rate

float

R

Actual line massflow rate.

LineSetpoint

rate

float

R/W

Line target massflow setpoint.

LineBatchCompleteMass

weight

float

R

Actual weight delivered in the total batch.

LineBatchCompletePercent

percent

float

R

Actual weight delivered in the total batch in percent of the line batch setpoint.

LineTotalizer

weight

float

R/W

Summary weight information.

TempProportion

percent

float

R

Proportional percent of the Line setpoint to the total Line SP.

KSL Line Functions KSL line variable listing

9.1.2

9 9.1

KSL line command table

Use this table to construct functional commands for the KSL. Please note that the commands for Line function are lowercase.

Description Active selected recipe Batch pause for the line Recall the recipe Stop and preserve alarms for the line Stop and clear alarms for the line Start, run and clear alarms for the line Store the recipe Clear the line totalizer

Mnemonic cacr cpas crcr cspa cspc cstc cstr ctoc

10 KCM Built-In *.kgr Files 10.1 Protocols supported

10

KCM Built-In *.kgr Files

In this section, the pre-loaded kgr files for KCM data communications are shown. The user is also able to prepare and download custom kgr files specific to process needs. The KCM provides Built-In kgr files for each supported protocol. The Built-In kgr files can be used as a quick-start to test communications and as a starting point for building custom kgr files. Built-In kgr files can be extracted, customized and downloaded to the KCM as a custom kgr file using SmartConfig program. The select between the Built-In kgr files and a custom kgr file is made in the KSU Communication menu. Setting the Host File selection in that menu to selects the Built-In file as described in this section. Selecting file selects the custom downloaded kgr file that the user designs. The KSL supports only Modbus, AB-DF1 and Siemens 3694R protocols.

10.1

Protocols supported

Protocols supported for the Built-In kgr files are: • Modbus • Modbus Plus • Modbus TCP • AB Allen Bradley DF1 • Siemens 3694R • DeviceNet • ProfibusDP • EthernetIP Note:

These protocols will require a communication adapter card to be installed in the KCM.

KCM Built-In *.kgr Files 10 Communication settings 10.2

10.2

Communication settings

Below are the communications settings for each Built-In kgr file protocol. These settings appear in the header of the kgr file.

Protocol

Baud

Bits

Parity

Stop

Details

Bits

Modbus-MB

19200

8

Even

1

MS_Byte_First, Node = 0

AB-DF1

9600

8

Even

1

LS_Byte_First, Node = 0

Siemens 3694

9600

8

Even

1

MS_Byte_First, Node = 0

ProfibusDP

MS_Byte_First, In=64 bytes, Out=64 bytes, Node = 0.

Modbus TCP (Modbus over Ethernet)MBTCP

MS_Byte_First, IP address = 10.20.10.100, NetMask = 255.0.0.0, and the Gateway = 0.0.0.0

Modbus Plus MB+

MS_Byte_First, Global Database settings = (SRCID=0, NumWords=0, Offset=0), Node=0.

DeviceNet

MS_Byte_First, No I/O Blocks, Input bytes=62, Output bytes=40, Note: DeviceNet address is set by switches

EthernetIP (DeviceNet over Ethernet)

MS_Byte_First, No I/O Blocks, Input bytes=62, Output bytes=40, IP address = 10.20.10.100, Net Mask = 255.0.0.0, Gateway = 0.0.0.0

10 KCM Built-In *.kgr Files 10.3 Variable locations and mapping

10.3

Variable locations and mapping

The first group of variables are global floating point reads from the KCM. That means the registers are the same for all KCM applications. 10.3.1

Byte

MB, MB+,

Number

MBTCP register

AB-DF1, DeviceNet, ProfibusDP, Siemens, Ethernet IP register

0

40001

0

Floating point reads from the KCM

Parameter Name

KCM Application

Data Type

0

Maximum Flow

LWF, WBF, PID, SFM

Float

40001

0

MaxBatch Size

LWB, WBB, SFB

Float

4

40003

2

Setpoint

LWF, WBF, PID, SFM

Float

4

40003

2

Batch Size

LWB, WBB, SFB

Float

8

40005

4

Totalizer

All applications

Float

12

40007

6

Massflow

LWF, WBF, PID, SFM

Float

12

40007

6

Batch Complete Mass

LWB, WBB, SFB

Float

16

40009

8

Drive Command

All applications

Float

20

40011

10

Motor Speed

All applications

Float

24

40013

12

Aver Feeding Factor

LWF, LWB, PID

Float

24

40013

12

Nominal Belt Load

WBF, WBB

Float

24

40013

12

Chute Net Weight

SFM, SFB

Float

28

40015

14

Netweight

LWF, LWB

Float

28

40015

14

Belt Load

WBF, WBB

Float

28

40015

14

Divert Net Weight

SFM, SFB

Float

28

40015

14

Prop Contrib Freq

PID

Float

32

40017

16

Refill Level Max

LWF, LWB

Float

32

40017

16

Belt Speed

WBF, WBB

Float

32

40017

16

Chute Gross Weight

SFM, SFB

Float

32

40017

16

Integ Contrib Freq

PID

Float

KCM Built-In *.kgr Files 10 Variable locations and mapping 10.3

Floating point reads from the KCM, con’t

Byte

MB, MB+,

Number

MBTCP register


Parameter Name

KCM Application

Data Type

36

40019

18

Refill Level Min

LWF, LWB

Float

36

40019

18

Belt Slip Value

WBF, WBB

Float

36

40019

18

Divert Gross Weight

SFM, SFB

Float

36

40019

18

Deriv Contrib Freq

PID

Float

40

40021

20

Batch Time

LWB, WBB, SFB

Float

40

40021

20

Process Variable

PID

Float

44

40023

22

Fast Drive Command

LWB, WBB, SFB

Float

48

40025

24

Dribble mand

LWB, WBB, SFB

Float

10.3.2

Drive

Com-

Condensed process status and alarm status reads

These bits show the functional condition and alarm status of the particular KCM. See section 7.1. for more information. These parameters are two word integer reads.

Byte

MB, MB+,

Number

MBTCP register


Parameter Name

KCM Application

Data Type

52

40027

26

CondensedProcStatus

All applications

BitMapped

56

40029

28

CondensedAlarmStatus

All applications

BitMapped


10.3.3

Heartbeat, single word read

Read this value to verify data communication and KCM functionality.

Byte

MB, MB+,

Number

MBTCP register


60

40031

30

Parameter Name

KCM Application

Data Type

Heartbeat

All applications

Integer

10.3.4

Single word writes for control

Use these registers to set LWF/LWB Refill and SFM/SFB Bypass valve control. Note the change in address sequence from the ‘reads’.

Byte

MB, MB+,

Number

MBTCP register


Parameter Name

KCM Application

Data Type

62

41025

1024

Refill Enable/Disable

LWF, LWB

Integer

62

41025

1024

Bypass Valve

SFM, SFB

integer

10.3.5

Command register

This table provides a single register write for KCM commands.

Byte

MB, MB+,

Number

MBTCP register


64

41026

1028

Parameter Name

KCM Application

Commands from Com- All applications mand table See next table.

Data Type

Bitmapped

KCM Built-In *.kgr Files 10 Variable locations and mapping 10.3

10.3.6

Command functions

The Built-In kgr file provides the following bit mapped commands at byte number ‘64’. . Bit Number

Mnemonic

Definition

0

CALA

Alarm acknowledge

1

CALC

Alarm clear

2

CSPA

Stop and keep alarm

3

CSPC

Stop and clear alarms

4

CSTC

Start and clear alarms

5

CTOC

Clear totalizer

6

CMAM

Set gravimetric mode

7

CVOM

Set volumetric mode

8

CTAR

Set the tare

9

CTR2

Start dynamic tare, WBF, WBB only

10

CCFF

Start FF calibration - LWF only

11

CRMD

PID Ramp Up - PID only

12

CMRU

PID Ramp down - PID only

13

CPAS

Batch pause, LWB, WBB, SFB only

14

CTON

Enable totalizer

15

CTOF

Disable totalizer


10.3.7

Floating point writes to the KCM

Use this table to configure the writes (float-2 register) for the application.

Byte

MB, MB+,

Number

MBTCP register

AB-DF1, DeviceNet, ProfibusDP, Siemens, Ethernt IP register

Parameter Name

KCM Application

Data Type

0

41027

1026

Maximum Flow

LWF, WBF, PID, SFM

Float

0

41027

1026

Maximum Batch Size

LWB, SFB

Float

4

41029

1028

Setpoint

LWF, WBF, PID, SFM

Float

4

41029

1028

Batch Size

LWB, SFB

Float

8

41031

1030

Initial Feeding Factor

LWF, LWB, PID

Float

8

41031

1030

Nominal Belt Loading

WBF, WBB

Float

8

41031

1030

Bypass Interval

SFM, SFB

Float

12

41033

1032

Refill Level Maximum

LWF, LWB

Float

12

41033

1032

Prefeed DC Span

WBF, WBB

Float

12

41033

1032

Overall Span

SFM, SFB, PID

Float

16

41035

1034

Refill Level Minimum

LWF, LWB

Float

16

41035

1034

Belt Slip Alarm Limit

WBF, WBB

Float

16

41035

1034

Prop Gain

PID

Float

16

41035

1034

Chute Weight Span

SFM, SFB

Float

20

41037

1036

Scale Span

LWF,LWB, WBF, WBB

Float

20

41037

1036

Deriv Time

PID

Float

20

41037

1036

Divert Weight Span

SFM, SFB

Float

24

41039

1038

Batch Time

LWB, SFB

Float

24

41039

1038

Process Variable

PID

Float

28

41041

1040

Fast Drive Command

LWB, SFB

Float

32

41043

1042

Dribble mand

LWB, SFB

Float

Drive

Com-

Index

Index A AB CIF 58 Access information 5, 56 Al. Ack 26 Al. Clr 26 Alarm ID code 46 ALS Input 26 ALS Output=4 27 Any alarm 27 ASR-map 27 Aver Feeding Factor 60

B Batch Complete 33 Batch Complete Mass 60 Batch Complete=16 28 Batch Pause=15 28 Batch Size 60, 64 Batch Size=1 33 Batch Size=5 34 Batch Time 61, 64 Batch% Complete=6 34 Belt Drift=16 29 Belt Index=17 29 Belt Load 60 Belt Load=7 30 Belt Slip Alarm Limit 64 Belt Slip Value 61 Belt Speed 60 BlowOff=11 32 Blow-off=13 28, 33 Bypass Fb=15 32 Bypass Interval 64 Bypass Valve 62 Bypass Valve=10 32

C cacr 57 CALA 35, 63 CALC 35, 63 Calib=15 30, 31 Calib=19 28 CCBC 37 CCFF 36, 37, 63 CCRF 36, 37 CDBI 35 CETY 36, 37 CHCA 35 CHDF 35

CHDO 35 CHRU 35 CHST 35 Chute 60 Chute Gross Weight 60 Chute Weight Span 64 CMAM 36, 37, 63 CMRD 36 CMRU 36, 63 Commands 6 condensed alarm status words 53 CondensedAlarmStatus 61 CondensedProcStatus word 38 CPAS 37, 63 cpas 57 crcr 57 CRMD 63 CSPA 35, 63 cspa 57 CSPC 35, 63 cspc 57 CSTC 35, 63 cstc 57 cstr 57 CTAR 36, 37, 63 CTOC 35, 63 ctoc 57 CTOF 35, 63 CTON 35, 63 CTR2 36, 63 CVOM 36, 37, 63

D Data Lock=14 26 Data types 6 Deriv Contrib Freq 61 Deriv Time 64 DeviceNet 58 Divert Gross Weight 61 Divert Net Weight 60 Divert Weight Span 64 Dribble 33 Dribble Drive Command 61, 64 Dribble=15 28 Drive Cmd 29 Drive Command 60 Drive Command=2 34 Drive Command=3 31 Drive Command=4 31

DriveCommand=5 DriverEna 27 Dynamic Tare=18

30,

32

29

E Empty 33 Empty=15 29 Empty=16 28 EthernetIP 58 expanded PSW 42 Ext. Al. 33 External alarm=12 26

F Fast Drive Command 64 Feeder run 27 Feedfactor 29 Feedfactor=4 34 Feedfactor=6 31 Feedfactor=7 32 FF Calibration 33

61,

G global floating point reads

60

H Hard alarm 27 HiLoGear=14 28,

33

I Initial Feeding Factor 64 Integ Contrib Freq 60 Interlock 26

L LineBatchCompleteMass 56 LineBatchCompletePercent 56 LineBatchSize 56 LineMassflow 56 LineMaxBatchSize 56 LineMaxRate 56 LineSetpoint 56 LineTotalizer 56 listing of KSL line variables 56 Loader Enable=21 28 Loader Level=20 28 Loader Run=12 33 Loader=12 28 Loc/Ext 26 LWB 6 LWF 6

K-Tron KCM Docu. Inc. Stops

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