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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 CH-5702 Niederlenz, K-Tron (U.S.A.) Rt. 55 and Rt. 553 Pitman, NJ 08071, Web:

Tel. (062) 885 71 71 Fax (062) 885 71 80 Tel. (856) 589 -9083 Fax (856) 589 - 5664 http://www.ktron.com

Before you call, gather the following information… « Do you have alarm displays? What are they exactly? « Are you able to eliminate the cause of the alarm displays? « Have you modified part of the system, product or operating mode? « Have you tried to remedy the fault in accordance with the operating and service instructions? « Record the six digit project or job number located on the machine and in the project manual. – Example: 403214 Use of the manual: « This arrow is used for identifying one-step actions or actions that have no specific order. 1. Numbers in a list identify tasks that have sequences you have to follow. V This icon indicates a general cautionary note. Indicates an electrical hazard. Reference to another manual section. Marks helpful information. Indicates that tools are needed for the task. Specifies where information or a situation must be checked. Indicates where power is applied or removed. Don’t place hands or other body parts into machine. Order no.: 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, K-TRON MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NOR ANY OTHER WARRANTY, EXPRESS OR IMPLIED, WITH RESPECT TO THE EQUIPMENT.” If an error or ommission is found, please contact: [email protected].

Table of Contents 1

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

1.1 1.1.1

Safety symbol definitions .................................................................................................... 1 Related safety/electrical icons ............................................................................................ 1

1.2

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

1.3

Organizational measures .................................................................................................... 2

1.4

Operator responsibilities ..................................................................................................... 2

1.5

Safety-conscious operation ................................................................................................ 3

1.6

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

1.7

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

1.8

Additional equipment .......................................................................................................... 4

1.9

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

1.10

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

1.11

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

1.12 1.12.1

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

2

Data Structures, Formats and Data Types for SmartConnex-II .................................... 5

2.1

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

2.2 2.2.1 2.2.2

Data descriptions ................................................................................................................ 6 Data types ........................................................................................................................... 6 Application types ................................................................................................................. 6

2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8 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 ................................................................................................................ 7 KCM global variables: Process ........................................................................................... 7 KCM global variables: Alarms ............................................................................................. 8 KCM global variables: Scale parameters ............................................................................ 9 KCM global variables: Digital I-O ...................................................................................... 10 KCM global variables: Analog I-O ..................................................................................... 11 KCM global variables: Modbus I-O ................................................................................... 11 KCM global variables: HCU Loader Params ..................................................................... 12 HcuSelParamNum Definitions .......................................................................................... 12 KCM global variables: Communications ........................................................................... 14 KCM global variables: Miscellaneous ............................................................................... 14 KCM variables: LWF ......................................................................................................... 16 KCM variables: LWB ......................................................................................................... 18 KCM variables: PID .......................................................................................................... 21 KCM variables: SFM ......................................................................................................... 22 KCM variables: VOL ......................................................................................................... 24 KCM variables: WBF ........................................................................................................ 24

2.4

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

3

I-O Functions ................................................................................................................... 26

3.1 3.1.1

Global I-O functions for all applications ............................................................................ 26 Global digital inputs .......................................................................................................... 26

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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

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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

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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

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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

Safety symbol definitions

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

CAUTION

!

CAUTION

! WARNING

!

DANGER

V CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

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

V WARNING indicates a potentially hazardous situation which, if not avoided, may result in death or serious personal injury.

V DANGER indicates an imminently hazardous situation, which if not avoided, will result in death or serious injury.

1.1.1

Related safety/electrical icons

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

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1 1.2

Safety Notes Proper use

1.2

Proper use

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

1.3

Organizational measures

V Observe the safety notes for the connected feeding devices. V In addition to the operating instructions, always comply with generally prescribed safety regulations governing accident prevention and environmental safety. V Always keep the metering device operating instructions within easy reach. Ensure that they are always complete and legible.

1.4

Operator responsibilities

V Ensure that only qualified and trained personnel work with the KCM. V Establish personnel responsibilities for operation and maintenance. V Ensure that personnel have read and understood the operating instructions to all installation components, particularly these safety notes. V The operator must have damaged or missing components replaced immediately. V The operator of the KCM is responsible for compliance with the legally prescribed accident and safety regulations.

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Docu-No.: 0590020612-EN Rev. 1.0.0

Safety Notes Safety-conscious operation

1.5

1 1.5

Safety-conscious operation

V Any changes (including changes to operational behavior) which affect safety must be immediately reported to the responsible member of staff. V Perform all operations with safety in mind. V Do not make any internal adjustments to the KCM while the feeder is in operation.

1.6

Safety devices

V The electrical safety devices must not be altered. This increases the danger of accidents. V Never operate the KCM with the housing open. V Replace damaged cables and connections immediately. V Only operate the feeding equipment if all safety devices are installed and fully functional. V Check that the safety devices on the KCM and on the feeding equipment operate properly daily. V Never open or remove covers or hoods while the feeding equipment is in operation. V 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

!

DANGER

High voltage

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

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1 1.8

Safety Notes Additional equipment

1.8

Additional equipment

V Modifications to the KCM are prohibited. V The operator is responsible for complying with all safety regulations related to operation with the feeding equipment.

1.9

!

CAUTION

Removal from service

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

1.10

Customer service and repairs

V The KCM may only be repaired by – your authorized K-Tron customer service center or – qualified personnel, trained by K-Tron. V Only use original K-Tron parts for repairs.

1.11

Warranty

V See project specifications and sales agreements for warranty information.

1.12

Applied safety signs and placards

1.12.1

Selected safety signs on machines

Fig. 1.1 Power applied sign

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KCM Protocol

Docu-No.: 0590020612-EN Rev. 1.0.0

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 selected. 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.

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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

Function

LWF

Loss-in-Weight Feeder

WBF

Weigh Belt Feeder

PID

Page 6

Application types

Proportional, Integral, Derivative Controller

LWB

Loss-in-Weight Batch Feeder

SFM

Smart Flow Meter Controller

VOL

Volumetric feeder controller

KCM Protocol

Docu-No.: 0590020612-EN Rev. 1.0.0

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

KCM global variables: Process

Name

Units

Type

R or R/W

Description

ActualTemperature

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.

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KCM Protocol

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2 2.3

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

2.3.2

KCM global variables: Alarms

Name

Units

Type

R or R/W

Description

AlarmDelay

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

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

2.3.3 Name

Units

NumSFTReq

2 2.3

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.

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KCM Protocol

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2 2.3

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

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

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

2.3.5

KCM global variables: Analog I-O

Name

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

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KCM Protocol

Description

[0 to 3]

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2 2.3

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

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

Page 12

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

KCM Protocol

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

Number

Docu-No.: 0590020612-EN Rev. 1.0.0

2 2.3

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

KCM Protocol

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2 2.3

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

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.

Page 14

KCM Protocol

Docu-No.: 0590020612-EN Rev. 1.0.0

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

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.

Docu-No.: 0590020612-EN Rev. 1.0.0

KCM Protocol

Page 15

2 2.3

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

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 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.

Page 16

KCM Protocol

Docu-No.: 0590020612-EN Rev. 1.0.0

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

2 2.3

Name

Units

Type

R or R/W

Description

FltClearTime

msec.

integer

R/W

Built-in loader control, filter clear time.

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

Docu-No.: 0590020612-EN Rev. 1.0.0

KCM Protocol

Page 17

2 2.3

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

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 on the vibratory calibration curve.

VibY0

float

R

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

VibY1

float

R

Correction factor for vibratory feeder nonlinearity at 12% Drive Command.

VibY2

float

R

Correction factor for vibratory feeder nonlinearity at 17% Drive Command.

VibY3

float

R

Correction factor for vibratory feeder nonlinearity at 23% Drive Command.

VibY4

float

R

Correction factor for vibratory feeder nonlinearity at 33% Drive Command.

VibY5

float

R

Correction factor for vibratory feeder nonlinearity at 50% Drive Command.

VibY6

float

R

Correction factor for vibratory feeder nonlinearity at 70% Drive Command.

VibSPChgLimit

percent

2.3.12 Name

Units

KCM variables: LWB

Type

R or R/W

Description

AdaptGain

float

R/W

Learned gain value for LWF when adaptive tuning is active.

AdaptTuning

integer

R/W

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

AveFeedFactor

rate

float

R

Current average feeding factor.

BatCompMass

weight

float

R

Current batch weight delivered.

BatCompPerc

percent

float

R

Batch weight delivered in percent of setpoint.

Page 18

KCM Protocol

Docu-No.: 0590020612-EN Rev. 1.0.0

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

Name

Units

BatCount BatchTimeGrace

seconds

BatRefMode

2 2.3

Type

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

Built-in loader control, filter clear time.

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

JogEna

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

Docu-No.: 0590020612-EN Rev. 1.0.0

KCM Protocol

Page 19

2 2.3

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

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

Page 20

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.

KCM Protocol

Docu-No.: 0590020612-EN Rev. 1.0.0

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

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

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

VibY1

float

R

Correction factor for vibratory feeder nonlinearity at 12% Drive Command.

VibY2

float

R

Correction factor for vibratory feeder nonlinearity at 17% Drive Command.

VibY3

float

R

Correction factor for vibratory feeder nonlinearity at 23% Drive Command.

VibY4

float

R

Correction factor for vibratory feeder nonlinearity at 33% Drive Command.

VibY5

float

R

Correction factor for vibratory feeder nonlinearity at 50% Drive Command.

VibY6

float

R

Correction factor for vibratory feeder nonlinearity at 70% Drive Command.

VibSPChgLimit

Units

2 2.3

percent

2.3.13

KCM variables: PID

Name

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.

Docu-No.: 0590020612-EN Rev. 1.0.0

KCM Protocol

Page 21

2 2.3

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

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

Calibration drive command at flow 2.

CalDC3

percent

integer

R/W

Calibration drive command at flow 3.

Page 22

KCM Protocol

Docu-No.: 0590020612-EN Rev. 1.0.0

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

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 .

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 .

IntegralTime

seconds

float

R/W

Integral time interval for control.

InternalFiltLen

seconds

float

R/W

Massflow filter value.

MaterialFact0

weight

float

R

A0 flow error correction factor.

MaterialFact1

weight

float

R

A1 flow error correction factor.

MaterialFact2

weight

float

R

A2 flow error correction factor.

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.

Docu-No.: 0590020612-EN Rev. 1.0.0

KCM Protocol

Page 23

2 2.3

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

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

Integral time interval for control.

LoBeltLdAlrmLim

weight/ length

float

R/W

Low belt loading alarm limit.

integer

R/W

Location, motor or roller for velocity sensor.

PickupPos

Page 24

KCM Protocol

Docu-No.: 0590020612-EN Rev. 1.0.0

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;