wbf programming using the k- · pdf file806 k-commander weigh belt fdr. programming rev b...
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806K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF ProgrammingUsing the
K-Commander
806K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
806K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
No part of this publication may be reproduced or transmitted in any form or by anymeans electronic or mechanical including photocopy, facsimile or computer generateddistribution without written permission from the K-Tron Institute. All translationrights are reserved by the K-Tron Institute . The K-Tron Institute has made every effortto ensure the accuracy and validity of this document. However, errors and omissionsmay have occurred. If an error or omission is found, please contact the K-Tron Instituteat (609)589-0500.
806K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Table of Contents
General Information for Weigh Belt Feeder (WBF) Programming with K-Cdr. 1Overview ................................................................................................................................... 1Standard Key Arrangements .................................................................................................. 3Editing Variables ...................................................................................................................... 7Common Messages and Meanings from K-Cdr .................................................................. 9
Operator Programming of the WBF Function with the K-Commander .............. 10Overview ................................................................................................................................. 10WBF Feeder Overview, Page 00 ........................................................................................... 11WBF Belt Factor, Page 01....................................................................................................... 15WBF Pre-Feeder Prog., Page 02............................................................................................ 19WBF Current Alarms, Page 03.............................................................................................. 21WBF Alarm Limits, Page 04.................................................................................................. 28
Maintenance Programming of the WBF Function with K-Commander .............. 34Overview ................................................................................................................................. 34WBF Scale Programming, Page 05....................................................................................... 35WBF SFT Programming, Page 06 ......................................................................................... 39WBF Feeder Data, Page 07 .................................................................................................... 43Service Variable Index Listing.............................................................................................. 55WBF Frequency I-O, Page 08 ................................................................................................ 62WBF Control Parameters, Page 09 ....................................................................................... 66WBF Overview, Page 10 ........................................................................................................ 68WBF SPC Set-Up, Page 11 ..................................................................................................... 71WBF SPC Chart, Page 12 ....................................................................................................... 73WBF Software Part Numbers, Page 13................................................................................ 77Alarm Shutdown Masking.................................................................................................... 79Weigh Belt Feeder Calibration-WBF ................................................................................... 81Auto Cal Feature for WBF Software.................................................................................... 85Index......................................................................................................................................... 90
806.1K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
General Information for Weigh Belt Feeder (WBF)Programming with K-Cdr.
Overview
IntroductionK-Cdr
The following pages describe the K-Commander (K-Cdr ) pages orscreens for the weigh belt feeder application. A listing of menuselections is provided for each screen.
Definitions Here is a listing of common terms used in loss-in-weight feeding andcontrol.
Term Definition
Belt Loading This is the weight of material per length ofbelt. Measurement is in kg/m or lb/ft.
Belt Speed This value is the measured speed of theweigh belt in m/min or ft/min.
Drive Command This is the frequency output of the LWF K10Scontroller that normally provides the setpointsignal to the MDU or motor drive unit. Thelarger the value of drive command, thegreater the feedrate should be. Maximumoperational value of Drive Command is100%.
Feedrate This is the massflow output of the feeder.
Continued on next page
806.2K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Overview, Continued
Definitionscon’t
Term Definition
Gravimetric control The control is automatic. That is, themassflow is compared to the setpoint, and ifdifferent, a change in drive command willoccur.
STP Sample time period is the length of time for aweight sample to occur.
Tare The weight of the feeder and hopper, lessmaterial.
Total Gear Reduction This is the reduction value of the inlinereducer and sprocket set on the feeder.
Transport Delay This is the time delay from belt loadingcalculation to the time that that value is usedto calculate belt speed. This function is use tomove the weight measurement electronicallyto the feeder discharge.
Volumetric control The control is manual. That is, the massflowis calculated if possible, but no comparison toSetpoint is made and the Drive Commandremains fixed.
806.3K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Standard Key Arrangements
Introduction Many keys are the same and used in the same way on each screen. Thismap will describe the often used keys and each page section willdescribe those keys unique to that page. Here is a typical key layout forviewing.
Layout ofoften usedkeys
EditMode
F5 F6 F7 F8F1 F2 F3 F4GravMode
VolMode
F5 F6 F7 F8ChangeValue <ESC>
Standard keysand theirfunctions
Key
Number
Key Name Description
F1
Grav Mode
Places the control in Gravimetric orMass control. The WBF Controllermeasures the massflow, comparesthis value to the setpoint andcauses the Drive Command tochange so that the massflow willequal the setpoint
F2
Vol Mode
When operating in Volumetriccontrol, the Drive Command isfixed. There is no attempt by thecontroller to make the massflowvalue equal the setpoint.
F3 Unused
F4 Unused
F5
Edit Mode
When pressed, highlights the firstvariable that can be changed. Theswitch then becomes "ChangeValue".
Continued on next page
806.4K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Standard Key Arrangements, Continued
Standard keysand theirfunctions con’t
Key
Number
Key Name Description
F6
Causes the active page in Quadscreen to move counterclockwise. Itmoves the active screen once eachtime the key is pressed. These
F7 Causes the active page in Quadscreen to move clockwise. It movesthe active screen once each time thekey is pressed.
F8 Unused
Continued on next page
806.5K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Standard Key Arrangements, Continued
Display actionline above thefunction keys
The Action Line above the function keys indicates the current action of thecontroller.
EditMode
F5 F6 F7 F8F1 F2 F3 F4
Grav Run Local
GravMode
VolMode
Display Action Line
Here is a listing.
Located Function
Window above F1key
Indicates whether machine is inGravimetric or Volumetric control.
Window above F2key
Indicates whether machine isrunning or is stopped.
Window above F4key
If the word DISA is indicated, theRun Enable external interlock ispreventing the machine fromoperating. The message ALSHUTindicates that the Alarm Shutdownexternal interlock is preventing themachine from operating.
Window above F5 Indicates that a "Tare" is in effect.
Window above F6key
Indicates if machine is in Local,Ratio, Direct or Line 1-4 or Line 1-7Mode.
Continued on next page
806.6K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Standard Key Arrangements, Continued
When F5-Editis pressed
When key F5, the Edit key is pressed, certain keys take on newfunctions. This table describes those functions. This detail is applicablefor all pages in this section and will be shown only here.
Key
Number
Key Name Description
F5
Change Value
When this key is indicating"Change Value", pressing this keywill result in a pop-up menu beingdisplayed from which you canselect a value for entry by scrollingwith the F6 and F7 key.
F6 Permits selection of a parameterfrom a pop-up menu. As you pressthis key, you scroll down throughthe selections.
F7 Permits selection of a parameterfrom a pop-up menu. As you pressthis key, you scroll up through theselections.
F8
<Esc>
When F5 says "Change Value", thiskey , when pressed, gets you out ofthe data changing activity and backto the normal display.
806.7K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Editing Variables
Introduction This map gives you details about editing or changing machinevariables.
Changing avariable
Step Action
1 Press Key F5 when it says "Edit Mode"
2 Press Key F6 or F7 to highlight the desired variable to bechanged.
3 Press Key F5 now labeled" Change Value" to permit an entryof a number by the keyboard. From the keyboard, enter thedesired value.
4 If the variable requires a non-numeric selection, a pop-upmenu will be displayed on the screen Use the F6 and F7 keyto select the desired entry.
5 Press the Enter Key to load your desired selection.
6 Press F8 to return to normal operation.
Order of dataentry, animportant fact
The order of data entry is very defined and is all based from the scalerange setting. Please follow the next procedure to program thecontroller from default conditions. Use this procedure if data is lost in apower or battery back-up failure. If SFTs are used, you can skip tostep 3.
Step Action
1 Check to see engineering units of operation are in Kg/hr-page Mcn.07
2 Program scale gross weight range, pg Mcn.05. See the tablenext for these values.
3 Change the engineering units to those of your operation.
4 Program Full Scale Setpoint on page Mcn.07
5 Program other values as required.
Continued on next page
806.8K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Editing Variables, Continued
Scale rangesfor WBF
The scale ranges for standard machines are listed. Other ranges may beused. Please confirm with your machine specification sheet.
Machine Type Scale Range
W300 6 Kg
W600 6 Kg
W1000 45 Kg
Loss ofprogrammingdata
If the battery on the K10S WBF controller fails, your enteredprogramming data will be lost. This condition is generally indicated bylooking at the variable labeled Full Scale Setpoint on page Mcn.07. Itwill be 0 if data has been lost. It is recommended that you retain a hardcopy printout of the programming data for each machine and its pages,plus the Line and System pages. You can use the K-Cdr print functionto help you.
If power is left off the system for 3 weeks or more, it is possible thatyour entered programming data will be lost due to the battery beingdischarged. If this is a problem, see your maintenance department forresolution.
806.9K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Common Messages and Meanings from K-Cdr
Introduction This section will present some common messages as displayed by theK-Commander (K-Cdr) and provide an explanation and resolution tothem. Alarm specific messages are found in the Alarm page 03.
Commonmessagelisting withresolution
The following table outlines common K-Cdr messages.
Message Meaning Resolution
Feeder Range Error The entry is outsidethe limits of thevariable selected
Re-check the entry.Check the rangelimits of the variable.
Hint: see the SerialProtocol for thoselimits.
NAK Due to FeederRunning
Some variables likescale range cannot bechanged while thefeeder is running
Stop the feeder tomake this change.
806.10K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Operator Programming of the WBF Function with theK-Commander
Overview
Introduction This section deals with the pages that the operator will likely program.Please note that the page numbers beginning with 01 is merely to givereality to the display and this number could range from 01 to 15.
806.11K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Overview, Page 00
IntroductionPage 00 The page 00 or the Overview page for the weigh belt feeder holds most
of the information required by the operator to run the equipment. Usethe Scroll keys to move from page to page.
Page 00 layout This diagram shows the data layout. The second row of keys pop up whenthe Edit key is pressed and a variable is highlighted.
F5 F6 F7 F8Edit
Mode
F1 F2 F3 F4GravMode
VolMode
TotalizerClear
F5 F8ChangeValue <ESC>
PELLETS WBF : Feeder Overview M02.00
MASS FLOW SETPOINT 1000.000 Kg/hrACTUAL CURRENT MASS FLOW 999.980 Kg/hrBELT LOADING 2.891 Kg/mDRIVE COMMAND 57.770 %TOTALIZER VALUE 43456.500 KgBELT SPEED 5.766 m/minMOTOR SPEED 1039.860 RPM
Continued on next page
806.12K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Overview, Page 00, Continued
Page 00variable list
The following is a listing and description of each variable on this page.A "•" mark shows the values that you can edit. A "#" indicates that thevalue is changed by a Function key.
Variable Name Edit? Description
Massflow Setpoint • This is the operating setpoint of thefeeder and this value can bechanged when the edit key ispressed and the variable ishighlighted in red. A value enteredin that is greater than the Full ScaleSetpoint will result in a "RangeError" message. The entry is inunits of rate. e.g. 1000 Lb/hr. Youmust press the enter key after entryof the value to load that value intothe Massflow Setpoint location.
Range of Values 0 to Full Scale Setpoint, pgMcn.07Default value: 0
Actual Current Massflow This is the result of what the feederis delivering into the process in theunits of setpoint. For example, thevalue might be 999.9 Lb/hr. Thisnumber represents the rate towhich material is being added tothe process.
Belt Loading If the "Tare" is done correctly, thisnumber represents the weight inKg/meter or Lb/ft of the materialon the weigh belt.
Continued on next page
806.13K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Overview, Page 00, Continued
Page 00variable listcon’t
Variable Name Edit? Description
Drive Command This value indicates how much ofthe controller output is used todeliver indicated actual massflowvalue.
Range of Operation Maximum Range: 0-125 % Nominal Range: 0-100 % Desired Range: 10%-100 %
Totalizer Value # This value is the quantity ofproduct that has been delivered ineither Kgs or Lbs since the last timethe Totalizer was reset or cleared.
Range of Operation Maximum Range: 999,999.999
Belt Speed This value is the speed of the belt ineither Meters/minute orFeet/minute. The Speed Pick-upGear Teeth Setpoint and the TotalGear Reduction must be setcorrectly.
Motor Speed If the Speed Pick-up Gear TeethSetpoint is correct, then this valuerepresents the motor rpm of thefeeder.
Continued on next page
806.14K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Overview, Page 00, Continued
Page 00 specialkey list
The following is a listing of keys and their function.
Key
Number
Key Name Description
F3 Totalizer Clear Will clear the totalizer value onpage 00 to zero.
806.15K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Belt Factor, Page 01
IntroductionPage 01 The page 01 for the weigh belt feeder holds the information regarding
belt loading factors. There are various belt loading values used by thecontroller. Please refer to the WBF Control section for additionalinformation. Use the Scroll keys to move from page to page.
Page 01 layout This diagram shows the data layout. The second row of keys pop up whenthe Edit key is pressed and a variable is highlighted.
EditMode
F5 F6 F7 F8F1 F2 F3 F4
PELLETS WBF : Belt Factors M02.01
BELTLOAD SETPOINT 3.666 Kg/mTOTALIZER DEADBAND LIMIT 0 Kg/mBELTLOADING 2.891 Kg/m
MATERIAL FED IN CALIB. 00.000 KGCALIB CORRELATION 98.76%CALIB TIME 60 secCALIB DRIVE COMMAND 50%
GravMode
VolMode
F5 F6 F7 F8ChangeValue <ESC>
Continued on next page
806.16K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Belt Factor, Page 01, Continued
Page 01variable list
The following is a listing and description of each variable on this page.A "•" mark shows the values that you can edit. A "#" indicates that thevalue is changed by a Function key.
Variable Name Edit? Description
Belt Load Setpoint • This value is used for twofunctions. First, in Vol Control, thisvalue is used to determine drivecommand. The formula is:
DC(vol) = [SP/(BLS *k)]*100%
where DC = Drive Command, SP =setpoint, BLS = Belt Load Setpointand k = a scaling factor that is notknown.
The factor BLS is also used to scaleBelt Loading if the display in % isdesired. The Formula is:
Belt Load(%) = 100*BL/BLS
where BL = actual belt loading andBLS = belt load setpoint.
Range of Values 0 toDefault value: 0
Continued on next page
806.17K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Belt Factor, Page 01, Continued
Page 01variable listcon’t
Variable Name Edit? Description
Totalizer DeadbandLimit
• This value sets the limit for whichbelt loading will be totalized. Forexample, if actual belt load is lessthan this limit, the displayed beltload will be zero. This prevents thetotalizer from recording erroneousvalues when the belt runs empty. Range of Values 0 toDefault value: 0
Beltloading This is the actual belt loading asdisplayed on page 00. Units areKg/meter or Lb/ft.
Material Fed inCalibration
This is the totalized amount ofmaterial fed during the calibrationcycle.
Calibration Correlation This is a percentage value thatrepresents a level of confidence inthe calibration results. The numbershould be between 90 – 100%.
Calibration Time This is the duration of the autocalibration cycle. 60 seconds is thedefault.
Calibration DriveCommand
This is the percentage of maximummotor speed used during thecalibration cycle. We recommend avalue between 40-60%.
Continued on next page
806.18K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Belt Factor, Page 01, Continued
Setting drivecommand invol control
This procedure permits step by step for setting drive command in Volcontrol. You will do this action when setting the Motor Drive Unit or tospecifically set a desired drive command when in Vol control. Note thatdrive command directly sets belt speed.
Step Action
1 Put the unit in "Vol" control.
2 Put the operating setpoint on page 00.
3 Determine the drive command that you desire
4 Enter a value of Belt Load Setpoint-BLS- on page .01
5 Run the feeder and read drive command.
6 Read Drive Command.
Drive Command Status What to do?Too High Increase Belt Load SetpointToo Low Decrease Belt Load Setpoint
7 When you have established the desired drive command andbelt speed, record the setting of BLS
8 You can now run feeder in Mass Control
806.19K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Pre-Feeder Prog., Page 02
IntroductionPage 02
The page 02 for the weigh belt feeder holds the information regardingpre-feeder span value. This value is only used when you have a pre-feeding device on your belt feeder.
Page 02 layout This diagram shows the data layout. The second row of keys pop up whenthe Edit key is pressed and a variable is highlighted.
EditMode
F5 F6 F7 F8F1 F2 F3 F4
PELLETS WBF : Belt Load Prog. M02.02
GravMode
VolMode
F5 F6 F7 F8ChangeValue <ESC>
PRE-FEEDER DC SPAN 1.0000
Continued on next page
806.20K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Pre-Feeder Prog., Page 02, Continued
Page 02variable list
The following is a listing and description of each variable on this page.A "•" mark shows the values that you can edit. A "#" indicates that thevalue is changed by a Function key.
Variable Name Edit? Description
Pre-Feeder DC Span • This entry will scale an outputcalled Pre-feeder Drive Commandto be a desired frequency with aspecific belt speed of the machine.The bigger the span, the higher thepre-feeder speed will be with agiven belt speed. Range of Values 0 to 10,000Default value is 1.000
Prefeeder set-up
Using a prefeeder requires that you set a frequency output #1-3 on pageMcn.08 to "Prefeeder", connect this signal by some means at theappropriate I-O point to the prefeeder and then use the Prefeeder D.C.Span to cause the belt loading to increase or decrease as you increase ordecrease the Prefeeder D.C. Span. As Prefeeder D.C. Span increases, thesignal from the selected frequency output also increases causing theprefeeder to deliver more material.
806.21K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Current Alarms, Page 03
IntroductionPage 03
The page 03 for the weigh belt feeder holds the information regardingfeeder alarms. A list of alarm messages will be presented here. Alsoplease refer to the troubleshooting section of your manual for moreinformation. Use the Scroll keys to move from page to page.
Page 03 layout This diagram shows the data layout.
F5 F6 F7 F8F1 F2 F3 F4
PELLETS WBF: Current Alarms M02.03
Alarm 1:Alarm 2:Alarm 3:Alarm 4:Alarm 5:Alarm 6:Alarm 7:Alarm 8:Alarm 9:Alarm 10:
FEEDER STOPPED BY Motor Drive Failure
GravMode
VolMode
AlarmAck
ClearAlarm
Continued on next page
806.22K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Current Alarms, Page 03, Continued
Alarmmessage tablewith cause andremedy
Note: If you see a message with three capital characters together likeDHS, DLS, you can be assured that they are mnemonics used by theserial data channel and information can be found in the serial protocolsection.
Alarm Cause Remedy
External AlarmActive
A digital input on theK10S Controller Pcboard is active.
Clear external alarminput to K10Scontroller Pc board.
Drive Comm greaterthan DHS
Actual Drivecommand is greaterthan the Alarmsetpoint called DriveCommand HighLimit, K-Cdr pageMcn.04.
The setpoint is toohigh for the givenconditions of feederand material.Material blockagepossible. Important ifMass Flow Low alarmis present.
Drive Comm less thatDLS
Actual Drivecommand is lowerthan the Alarmsetpoint called DriveCommand LowLimit, K-Cdr pageMcn.04.
Setpoint is too low fora given materialand/or feeder. Re-size equipment to updrive command.
Fdr ControllerTimeout
External channel datacommunicationsbetween K10S Pcboard and K-Cdr hasfailed.
Check baud rates atboth ends of datachannel, check powerat K10S Pc board,Review leds on K10SPc board.
Fdr Internal ChannelFailure
Internal channel ofK10S Pc board hasfailed.
Check physicalconnections and slavedevice that isconnected to this datachannel.
Continued on next page
806.23K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Current Alarms, Page 03, Continued
Alarmmessage tablewith cause andremedy con’t
Alarm Cause Remedy
Belt Load > BHS The actual beltloading is greaterthan High Belt Loadalarm limit, K-Cdrpage Mcn.02.
Material may beflooding onto belt,gate may be set toohigh for materialdensity. Value of BHSwas automaticallyrecalculated when anew value of BeltLoad Setpoint wasentered and is nowwrong.
Belt Load <BLS The actual beltloading is less thanLow Belt Load alarmlimit, K-Cdr pageMcn.02.
Material may beflooding onto belt,gate may be set toohigh for materialdensity. Value of BHSwas automaticallyrecalculated when anew value of BeltLoad Setpoint wasentered and is nowwrong.
Feeder InvalidCommand
The K10S Pc does notrecognize thecommands sent bythe K-Cdr.
Check that K10S Pcsoftware iscompatible withcurrent level of K-Cdrsoftware.
Feeder Range Error The entry value isgreater or less thanthe value allowed forthis variable.
Check the limits forthis variable. UseCommunicationProtocol for helphere.
Continued on next page
806.24K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Current Alarms, Page 03, Continued
Alarmmessage tablewith cause andremedy con’t
Alarm Cause Remedy
I-O Board Failure Failure betweenK-Cdr Controller andI-O Pc boards.
Check hardware inK-Cdr for correctoperation. Refer toled chart andhardware description.
Rate Greater thanSetpoint
Actual mass flow rateis greater than thesetpoint by theMassflow + AlarmLimit, K-Cdr pageMcn.04
Check for flooding ofmaterial. Check to seeif setpoint is rapidlychanging. Make surelimit setting is nottighter than the feedsystem can deliver.
Rate Less thanSetpoint
Actual mass flow rateis less than thesetpoint by theMassflow - AlarmLimit, K-Cdr pageMcn.04
Be sure that feeder isdischarging. Makesure limit setting isnot tighter than thefeed system candeliver. Check withDrive Commandalarms. Check formaterial starvation atinlet section.
Scale/SFT# "xx"Overrange
The scale orindividual SFT asidentified by the "xx"is in overrange.
SFT has weight on itgreater than itscapacity. Removeweight from theweigh bridge or SFT.
MDU Alarm Occurs when K10Scontroller digitalinput #42 is takenlow.
If used, it indicatesthat the motor driveis in alarm and thedrive must becorrected.
Continued on next page
806.25K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Current Alarms, Page 03, Continued
Alarmmessage tablewith cause andremedy con’t
Alarm Cause Remedy
Scale/SFT# "xx"Underrange
The scale orindividual SFT asidentified by the "xx"is in underrangecondition.
SFT has appliedweight that is lessthan its zero value orformula value.Generally a failurecondition in thetransducer orweighbridge.Binding or forcedunloading of the SFTmay also result in thisproblem.
Weight ProcessorFailure
Controller is notreceiving a weightsignal from SFTs towhich it is connected.
Many problems cancause this situation.An SFT failure, aScale Interface Pcfailure, a powerfailure to the SFT orScale Interface Pcboard.
Controller BoardFailure
The K10S controllerpc board has failed
Replace the offendingK10S controller pcboard. Locate byaddress. Reprogram.
Display Board Failure The K10S DU ordisplay pc board hasfailed
Replace the offendingK10S DU pc boardand reprogram.
Belt Slip Alarm The weigh belt isbroken or is slippingbeyond its alarm limit
Check the weigh beltfor tears, build-up orother problem
Continued on next page
806.26K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Current Alarms, Page 03, Continued
Feederstopped byconditions
The last line on the display shows how the feeder was last stopped.Here is a listing of the causes as indicated.
Message Meaning
Board Reset Message The K10S controller pc board isin reset.
Run Disable Message The Run Enable Input ispreventing the unit fromrunning.
Stop Bit Message The feeder was stopped by thestop bit input.
Alarm Shutdown Message The feeder was stopped by thealarm shutdown input.
Local Display Message The feeder was stopped by stopbutton on the local display.
External Display Message The feeder was stopped by stopbutton on the remote display.
Zero Setpoint Message No setpoint is present.
Drive Command Low Message Drive command is below 1%.
Motor Drive Failure Message Motor is not running when toldto run with adequate drivecommand.
Continued on next page
806.27K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Current Alarms, Page 03, Continued
Alarm typedefinitions
Alarm Type Meaning
Pending Alarm An alarm condition is occurringbut the alarm timer has not timedout.
Hard Alarm The alarm is actuating the alarmsystem. The alarm indicator is red.
Acknowledged Alarm The alarm condition is still presentbut the alarm system has beensilenced.
Page 03 specialkey list
Key
Number
Key Name Description
F3
Alarm Acknowledge
Will silence the alarm system butretain the alarm message forcorrective action. Alarm indicatorwill turn yellow.
F4
Alarm Clear
Will clear an alarm if the conditionthat caused the alarm is no longerpresent. Alarm status indicator willreturn to white.
806.28K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Alarm Limits, Page 04
Introduction:Page 04
The page 04 for the weigh belt feeder holds the information regardingalarm limit functions. Use the Scroll keys to move from page to page.
Page 04 layout This diagram shows the data layout. The second row of keys pop up whenthe Edit key is pressed and a variable is highlighted.
EditMode
F5 F6 F7 F8F1 F2 F3 F4
PELLETS WBF : Alarm Limits M02.04
MASSFLOW (-) ALARM LIMIT 10 %MASSFLOW (+) ALARM LIMIT 10 %DRIVE COMMAND HIGH LIMIT 100 %DRIVE COMMAND LOW LIMIT 0 %ALARM DELAY SETTING 30 secSTART-UP DELAY SETTING 60 secMEASURED BELT SLIP 0.000 %BELT SLIP ALARM LIMIT 0.000 %BELTLOAD HIGH ALARM LIMIT 4.000 Kg/mBELTLOAD LO ALARM LIMIT 1.000 Kg/mCLEAR ALARMS ON STOPS DISABLED
GravMode
VolMode
F5 F6 F7 F8ChangeValue <ESC>
Continued on next page
806.29K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Alarm Limits, Page 04, Continued
Page 04variable list
The following is a listing and description of each variable on this page.A "•" mark shows the values that you can edit. A "#" indicates that thevalue is changed by a Function key.
Variable Name Edit? Description
Massflow (-) Alarm Limit • If the massflow drops below thisentry multiplied times the setpoint,a Low Mass Flow Alarm will occur.
ex: Setpoint = 1000 Kg/hr
Your entry is 10%.
Minimum deviation without alarm= -1000 * 0.1 = -100 Kg/hr or aflowrate of 900 Kg/hr which =1000-100. If the flow drops below900 Kg/hr an alarm will occur. Range of Values 0 to 100 %Default value: 10%
Massflow (+) AlarmLimit
• If the massflow goes above thisentry multiplied times the setpoint,a High Mass Flow Alarm willoccur.
ex: Setpoint = 1000 Kg/hr
Your entry is 10%.
Minimum deviation without alarm= 1000 * 0.1 = 100 Kg/hr or aflowrate of 1100 Kg/hr which =1000 + 100. If the flow goes above1100 Kg/hr an alarm will occur. Range of Values 0 to 100 %Default value: 10%
Continued on next page
806.30K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Alarm Limits, Page 04, Continued
Page 04variable listcon’t
Variable Name Edit? Description
Drive Command HighAlarm Limit
• Sets the point above which, if drivecommand goes, will result in analarm called High DriveCommand.
ex: This entry is 80%, If drivecommand exceeds this value, analarm will occur. Range of Values 5% to 100 %Default value: 100%
Drive Command LowAlarm Limit
• Sets the point below which, if drivecommand goes, will result in analarm called Low Drive Command.
ex: This entry is 10%, If drivecommand goes below this value, analarm will occur. Range of Values 0 to 95%. Must be 5% or greaterbelow Drive Command HighLimit.Default value: 0%
Continued on next page
806.31K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Alarm Limits, Page 04, Continued
Page 04variable listcon’t
Variable Name Edit? Description
Alarm Delay Setting • Sets the time that a mass flow ordrive command alarm must bepending before a hard alarm canexist ( actuate the alarm system ).Other alarms will bypass this delayand immediately actuate the alarmsystem. Range of Values 5 to 240 secondsDefault value: 30 seconds
Start-up Delay Setting • Sets the time, when the Run buttonfor a feeder is pressed, where themassflow and drive commandalarms will not be permitted tocause an alarm to occur. Range of Values 0 to 240 secondsDefault value: 60 seconds
Measured Belt Slip This is the percentage of slip that isdetected between idler and driverollers if the idler roller pick-up isused.
Belt Slip Alarm Limit • This is the percentage of belt slippermitted before an alarm occurs. Range of Values 0 to 100 %Default value: 0 %
The value of 0% disables thisalarm.
Continued on next page
806.32K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Alarm Limits, Page 04, Continued
Page 04variable listcon’t
Variable Name Edit? Description
Belt Load High AlarmLimit
• Sets the level of beltloading,beyond which will cause a HighBelt Load Alarm. As long as theactual belt loading on the feeder isless than this number, no alarmswill be established. Range of Values
Default value: 0
Low Belt Load AlarmLimit
• Sets the level of beltloading, belowwhich will cause a Low Belt LoadAlarm. As long as the actual beltloading on the feeder is more thanthis number, no alarms will beestablished. Range of Values
Default value: 0
Clear Alarms on Stops The stop button will send a clearalarms command if enabled.
Continued on next page
806.33K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Alarm Limits, Page 04, Continued
Setting highbelt load limit
Please follow the steps outline below to set this value. Set this value ifyou wish to get alarms or an output when beltloading exceeds thisvalue.
Step Action
1 Determine the maximum belt loading that you willencounter in operating your feeder.
2 Multiply this value by 1.2
3 Enter this resulting value in the Beltload High Alarm Limit
Setting lowbelt load limit
Please follow the steps outline below to set this value. Set this value ifyou wish to get alarms or an output when beltloading goes below thisvalue.
Step Action
1 Determine the minimum belt loading that you willencounter in operating your feeder. If it is zero, enter 0 instep 3.
2 Multiply this value by 0.8
3 Enter this resulting value in the Beltload Low Alarm Limit
806.34K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Maintenance Programming of the WBF Function withK-Commander
Overview
Introduction This section deals with the K-Cdr pages that are likely to be used bymaintenance personnel for calibration and servicing the equipment.
In this chapter This chapter will provide information on the following programactivities. Please note that the page numbers beginning with 01 ismerely to give reality to the display and this number could range from01 to 15.
806.35K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Scale Programming, Page 05
Introduction:Page 05
The page 05 for the weigh belt feeder holds the information regardingthe weighing system and the calibration and tare functions for it. Usethe Scroll keys to move from page to page.
Page 05 layout This diagram shows the data layout. The second row of keys pop up whenthe Edit key is pressed and a variable is highlighted.
F5 F6 F7 F8Edit
Mode
F1 F2 F3 F4GravMode
VolMode
PELLETS WBF : Scale Programming M02.05
SCALE GROSS WEIGHT RANGE 6.000 KgMEASURED GROSS WEIGHT 1.189 KgMATERIAL NET WEIGHT 0.544 KgBELT TARE WEIGHT 0.645 KgWEIGHT SPAN 1.000BELT INDEX Disabled
F5 F6 F7 F8ChangeValue <ESC>
T
Continued on next page
806.36K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Scale Programming, Page 05, Continued
Page 05variable list
The following is a listing and description of each variable on this page.A "•" mark shows the values that you can edit. A "#" indicates that thevalue is changed by a Function key.
Variable Name Edit? Description
Scale Gross WeightRange
• This is the entry for your scalegross capacity which you will findon the scale tag. The units of entryare in Kg. Failure to have the unitsin Kg/hr will cause an entry error. Range of Values 0.001 Kg to 1,000,000,000 KgDefault value: 0.001 Kg
Measured Gross Weight This is the gross weight value asseen by the weigh bridge whichsupports the weigh belt andmaterial. The units are in lbs or kgs.
Material Net Weight This value is the amount ofmaterial on the belt sensed by theweigh bridge and the transducermounted therein. The units are inlbs or kgs.
Material Net Weight = MeasuredGross Weight -Tare
Belt Tare Weight •
#
This value represents the weight ofthe weigh bridge and belt. Thisnumber can be entered when thisdata value is highlighted or thesame result can come frompressing the "Tare" push-button.Please record this value for futureuse. Range of Values 0.0 Kg to 1,000,000,000 KgDefault value: 0.000 Kg
Continued on next page
806.37K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Scale Programming, Page 05, Continued
Page 05variable listcon’t
Variable Name Edit? Description
Weight Span • This value will correct an error incalibration. This number spans thebelt loading not net weight.NWS =
CWS *( actual sample average/setpoint)
where NWS = New Weight Span
CWS = current weight span and sampleweight is the average of some weightsamples delivered from the machine.
Range of Values 0.1 to 10Default value: 1.000
Belt Index • If enabled, the controller will use asensor to detect a reference positionon the belt such that during tareand subsequent operation, a beltmemory function will be usedimproving feeder performancewhen non-uniform weigh belts areused.
Disabled <Enabled
The default entry is "Disabled"
Continued on next page
806.38K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Scale Programming, Page 05, Continued
Determiningscale ranges
If You Have ?? Then Do
If you have a W300 or W600 Enter 6 Kg as scale range.
If you have a W1000 Enter the value of 45 Kg forthe scale range.
For other belt feeder equipment Review the specificationsheets for the equipment toobtain the required value.
Page 05 keylist
Key
Number
Key Name Description
F3 Tare Pressing this button when thefeeder hopper is empty will tarethe scale system and enter the tarevalue in the Feeder Tare Weightvariable.
The feeder will run at 63% drivecommand during the tare cycle.
806.39K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF SFT Programming, Page 06
IntroductionPage 06
The page 06 for the weigh belt feeder holds the information regardingthe SFT programming system. Use the Scroll keys to move from pageto page.
Page 06 layout This diagram shows the data layout. The second row of keys pop up whenthe Edit key is pressed and a variable is highlighted.
EditMode
F5 F6 F7 F8F1 F2 F3 F4
PELLETS WBF : SFT Programming M02.06
NODE # OF SELECTED SFT 1SFT CONNECT/DISCONNECT DscnctNUMBER OF SFTS REQUIRED 1SFT RAW WEIGHT 0.000 KGSELECTED SFT STATUS 00000000SFT TYPE CODE 0SFT CONFIGURATION - - - - - - - - - - - - - - -
GravMode
VolMode
F5 F6 F7 F8ChangeValue <ESC>
PollSFTs
Continued on next page
806.40K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF SFT Programming, Page 06, Continued
Page 06variable list
The following is a listing and description of each variable on this page.A "•" mark shows the values that you can edit. A "#" indicates that thevalue is changed by a Function key.
Variable Name Edit? Description
Node # of Selected SFT • This entry is the address of the SFTthat you wish to look at.
SFT Connect/Disconnect • Dscnct <Connct
This entry allows you to eitheractivate the selected SFT into thesystem by picking Connect or toremove the selected SFT from thesystem by selecting disconnect.Default value is "Dscnct".
Number of SFTsRequired
• Set this to the number of SFTs usedin the particular feeder system.Normally a value of 1 is enteredhere.
SFT Raw Weight This represents the weight appliedto the SFT that is selected byaddress above. If the SFT weightexceeds the SFT range, an error willoccur.
Selected SFT Status A code is shown here that describesthe operational status of the SFTselected. Used by service only. Thisnumber is a decimal value of a hexnumber ( 2 byte) that describesvarious problems with the SFTbeing interrogated. There shouldbe some number in this location,zero is a type of failure.
Continued on next page
806.41K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF SFT Programming, Page 06, Continued
Page 06variable listcon’t
Variable Name Edit? Description
SFT Type Code This identifies the gross scale rangeof the selected SFT. For a W300 andW600 machine, this variable willread 0006.
SFT Configuration • By pressing the ENT key, you willcause a "Poll" to result and thusidentify the connected SFTs. Toconnect an SFT, its address must bepreset to "0". SFT failure codes willshow here in the address locationthat is indicating the failure.
SFT Failure Codes "f" = SFT failure of its internalparts. A vibrating wire or othermalfunction has occurred. TheSFT is still communicating withthe controller. "t" = Timeout. The SFT is notcommunicating with thecontroller. The reasons are many. "?" = Incorrect response fromSFT. " - ' = No SFT at the locationindicated.
Continued on next page
806.42K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF SFT Programming, Page 06, Continued
Page 05 keylist
Key
Number
Key Name Description
F3
Poll SFTs
Pressing this button will cause theK10 processor to send a poll on theWeight channel to locate connectedand operational SFTs by address.
Specialaddressing forSFT’s usingthe QuadController
If you have selected QWBF300 or QWBF600 as feeder type on Mxx.07use the information below for SFT addressing.
Special care must be taken in addressing SFT’s when using the QuadController Software. The Quad software will automatically assign anSFT to a particular feeder depending on the SFT’s address. For QWBFselections use the table below for addressing assignments.
Feeder # Single SFT
1 1
2 4
3 7
4 10
Note: If you are using multiple Quad controller boards, this addressingscheme is repeated for each Quad Controller board
806.43K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Data, Page 07
Introduction:Page 07
The page 07 for the weight belt feeder holds the information that scalesthe feeder unit. Use the Scroll keys to move from page to page.
Page 07 layout This diagram shows the data layout. The second row of keys pop up whenthe Edit key is pressed and a variable is highlighted.
F5 F6 F7 F8Edit
Mode
F1 F2 F3 F4GravMode
VolMode
PELLETS WBF : Feeder Data M02.07
FULL SCALE SETPOINT 2000.000 Kg/HrUNITS SELECTION Kg/HrEXT. TOTALIZER INCR. 1.000 KgFEEDER TYPE SELECTION W300SPEED PICKUP GEAR TEETH 260TOTAL GEAR REDUCTION 89.00FEEDER MODE LocalPROGRAMMING PRIORITY LCD Locked OutBELT LENGTH ( m ) 1.880DRV PULLEY CIRCUMFERENCE ( m ) 0.359TRANSPORT LENGTH ( m ) 0.265WEIGH DECK LENGTH ( m ) 0.356SERVICE VARIABLE INDEX UndefinedSERVICE VARIABLE VALUE 0.0000
F5 F6 F7 F8ChangeValue <ESC>
Continued on next page
806.44K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Data, Page 07, Continued
Page 07variable list
The following is a listing and description of each variable on this page.A "•" mark shows the values that you can edit. A "#" indicates that thevalue is changed by a Function key.
Variable Name Edit? Description
Full Scale Setpoint • This entry sets the maximum valueof setpoint that you can enter onpage 0 without getting and errormessage and this value also sets thescaling for the frequency I-O that isused by the controller. Range of Values 0 to 1,000,000,000Default value: 0
Units Selection • Kg/hr <Kg/mlb/hrlb/minton/hrE. ton/hrg/hrg/min
Select the units of choice for youroperation. The units of operationfor each feeder must be the same ifyou are going to work in the Linemode of control. Default value is"Kg/hr".
Continued on next page
806.45K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Data, Page 07, Continued
Page 07variable listcon’t
Variable Name Edit? Description
Ext. Totalizer Increment • This value determines how manyLbs or Kgs are delivered for eachpulse that would be sent from thecontroller to an external totalizer. Range of Values 0 to 1,000,000,000Default value: 0
Continued on next page
806.46K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Data, Page 07, Continued
Page 07variable listcon’t
Variable Name Edit? Description
Feeder Type Selection • This selection sets the weigh beltfeeder software to work with thecorrect feeder type. The "Q" in frontof the number is used with theelectronic hardware used the"QUAD" feeder controller.
VIBLWF120<LWF240W300W600W1000QLWF120QLWF240QWBF300QWBF600QWBF1000QWBF-HFPIDNOT USED
Caution: Make this selection basedupon the kind of feeder that youare connected to. The normalselections are W300, W600 andW1000. The default value is"W300". If a belt feeder other than aW300 or W600 is used, selectW1000 and enter the specific beltlength, drive pulley circumference,transport length and weigh decklength.
Continued on next page
806.47K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Data, Page 07, Continued
Page 07variable listcon’t
Variable Name Edit? Description
Speed Pick-up GearTeeth
Changes have occurred
Check the feederspecification sheet to besure what speed pick-upgear you have.
• This entry scales the RPM displayto read correctly and also scales thebelt speed indication. Look to thefeeder specification sheet todetermine this entry. Normally theentry is either 260 for W300 andW600 or 240 for W1000 feeders.European feeders use 240 only. Asof June 1998, W300/W600 use 120tooth gear. Check the spec sheet.
Range of Values 1 to 999Default value: 240
Total Gear Reduction-TGR
• This value scales the motor speedto provide the correct belt speedindications. This value is theproduct of the inline gear reductionand the sprocket ratio of the feeder.It is called total gear reduction andis calculated like this:
ex:
Inline reduction of 17:1, a reducersprocket of 14 teeth and drivensprocket of 40 teeth.
TGR= 17*(40/14) = 48.57 is theentry in this example
Range of Values 1 to 2322Default value: 11.
Continued on next page
806.48K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Data, Page 07, Continued
Page 07variable listcon’t
Variable Name Edit? Description
Feeder Mode • Local <RatioDirectLine 1Line 2Line 3Line 4
Determines whether a feeder is tobe operated by itself or a part ofLines 1 to 4. This entry determineswhere the controller's setpointcomes from. Refer to the section onControl Modes to learn how eachselection affects the function of thecontroller. The default value is"Local".
Continued on next page
806.49K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Data, Page 07, Continued
Page 07variable listcon’t
Variable Name Edit? Description
Programming PriorityLCD
• Permits the user to program thepriority selection entry for a K10SDisplay Unit - DU- that isconnected to this machine'sInternal Data Channel.
Selections are shown in the pop-window that appears at the rightmiddle side of the screen.
Locked OutSP onlySP and AlarmAll <
Locked Out as a selection meansthat the operator can view allvariables but can make no changesto any variables.
SP Only as a selection means thatthe operator can only change theSetpoint for machines or lines
SP and Alarm as a selection meansthat the user can only modify themachine setpoint and its alarmlimit values. The operator can alsochange the line setpoints.
All as a selection means that everyvariable can be altered for everymachine or situation in the system.
Continued on next page
806.50K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Data, Page 07, Continued
Page 07variable listcon’t
Variable Name Edit? Description
Belt Length • This is the length of the weigh beltin meters. For W300 and W600feeders, this entry is automaticwhen selected feeder type. If aHasler feeder is being used, enterthe belt length from thespecification sheet.
W300 = 1.880 meters
W600 = 1.880 meters
Drive PulleyCircumference
• This is the circumference of thedrive pulley in meters. For W300and W600 feeders, this entry isautomatic when selected feedertype. If a Hasler feeder is beingused, enter the drive pulleycircumference from thespecification sheet.
W300 = 0.359 meters
W600 = 0.359 meters
Transport Length • This is the transport length of theweigh bridge in meters. For W300and W600 feeders, this entry isautomatic when selected feedertype. If a Hasler feeder is beingused, enter the transport lengthfrom the specification sheet.
W300 = 0.265 meters
W600 = 0.229 meters
Continued on next page
806.51K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Data, Page 07, Continued
Page 07variable listcon’t
Variable Name Edit? Description
Weigh Deck Length • This is the distance that describesthe active length of the weighbridge in meters. For W300 andW600 feeders, this entry isautomatic when selected feedertype. If a Hasler feeder is beingused, enter the weigh deck lengthfrom the specification sheet.
W300 = 0.356 meters
W600 = 0.268 meters
Continued on next page
806.52K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Data, Page 07, Continued
Page 07variable listcon’t
Variable Name Edit? Description
Service Variable Index • This permits selection of often hiddenvariables in the K10S. Used by K-Tronservice personnel.
Undefined <Calibrate Drive CommandStop clears alarmsExt Totalizer Pulse IncFull Scale Drive CommandGear ReductionGear Tooth SettingUse Refill ArrayAllow RefillsAlarm Shutdown MaskFeeder TotalizerScale RangeBit Input 1 SelectionBit Input 2 SelectionBit Input 3 SelectionBit Input 4 SelectionBit Output 1 SelectionBit Output 2 SelectionBit Output 3 SelectionBit Output 4 SelectionFeedfactor Array 0Feedfactor Array 1Feedfactor Array 2Feedfactor Array 3Feedfactor Array 4Feedfactor Array 5Feedfactor Array 6Feedfactor Array 7Feedfactor Array 8Feedfactor Array 9Feedfactor Array 10
SAB Input UsageSAB Input RangeSAB Input Current ValueSAB Input Calib ValueSAB Output Usage Chn 1SAB Output Usage Chn 2SAB Output Usage Chn 3SAB Output Range Chl 1SAB Output Range Chl 2SAB Output Range Chl 3SAB Output Value Chl 1SAB Output Value Chl 2SAB Output Value Chl 3SAB Output Cal Val Chl 1SAB Output Cal Val Chl 2SAB Output Cal Val Chl 3Feeder 1 TypeFeeder 2 TypeFeeder 3 TypeFeeder 4 TypeFreq. Input 6 HysteresisFreq. Input 6 OffsetSpurious CaseNameplate MS-Motor SpdNameplate Motor PowerActual Motor PowerPert ResidualLo Motor Gain LimitCalib. TimeRefill Timer 2WBF Slip Idler Y/NQuad Old Style SAB addr
MDU Status
Service Variable Value • The value of what is in the selected variableindex.
Continued on next page
806.53K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Data, Page 07, Continued
Feeder modesof control
The following is a brief description of the feeder modes of control.
Mode Action
Local Setpoint is entered on Mcn.00 of each machine
Ratio Entry is in % and the operating setpoint is the product of that% value and the incoming reference setpoint frequency.Enter at page Mcn.00.
Direct Same as Ratio but the % value equals 100% and cannot bechanged.
Line1-7 Puts machine into the Line mode to be a part of a recipe.
Please remember that when in Local, Ratio or Direct, each machine isindependent of every other machine that is connected to the K-Cdr. Amachine that is in Line 1 - 4 is essentially connected to any othermachine in that same line.
ProgramPriority
The following table is a listing of variables that are permitted to bealtered when the stated program priority selection is in place. A controllisting is also provided.
Protection Control Editable Variables
All Run/Stop isactive. Mass/Volis active plus anyfunction key for amachine.
Any variable that can be editedon the machine is allowed to bechanged under this protection.
Continued on next page
806.54K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Feeder Data, Page 07, Continued
Protection Control Editable Variables
SP Run/Stop isactive. Mass/Volis active only.
Only the Setpoint of themachine can be changed.
SP and Alarm Run/Stop isactive. Mass/Volis active plusAlarm Ack/Clr isused.
The following variables can bechanged:
WBF Machines:
Mass Flow Error +
Mass Flow Error -
Drive Command High Limit
Drive Command Low Limit
Alarm Delay
Start-Up Delay
Belt Load High Alarm Limit
Belt Load Low Alarm Limit
Locked Out None for selectedmachine.
No variables for the selectedmachine can be changed.
806.55K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Service Variable Index Listing
Servicevariable indexand valuelisting
The table below shows the Service Variable Index selections and theService Variable Values that can be entered or read.
Service VariableIndex
Function Service VariableValue Range
Calib DC (LWF only) Enter the Drv Cmd tobe used during theCalib cycle
1 to 100% (default10%)
Stop Clrs Alarms 0 = No
1 = Yes
Ext. Totalizer Pulse Sets the increment tothe ext. totalizer pulseoutput
0.0001 to 999999
Full Scale Drv Cmd Sets the Drive Cmdoutput freq range at100% Drive Cmd
1.000 to 40,000Hz(default 10,000Hz)
Gear Reduction 1.000 to 999999(default 11.00) Set at1.000 for LWF
Gear Teeth Enter the number ofteeth on the speedpickup gear
1 to 999999
Use Refill Array(LWF only)
Selects whether or notrefill array is used
0 = No
1 = Yes
Refill Only Run
(LWF only)
Sets the auto refillfunction to occur onlywhen feeder isrunning
0 = No
1 = Yes
Alarm ShutdownMask
This entry allows youto select which alarmswill cause an alarmshutdown
See Alarm ShutdownMask procedure laterin this section
Pre Load Totalizer Allows you topreload the totalizer
0.0000 to 999999
Continued on next page
806.56K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Service Variable Index Listing, Continued
Servicevariable indexand valuelisting con’t
Load Scale Range This is a read onlyentry. It shows theGross Scale Range.
Bit Input 1 This entry allow youto select the functionof the bit input
0 = Run Ena1 = Alrm Shut2 = Start3 = Stop4 = Mass Ena5 = Cust. Alrm6 = Motor Fail7 = Refill Bypass (LWF)8 = Refill Cmd (LWF)
Bit Input 2 Same as Bit Input 1
Bit Input 3 Same as Bit Input 1
Bit Input 4 Same as Bit Input 1
Bit Output 1 This entry allows youto select the functionof the bit output
0 = Drv Ena1 = Ref Win (LWF)2 = Fdr Run3 = Alrm Relay4 = Alrm Shut5 = Alrm Shut Col6 = Alrm Relay Col7 = Tot Pulse8 = Mass Mode9 = Ref Comp (LWF)10 = Ref Req (LWF)11 = Ref Time (LWF)12 = Ref Time Col13 = Tare (WBF)14 = Beltload Lo(WBF)15 = Beltload Hi(WBF)
Bit Output 2 Same as Bit Output 1
Continued on next page
806.57K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Service Variable Index Listing, Continued
Servicevariable indexand valuelisting con’t
Bit Output 3 Same as Bit Output 1
Bit Output 4 Same as Bit Output 1
FF0 thru FF10 Feedfactors at arraypositions 0 thru 10
Read Only
SAB Analog InputAssignment
This entry allows youto set the function forthe SAB analog input
0 = Unassigned1 = Setpoint2 = Spd Feedback3 = Calibrate
SAB Input Range This entry allows youto set the range of theincoming analogsignal to the SAB Bd.
0 = 0 to 1 V1 = 0 to 5 V2 = 1 to 5 V3 = 0 to 10 V4 = 0 to 20ma5 = 4 to 20ma
SAB Current InputValue
This is the freq valueof the current input.
0 - 10,000Hz Readonly
SAB Input CalibValue
Refer to DCS# 564 forCalib instructions
SAB OutputAssignment 1
This entry allows youto select what theoutput will represent.
0 = Unassigned1 = Calib Output2 = Massflow3 = Setpoint4 = Net Wt5 = Drv Cmd6 = Motor Spd7 = Feedfactor8 = Dev from SP9 = Beltload10 = Batch %11 = Batch size12 = Pre Fdr DC
SAB OutputAssignment 2
Same as Assignment1
Continued on next page
806.58K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Service Variable Index Listing, Continued
Servicevariable indexand valuelisting con’t
SAB OutputAssignment 3
Same as Assignment2
SAB Output Range 1 This entry allows youto set the analogoutput range
0 = Disa1 = 0 to 10 V2 = 0 to 20ma3 = 4 to 20ma
SAB Output Range 2 Same as output 1
SAB Output Range 3 Same as output 1
SAB Output Value 1 This is the currentvalue for output 1
Read only
SAB Output Value 2 This is the currentvalue for output 2
Read only
SAB Output Value 3 This is the currentvalue for output 3
Read only
SAB Output 1 CalibValue
See DCS#564 forcalibrationinstructions
SAB Output 2 CalibValue
Same as above
SAB Output 3 CalibValue
Same as above
Continued on next page
806.59K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Service Variable Index Listing, Continued
Servicevariable indexand valuelisting con’t
FTS FDR 1 This entry selectsfeeder 1 type
6 = QVIB7 = QLWF1208 = QLWF2409 = QW30010 = QW60011 = QW100012 = QW-HF13 = QPID14 = Not used
FTS FDR 2 Same as above
FTS FDR 3 Same as above
Fr6Hyster This entry sets thehysteresis for freqinput #6
0 to 1000Hz
Fr6 Offset This entry sets theoffset for freq input#6
0 to 1000Hz
Nameplate MotorSpeed
Entered value ofNamplate motorspeed forprogrammable motordrive
Standard range is1800 to 2500 rpm
Nameplate MotorPower
Entered value ofNamplate motorspeed for softwareprogrammable motordrive
Units are watts.
Actual Motor Power Actual motor powerbeing drawn.
Continued on next page
806.60K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Service Variable Index Listing, Continued
Servicevariable indexand valuelisting con’t
Pert Residual Moving average ofthe current PERTlevel. Moreresponsive todisturbance thanMSD.
The smaller thenumber, the better thefeeder is functioningin your process. Workto lower the numbervia changes to theenvironment in whichthe feeder operates.
Low Motor GainLimit
An entered limit thatif the Motor ControlGain, page Mcn.09,drops below, analarm occur.
0 = default
Max = 100
Alarm is "Low MotorGain"
Calibrate Time Time for feedfactorcalibration
30-300 seconds
Refill Timer 2 This timer becomesactive when theregular Refill Timerexpires. If the netweight is still belowthe Refill Requestpoint after this timerexpires, the controllerwill display the realmassflow while thecontroller remains involumetric control.The Kalman filterparameters remainunchanged.
0 seconds is default
maximum setting>100,000
WBF Slip Idler Y/N For weigh belt feederapplications.
Continued on next page
806.61K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Service Variable Index Listing, Continued
Servicevariable indexand valuelisting con’t
Quad Old Style SABaddr
For Quad SABapplications
0 is the correct valuefor current SAB apps
MDU Status Indicates operationalstatus ofprogrammable motordrives
Hex value. See relatedsoftwareprogrammable motorcontroller
806.62K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Frequency I-O, Page 08
Introduction:Page 08
The page 08 for the weigh belt feeder holds the information thatprograms the Frequency I-O functions. Use the Scroll keys to movefrom page to page.
Page 08 layout This diagram shows the data layout. The second row of keys pop up whenthe Edit key is pressed and a variable is highlighted.
EditMode
F5 F6 F7 F8F1 F2 F3 F4
PELLETS WBF : Frequency I-O M02.08
FREQUENCY OUTPUT #1 Not AssignedFREQUENCY OUTPUT #2 Not AssignedFREQUENCY OUTPUT #3 Not AssignedFREQUENCY INPUT #1 Not AssignedFREQUENCY INPUT #2 Alt Speed FeedbackFREQUENCY INPUT #3 SetpointFREQ INPUT #1 VALUE 0.000FREQ INPUT #2 VALUE 0.000FREQ INPUT #3 VALUE 0.000SCALED FREQ INPUT #3 0.000SCALE FACTOR INPUT #3 1.000FREQ IN #3 DEADBAND 1 Hz
GravMode
VolMode
F5 F6 F7 F8ChangeValue <ESC>
Continued on next page
806.63K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Frequency I-O, Page 08, Continued
Page 08variable list
The following is a listing and description of each variable on this page.A "•" mark shows the values that you can edit. A "#" indicates that thevalue is changed by a Function key.
Variable Name Edit? Description
Frequency Output 1-3 • Not Assigned <MassflowSetpointBeltloadingDev. from SetpointDrive CommandBelt SpeedPrefeeder D.C.
These outputs can be configuredfor a number of different functionsas shown. The scaling chart followsthis section. Default value is " NotAssigned".
Frequency Input 1-2 Not Used
Frequency Input #3 • This is the ratio or direct setpointinput for the controller if use.
Frequency Input #1-#3Value
These variables show the incomingfrequency at these inputs.
Scaled Frequency Input#3
This is the frequency value of Input#3 after it has been scaled by theScale Factor for Input #3.
Continued on next page
806.64K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Frequency I-O, Page 08, Continued
Page 08variable listcon’t
Variable Name Edit? Description
Scale Factor Input #3 • This value scales the incomingfrequency as presented to Input #3.The frequency will be used toprovide the ratio or direct controlsignal as set on page 07. Theprocedure on how to set this valueis described in DCS#322.
Range of Values 0 to 999Default value is 1.000
Frequency In #3Deadband
• This value sets the variation level atwhich the frequency signal will beignored. For example, if the entry isset to 10 Hz, any frequency input toInput #3 that varies less than 10 Hzwill be recognized as non-changing.
Range of Values 0 to 1,000,000,000 HzDefault value is 1 Hz
Continued on next page
806.65K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Frequency I-O, Page 08, Continued
Frequencyoutput scaling
The following table indicates the equations for frequency outputs forthe WBF application. Note: FSS = Full Scale Setpoint from page 07.
Frequency Name Equation for Output
Massflow Ouput Fo = (Massflow/FSS) * 10kHz
ex: Fo= (5000Kg/Hr/10000Kg/Hr) *10kHz
Fo = 5000 Hz.
Setpoint Output Fo = (Operating Setpoint/FSS) * 10kHz
ex: Fo= (3000Kg/Hr/10000Kg/Hr) *10kHz
Fo = 3000 Hz.
Beltloading Output Fo =
(Actual belt load/Belt Load Setpoint)*5Khz
ex: Fo = (2 lb/ft/5lb/ft )*5kHz = 2000 Hz.
Deviation fromSetpoint Output
Fo = 5Khz + 10kHz*(Massflow Error/FSS)
ex: Massflow error = -50 Kg/Hr:
Fo = 5 kHz + 10kHz(-50/10000) = 4950Hz
Note sign of the massflow error.
Drive CommandOutput
Fo =
10Khz* (Current Drive Command%)/100%
ex: 10kHz *( 43%/100%) = 4300 Hz.
Belt Speed Output Fo = Motor speed frequency.
Prefeeder D.C. Frequency output that approximates drivecommand but scaled by PreFeeder D.C. Span
806.66K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Control Parameters, Page 09
Introduction:Page 09
The page 09 for the weigh belt feeder holds the information thatprograms the control parameters for the feeder. Use the Scroll keys tomove from page to page.
Page 09 layout This diagram shows the data layout. The second row of keys pop up whenthe Edit key is pressed and a variable is highlighted.
EditMode
F5 F6 F7 F8F1 F2 F3 F4
PELLETS WBF : Control Parameters M02.09
INTEGRAL GAIN 0.100MASSFLOW FILTER LENGTH 2 secFEEDER RUN TIME 0.0000
GravMode
VolMode
F5 F6 F7 F8ChangeValue <ESC>
DRIVE COMMAND CEILING 125%
Continued on next page
806.67K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Control Parameters, Page 09, Continued
Page 09variable list
The following is a listing and description of each variable on this page.A "•" mark shows the values that you can edit. A "#" indicates that thevalue is changed by a Function key. A $ symbol indicates that the valuecan be changed but you should let the controller do it for you.
Variable Name Edit? Description
Integral Gain $ This value determines how reactivethe controller is to errors inmassflow that occur over time. Thelarger the number, the morecorrective action occurs to the drivecommand when a massflow erroris detected. Normally the value of0.1 is standard for most K-Tron beltfeeders. Range of Values 0 to 200 Default value: 0.1
Massflow Filter Length • The larger this value is, the morestable the massflow display will be.This value has no affect on control.The entry value is in seconds. Range of Values 0 to 300 secondsDefault value: 2 seconds
Feeder Run Time • This is the length of time in hoursthat the feeder has been runningsince the variable was cleared.Enter the value of "0" to clear thevariable.
Drive Command Ceiling This limits the maximum drivecommand output.
806.68K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Overview, Page 10
Introduction:Page 10
Page 10 for the weigh belt feeder depicts in a graphic way what is goingon with the feeder. Use the Scroll keys to move from page to page.
Page 10 layout This diagram shows the data layout. The second row of keys pop up whenthe Edit key is pressed and a variable is highlighted.
S ET POINT1000.00
MASSFLOW 999.98
AlarmAck
F5 F6 F7 F8F1 F2 F3 F4
PELLETS WBF : Overview M02.10
DRIVE COMMAND57.77
ClearAlarm
Continued on next page
806.69K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Overview, Page 10, Continued
Page 10graphicdescription
The following is a listing and description of each variable on this page.A "•" mark shows the values that you can edit. A "#" indicates that thevalue is changed by a Function key. A $ symbol indicates that the valuecan be changed but you should let the controller do it for you.
Display Element Description
This graphic shows the feederrunning. When the feeder isrunning the left roller turns greenand when an alarm occurs, thisroller turns red. When the alarmhas been acknowledged, the rollerturns yellow.
DRIVE COMMAND57.77
DRIVE COMMAND57.77
This graphic shows drivecommand. The point to the left isthe Min Drive Command Limit andthe point to the right is the MaxDrive Command Limit. If the drivecommand exceeds 100%, the activeportion will extend to the rightbeyond the bar outline. The Alarmlevel pointers are in red. The valueof belt loading is shown above thebar.
SETPOINT1000.00
SETPOINT1000.00
This graphic shows the value of thesetpoint in relation to the Full ScaleSetpoint that was programmed onpage 07. The value of setpoint isshown above the bar.
Continued on next page
806.70K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Overview, Page 10, Continued
Page 10graphicdescriptioncon’t
Display Element Description
MASSFLOW 999.98
MASSFLOW 999.98
This graphic shows the actual valueof massflow with the Massflow +and - alarm limits indicated. TheAlarm pointers are in red. Thevalue of current massflow is shownabove the bar.
Page 10 specialkey list
Key
Number
Key Name Description
F3 Alarm Acknowledge When pressed will acknowledgethe alarm present.
F4 Alarm Clear When pressed will clear the alarmthat is present if the conditions thatcaused the alarm are no longerpresent.
806.71K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF SPC Set-Up, Page 11
Introduction:Page 11
Page 11 for the weigh belt feeder identifies some SPC selections for thiscontroller Use the Scroll keys to move from page to page.
Page 11 layout This diagram shows the data layout. The second row of keys pop up whenthe Edit key is pressed and a variable is highlighted.
F5 F6 F7 F8F1 F2 F3 F4
PELLETS WBF : SPC Set-Up M02.11
F5 F6 F7 F8ChangeValue <ESC>
SPC VARIABLE TO LOG MFASPC X-BAR SAMPLE WIDTH 5CHART SCALING FACTOR 1.0000
Continued on next page
806.72K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF SPC Set-Up, Page 11, Continued
Page 11variable list
The following is a listing and description of each variable on this page.A "•" mark shows the values that you can edit. A "#" indicates that thevalue is changed by a Function key.
Variable Name Edit? Description
SPC Variables to Log • NONEMFA <
Selecting any one will permittrending of the variable.
MFA = Actual Mass Flow
The default value is "None"
SPC X-Bar Sample Width • 5 <102050100
Determines the number ofindividual values from the variableselection process to be averaged ineach point on the graph. Thedefault value is "5".
Chart Scaling Factor • This entry scales the chart. A valueof 1 is default.
806.73K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF SPC Chart, Page 12
IntroductionPage 12
This page provides charting of selected variables, one at a time selectedfrom page 11 of the controller.
Page 12 layoutPELLETS WBF : SPC Chart M02.12
F6 F7F1Move
Backward
F2Move
Forward
F3Zoom
In
F4Z oom
O u t
F5End of Log
Add Pt
F 8M oreK ey s
F1S tar t
o f L o g
F2End LogAdd New
F 3Cycle
Snapshots
Basics of SPCoperation
Each point indicated on the chart is an average of the number ofsamples of the selected variable specified by the sample widthparameter set on pg Mcn.11. Samples are taken every two seconds. Theamplitude of the points on the chart (in pixels) is equal to:
Amplitude = 2000*(chart scaling factor)* Deviation from target where chart scaling factor is set on page Mcn.11.
The height of the chart between zero deviation and either dashed line is100 pixels.
Continued on next page
806.74K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF SPC Chart, Page 12, Continued
Basics of SPCoperation,con’t
The purpose of the scaling factor is to provide visibility and usefulnessto the chart when variable deviation is either very small or very large.The chart clips any point greater than 150 pixels.
All date is stored in the RAM card for use by the operator.
Basics of SPCoperations -displayedvalues
There are a number of values displayed on the screen.
Value Meaning Located?
SPC Values - UpperControl Limit
Computed value ofthe upper controllimit from allprevious data points
The top numberlocated just under theupper dashed line.
SPC Values - LowerControl Limit
Computed value ofthe lower controllimit from allprevious data points
The bottom numberjust under the lowerdashed line.
SPC Values -Standard Deviation
Current value ofcomputed standarddeviation from allprevious data points
At the right hand sideof the graph near the"x" axis.
Continued on next page
806.75K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF SPC Chart, Page 12, Continued
Basics of SPCoperation-messages
There are a number of messages that are also presented to the user.
Message Meaning
SPC Message - No SPC VariableSelected
No data point for plotting hasbeen selected on page Mcn.11 -"SPC Variable to Log".
SPC Message - No Points LoggedYet
An SPC variable has beenselected but because the feeder isnot running or has not collectedenough data points yet, no plot isprovided.
SPC Message - Real-time Display Indicates that the current displayis of current data values and newdata points are replacing oldones as time moves along.
SPC Message - Display Frozen Indicates that the current displayis of old data and that new datapoint additions are suppressed.The displayed values do notchange when the chart is shifted.
SPC Message - Start of Log Indicates the current displayincludes the oldest point in thelog and the display cannot bemoved further backward in time.
SPC Message - Alarm Snapshot#N
The current display shows aselected alarm snapshotidentified by a number.
Note: If the display is zoomed, only 52 points are shown rather than thenormal 104.
SPC note fordata retrieval
A K-Tron PC program titled SPC.EXE will permit extraction of all SPCdata stored in the ram card. Access is via the Config. port on the K-Cdr.
Continued on next page
806.76K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF SPC Chart, Page 12, Continued
Basics of SPCoperation, keydescriptions
The following listing describes key operations for page Mcn.12.
Key Key Name Meaning
F1 SPC Move Backward Key Causes the display to show olderdata.
F2 SPC Move Forward Key Shifts the display to show newerdata points.
F3 SPC Zoom In Key Expands the time base to showonly 52 data points, half ofnormal.
F4 SPC Zoom Out Key Compresses the display in timeto show 104 data points, thenormal number.
F5 SPC End of Log, Add New PointKey
Shifts the display to the presenttime. The display then continuesto add new data points as thefeeder runs.
F8 SPC More Keys Displays new functions for keysF1-F3.
F1 SPC Start of Log Key Shifts the display to show theoldest data in the ram card.
F2 SPC End of Log, Add New PointsKey
Shifts the display to the presenttime. The display then continuesto add new data points as thefeeder runs.
F3 SPC Cycle Thru Snapshots Key As this key is pressed, thedisplay cycles through all alarmsnapshots taken beginning withthe oldest one. There can be up to10 of these recalled. The snapshotshows the display with data inwhich any feeder alarm occurred.The condition is triggered bysetting bit 14, 15 of the PSR word.
806.77K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Software Part Numbers, Page 13
Introduction:Page 13
Page 13 for the weigh belt feeder identifies the software part numbersfor this controller Use the Scroll keys to move from page to page.
Page 13 layout This diagram shows the data layout. The second row of keys pop up whenthe Edit key is pressed and a variable is highlighted.
F5 F6 F7 F8F1 F2 F3 F4
PELLETS WBF : SW Part Numbers M02.13
CONTROLLER SW PART # C9700-20001-L
Continued on next page
806.78K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
WBF Software Part Numbers, Page 13, Continued
Page 13description
The number shown on this page is for the software that is used in thecontroller identified by the first two numbers in the Machine linepaging.
ex: M01.13 is machine 1M05.13 is machine 5
The number displayed [ C9700-20001-K ] is the software part numberand revision letter that you should know for the WBF controller pc cardif you call our service department for help.
806.79K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Alarm Shutdown Masking
Introduction The Alarm Shutdown Mask allows the user to select the alarms thatwill not activate the alarm shutdown output. This is done using theK10S ASR word and calculating the decimal value and then enteringthat value in the Service Variable Value on the K-Commander. Below isa list of alarms for LWF with an example.
Bit Function Decimal Value
0 Belt Slip Alarm 1
1 External alarm active 2
2 Unassigned 4
3 Unassigned 8
4 Unassigned 16
5 Unassigned 32
6 Battery Low 64
7 Nak’d due to feeder running 128
8 Beltload > HBL 256
9 Scale Overrange 512
10 Scale Underrange 1,024
11 Beltload < LBL 2,048
12 Rate > Setpoint 4,096
13 Rate < Setpoint 8,192
14 Drive Command > DHS 16,384
15 Drive Command < DLS 32,768
16 Ext. Channel Range Error 65,536
17 Ext. Channel Invalid Command 131,072
18 Ext. Channel Fail 262,144
19 Int. Channel Range Error 524,288
Continued on next page
806.80K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Alarm Shutdown Masking, Continued
Alarmshutdownmask con’t
20 Int. Channel Failure 1,048,576
21 Weight Processor Failure 2,097,152
22 Unassigned 4,194,304
23 MDU alarm 8,388,608
Total 16,777,215
(all alarms)
Example: I do not want a Int. Channel Range Error to shutdown thefeeder. I would then subtract the Int. Channel Range Error decimalvalue from the default value and enter the new value.
16,777,151 (default) - 524,288 (decimal value of Int. Channel Range
Error--------------
New Value 16,252,927
Note: The default value is 16,777,151 because the Low Battery shouldnot shutdown the feeders.
806.81K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Weigh Belt Feeder Calibration-WBF
Introduction This section will help you to calibrate your weigh belt feeder. Please dothe tare calibration first.
Tarecalibration-WBF
To set the weigh belt feeder tare, please do the following.
Step Action
1 Empty the weigh belt feeder so that the weigh belt is clean
2 Run the feeder in Volumetric control with a Drive Commandof nearly 50%.
Adjust Massflow Setpoint and Belt Load Setpoint to adjust theDrive Command.
3 Stop the feeder.
4 Press the Tare Button, Key F3 on page Mcn.05. The feederwill run for a number of belt revolutions and then stop.
5 Record the value entered in the Belt Tare Weight location.
6 Plot this value as a point on your Tare or Zero Run Chart.
7 Tare is complete.
Continued on next page
806.82K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Weigh Belt Feeder Calibration-WBF, Continued
The tare runchart
It is useful to graph out the calibration values for tare. Here is a runchart for tare. Note that for a number of weeks, tare calibration wasquite constant. But on June 1, a problem developed. Rather than justrecalibrating, this chart tells us that something is wrong and needsrepair. A repair can be made to correct an otherwise hidden problem.
Please note that the starting tare value scaling is arbitrary but must befine enough to see what is happening to the calibration of the machine.
0.5 Kg
0.6 Kg
0.7 Kg
0.8 Kg
0.9 Kg
1.0 Kg
0.4 Kg
0.3 Kg
0.2 Kg
0.1 Kg
0.0 Kg
0.55 0.575 .056 0.54 0.53 0.55
3/21 3/31 4/6 4/21 5/3 5/18 6/1
0.3
Continued on next page
806.83K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Weigh Belt Feeder Calibration-WBF, Continued
Spancalibration bytaking catchsamples-WBF
To do the this span calibration, the tare calibration must be completedfirst.
Step Action
1 Run the weigh belt feeder in VOL control and allow materialto flow onto the belt. Run so that the pile of material is stableand that belt loading is also stable.
2 Put the unit into GRAV control at some desired setpoint.
3 Start the feeder and let it stabilize its flowrate. Watch to seethat drive command is stable.
4 Take 5 consecutive 1 minute samples in five separatecontainers. Be sure each container is tared.
ex: 1.000 kg, 1.004 kg, 1.006 kg. 1.003 kg. 1.004 kg
5 Add the samples together and divide by 5.
1.000
1.004
1.006
1.003
1.004
= 5.017/5 = 1.0034 kg
6 Calculate your new span by the following formula: See pageMcn.05 for current span.
New Span =
Current Span *( Actual Samples/ Desired Samples)
Your setpoint was 60 Kg/hr so the desired setpoint in 1minute is 1 Kg. Current Span = 1.002
New Span = 1.002*(1.0034/1) = 1.005. Enter on page Mcn.05.
7 Take 5 more samples as in step 4 and recheck yourcalculations. If you have done it correctly, the span will notchange.
8 Record the new span value on the Span Run Chart.
9 You have calibrated the feeder. You can now run the feederin production.
Continued on next page
806.84K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Weigh Belt Feeder Calibration-WBF, Continued
Totalizermethod forspancalibration-WBF
You may elect to use the totalizer to set the feeder span rather thantaking catch samples. If so, please follow this procedure.
Step Action
1 Run the weigh belt feeder in VOL control and allow materialto flow onto the belt. Run so that the pile of material is stableand that belt loading is also stable. Stop the feeder.
2 Put the unit into GRAV control at some desired setpoint.
3 Clear the totalizer. Be sure that you have a large container tocatch the flow of material during this run.
4 Start the feeder.
5 When the container becomes full, stop the feeder.
6 Note the totalizer reading
7 Weigh the contents of the container
8 Compare the container weight to the totalizer. They shouldmatch.
9 Calculate the new span setting from the following equation:See page Mcn.05 for current span.
New Span =
Current Span*( Container Weight/Totalizer Weight)
ex: Current span = 1.004, Container weight =99 kgs, thetotalizer reads 100 kgs.
New span = 1.004 * ( 99/100) = 0.994
10 Enter the new span on page Mcn.05.
11 Redo steps 3-9 to check the accuracy of the new span value.
12 Record the new span value on the Span Run Chart.
13 You have calibrated the feeder. You can now run the feederin production.
806.85K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Auto Cal Feature for WBF Software
IntroductionIn release ‘R’ of the K10S WBF software and K-Commander softwareRev. ‘L’, a new calibration function was added. You will set up andinitiate this function on the Belt Factor page Mcn.01.
Setting up thefeeder forautocalibration
Step Action1 Put material in the hopper. Put feeder in (GRAV) mode.2 Enter a setpoint close to your normal operating setpoint.
Run the feeder.3
Adjust the slide gate height to change the belt loading andbelt speed in order to meet the following conditions:
� The pile of material should be centered and not touchingthe side skirts.
� If you are running a pelletized material the belt speedshould be less than 60 ft/min.
� If you are running a powder, than the belt speed shouldbe less than 24 ft/min.
� The belt speed should be greater than 6 ft/min.
1. Record the actual belt loading when all of previousconditions have been met.
2. Calculate operational belt speed = normal setpoint / beltload
3. Calculate operational drive command =(operational beltspeed / max belt speed) * 100
For example:Belt load = 2 lb/ftMassflow Setpoint = 2400 lb/hr or 40 lb/minOp. Belt speed = (40 lb/min) / ( 2 lb/ft ) = 20 ft/minOp. Drive comm. = ( 20 / 60 ) * 100 = 33%
Continued on next page
806.86K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Auto Cal Feature for WBF Software, Continued
Calibrationusing the AutoCal feature
You can use this procedure to simplify feeder performance validation. Itis recommended that a tare be done first.
Step Action
1 Run the feeder in Vol control and allow material to flow ontothe belt. Run so that the pile of material is stable and that beltloading is also stable. Stop the feeder.
2 Setting Calibration Time
Go to the Belt Factors page Mcn.01 to set the time duration ofthe catch sample. The default setting is 60 seconds. Wesuggest that you set the Calibration Time to 300 seconds ifpossible. This allows for 5 minutes of sampling.
3 Setting Calibration Drive Command
Set the Calibration Drive Command to be equal to theoperational drive command, calculated in the previousprocedure.
4 Place a tared container under the feeder that can capture allof the material to be delivered in the Calibration Time.
Massflow Setpoint x Calibration Time = Weight
( 3000 lb / hr/3600 sec) x 300 seconds = 250 lb of product
5 Press F3 to commence the Calibrate Cycle process.
6 When the Calibrate Cycle is completed, look at theCalibration Correlation to verify that it is above 90%.
Continued on next page
806.87K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Auto Cal Feature for WBF Software, Continued
SampleCheck
Step Action
7 Quick Material Sample Check
When the calibration is complete, weigh the container andcompare it to the Material Fed in Calibration value. Calculatethe percentage error.
Cal.Matl.Fed value – actual material weight = Weight Difference.
The %error = (Weight Difference / Actual Mat. Weight) x 100
If the %error > 2% than you should contact a trainedmaintenance technician to identify the problem. You couldalso repeat the calibration procedure with a longerCalibration Time and recheck your %Error.
If the %error < 2% you can now put your feeder intooperation in Gravimetric mode.
!Remember, if you only took a single 60 second sample, you
may not have enough information regarding the accuracy of thefeeder. We do not recommend that you adjust SPAN with only one60 second sample. GO TO NEXT STEP!
Continued on next page
806.88K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Auto Cal Feature for WBF Software, Continued
SpanAdjustement
Step Action
8 If your calibration time was 300 seconds or longer you canuse your catch sample to change the span value if necessary.This is basically the same as using the totalizer methodexplained earlieer.
Calculate the new span setting from the following equation:
New Span, (Page Mcn.05) =
Current Span*( Container Weight/Material Fed in Calib)
ex: Current span = 1.004, Container weight =99 kgs, theMaterial Fed in Calib. reads 100 kgs.
New span = 1.004 * ( 99/100) = 0.994
Record the span value on your run chart.
Continued on next page
806.89K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Auto Cal Feature for WBF Software, Continued
The span runchart
It is useful to graph out the calibration values for span. Here is a runchart for span. Note that for a number of weeks, span calibration wasquite constant. Notice that unlike the tare run chart, no changes havebeen found outside a small band of variation.
1.100 1.104 1.095 1.100 1.100 1.100
3/21 3/31 4/6 4/21 5/3 5/18 6/1
1.000
1.100
1.200
1.300
1.400
1.500
0.900
0.800
0.700
0.600
0.500
1.105
806.90K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
Index
""Tare", 5
#
, 4, 6, 71, 72, 73
<<Esc>, 6
AAcknowledged Alarm, 27Actual Current Massflow, 12Actual Motor Power, 61Alarm Acknowledge, 27, 73Alarm Clear, 73Alarm Clear, 27Alarm Delay Setting, 31Alarm message table, 22Alarm Shutdown Mask, 83Alarm Shutdown Message, 26Alarm type definitions, 27All, 54ALSHUT, 5auto calibration, 90
BBasics of SPC operation, 77Basics of SPC operation- messages, 79Basics of SPC operation, key descriptions, 80Basics of SPC operations - displayed values, 78Belt Index, 37Belt Length, 50Belt Load <BLS, 23Belt Load > BHS, 23Belt Load High Alarm Limit, 32Belt Load Setpoint, 16Belt Loading, 12Belt Slip Alarm, 25Belt Slip Alarm Limit, 31Belt Speed, 1, 13Belt Speed Output, 67Belt Tare Weight, 36Beltloading, 17Beltloading Output, 67Board Reset Message, 26
CCalibrate Time, 62
Calibration using the Auto Cal feature, 91Changing a variable, 7Chart Scaling Factor, 76Common message listing with resolution, 9Controller Board Failure, 25
DDefinitions, 1Determining scale ranges, 38Deviation from Setpoint Output, 67Direct, 54DISA, 5Display action line above the function keys, 5Display Board Failure, 25Drive Comm greater than DHS, 22Drive Comm less that DLS, 22Drive Command, 1, 13Drive Command High Alarm Limit, 30Drive Command Low Alarm Limit, 30Drive Command Low Message, 26Drive Command Output, 67Drive Pulley Circumference, 50
EEdit Mode, 3Ext. Totalizer Increment, 45External Alarm Active, 22External Display Message, 26
FF1, 3F2, 3F5, 3, 6F6, 4, 6F7, 4, 6F8, 6Fdr Controller Timeout, 22Fdr Internal Channel Failure, 22Feeder Invalid Command, 23Feeder Mode, 48Feeder modes of control, 54Feeder Range Error, 9, 23Feeder Run Time, 69Feeder stopped by conditions, 26Feeder Type Selection, 46Feedrate, 1Frequency In. 3 DeadbandFrequency Input. 3Frequency Input #1-. 3 ValueFrequency Input 1-2, 65Frequency Output 1-3, 65Frequency output scaling, 67Full Scale Setpoint, 44
806.91K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
GGrav Mode, 3Gravimetric control, 2
HHard Alarm, 27
IIn this chapter, 1, 10, 34Integral Gain, 69Introduction Page 02, 19I-O Board Failure, 24
LLayout of often used keys, 3Line1-4, 54Local, 54Local Display Message, 26Locked Out, 55Loss of programming data, 8Low Belt Load Alarm Limit, 32Low Motor Gain Limit, 62
MMassflow (-) Alarm Limit, 29Massflow (+) Alarm Limit, 29Massflow Filter Length, 69Massflow Ouput, 67Massflow Setpoint, 12Material Net Weight, 36MDU Alarm, 24Measured Belt Slip, 31Measured Gross Weight, 36Motor Drive Failure Message, 26Motor Speed, 13
NNAK Due to Feeder Running, 9Nameplate Motor Power, 61Nameplate Motor Speed, 61Node. of Selected SFTNumber of SFTs Required, 40
OOverview page, 11
PPage 00 layout, 11Page 00 special key list, 14Page 00 variable list, 12Page 00 variable list con’t, 13Page 01 layout, 15Page 01 variable list, 16Page 02 layout, 19Page 02 variable list, 20
Page 03 layout, 21Page 03 special key list, 27Page 04 layout, 28Page 04 variable list, 29Page 05 key list, 38Page 05 layout, 35Page 05 variable list, 36Page 06 layout, 39Page 06 variable list, 40Page 07 layout, 43Page 07 variable list, 44Page 08 layout, 64Page 08 variable list, 65Page 09 layout, 68Page 09 variable list, 69Page 10 graphic description, 71Page 10 layout, 70Page 10 special key list, 73Page 11 layout, 75Page 11 variable list, 76Page 12 layout, 77Page 13 description, 82Page 13 layout, 81Pending Alarm, 27Pert Residual, 62Poll SFTs, 42Pre-Feeder DC Span, 20Prefeeder set-up, 20Program variables and program priority protection table, 54Programming Priority LCD, 49
RRate Greater than Setpoint, 24Rate Less than Setpoint, 24Ratio, 54Refill Timer 2, 62Run Disable Message, 26
SSample Check, 92Scale Factor Input. 3Scale Gross Weight Range, 36Scale ranges for WBF, 8Scale/SFT. \\"xx\\" Underrange. \\"xx\\" OverrangeScaled Frequency Input. 3Selected SFT Status, 40Service Variable Index, 53Service variable index and value listing, 56Service Variable Value, 53Setpoint Output, 67Setting drive command in vol control, 18Setting high belt load limit, 33Setting low belt load limit, 33SFT Configuration, 41SFT Connect/Disconnect, 40SFT Failure Codes, 41SFT Raw Weight, 40SFT Type Code, 41SP, 55SP and Alarm, 55Span Adjustement, 93Span calibration by taking catch samples-WBF, 87
806.92K-Commander Weigh Belt Fdr. Programming
Rev B Produced by the K-Tron Institute
SPC Cycle Thru Snapshots Key, 80SPC End of Log, Add New Point Key, 80SPC End of Log, Add New Points Key, 80SPC Message - Alarm Snapshot. NSPC Message - Display Frozen, 79SPC Message - No Points Logged Yet, 79SPC Message - No SPC Variable Selected, 79SPC Message - Real-time Display, 79SPC Message - Start of Log, 79SPC More Keys, 80SPC Move Backward Key, 80SPC Move Forward Key, 80SPC note for data retrieval, 79SPC Start of Log Key, 80SPC Values - Lower Control Limit, 78SPC Values - Standard Deviation, 78SPC Values - Upper Control Limit, 78SPC Variables to Log, 76SPC X-Bar Sample Width, 76SPC Zoom In Key, 80SPC Zoom Out Key, 80Special addressing for SFT’s using the Quad Controller, 42Speed Pick-up Gear Teeth, 47Standard keys and their functions, 3Standard keys and their functions con’t, 4Start-up Delay Setting, 31Stop Bit Message, 26STP, 2
TTare, 2, 38Tare calibration-WBF, 85The span run chart, 94The tare run chart, 86
Total Gear Reduction, 2Total Gear Reduction-TGR, 47Totalizer Clear, 14Totalizer Deadband Limit, 17Totalizer method for span calibration-WBF, 89Totalizer Value, 13Transport Delay, 2Transport Length, 50
UUnits Selection, 44
VVol Mode, 3Volumetric control, 2
WWBF Slip Idler Y/N, 62Weigh Deck Length, 52Weight Processor Failure, 25Weight Span, 37When F5-Edit is pressed, 6Window above F1 key, 5Window above F2 key, 5Window above F4 key, 5Window above F5, 5Window above F6 key, 5
ZZero Setpoint Message, 26