K-TRON KCM Manual

OPERATING AND
MAINTENANCE INSTRUCTIONS
Read this manual prior to opera-
ting or servicing the equipment.
This manual contains all safety
labels and warnings.
Original operating instructions
1090020601-EN Rev. 1.2.1
KCM
KCM
KCM
II 3D Ex tc IIIC T65°C
0590024903-D X
1190021904-A X

Service
If you need assistance, please call your local service center or:
K-TRON Pitman Tel. [phone]
Rt 55 and Rt 553 Fax [phone]
Pitman, NJ 08071
K-TRON (Switzerland) Tel. [phone]
Lenzhardweg 43/45 Fax [phone]
CH-5702 Niederlenz
K-TRON Salina Tel. [phone]
606 N. Front St. Fax [phone]
Salina, KS 67402-0017
Web: http://www.ktron.com
Before you call...
Do you have alarm displays? Can you eliminate their causes?
Have you modified part of the system, product or operating mode?
Have you tried to eliminate the fault in accordance with the operating
instructions?
Note down the project or job number. This can be found at the ma-
chine or in the project manual.
• Example: 0400545
Using the manual:
This arrow identifies an individual action.
1. Numbers identify a sequence of actions which have to be executed
step-by-step.
▲This symbol identifies a general safety note.
If an error or ommission is found, please contact:
[email protected].
Reference to another manual.
Important information.
This symbol indicates that tools are required for the following task.
Specifies where information or a situation must be checked.
Docu-No.: 1090020601-EN
Datum: 2012/Juli/09
Original: 1090020601-EN
“K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part
of operating personnel. Further, reference is made to the purchase order, acceptance or other document that con-
tains 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.”

Docu-No.: 1090020601-EN Rev. 1.2.1 Page3
Table of contents
1 Safety Notes ......................................................................................................................9
1.1 Safety symbols definitions ..................................................................................................9
1.1.1 Electrical Hazard Icon .......................................................................................................10
1.1.2 Ground Icon ......................................................................................................................10
1.1.3 ATEX Icon .........................................................................................................................10
1.2 Operator responsibilities ...................................................................................................10
1.3 Proper use ........................................................................................................................11
1.4 Special provisions X .........................................................................................................11
1.5 Organizational measures ..................................................................................................11
1.6 Safety-conscious operation ..............................................................................................11
1.7 Safety devices ..................................................................................................................12
1.8 High voltage ......................................................................................................................12
1.9 Additional equipment ........................................................................................................12
1.10 Customer service and repairs ...........................................................................................12
1.11 Removal from service .......................................................................................................13
2 Assembly and Function .................................................................................................14
2.1 Field of application ............................................................................................................14
2.1.1 Explosion proof marking ...................................................................................................14
2.1.2 Zones and device categories (gas) ...................................................................................14
2.1.3 Zones and device categories (dust) ..................................................................................15
2.1.4 Dust deposits and glow temperature ................................................................................15
2.1.5 Abbreviations ....................................................................................................................16
2.1.6 Additional programming information .................................................................................17
2.2 Overview ...........................................................................................................................18
2.3 Structure ...........................................................................................................................19
2.3.1 Enclosure ..........................................................................................................................19
2.3.2 Circuit assemblies .............................................................................................................20
2.4 Safety devices and warnings ............................................................................................21
2.4.1 Safety devices ..................................................................................................................21
2.4.2 Warnings ...........................................................................................................................21
3 Technical Data ................................................................................................................22
4 Installation .......................................................................................................................28
4.1 Unpacking .........................................................................................................................28
4.2 Tools .................................................................................................................................28
4.3 Dimensions KCM ..............................................................................................................29
4.4 Dimensions KCM SS ........................................................................................................30
4.5 KCM-SS Hygiene mounting ..............................................................................................30
4.6 Terminal descriptions ........................................................................................................31

Page 4 Docu-No.: 1090020601-EN Rev. 1.2.1
4.6.1 Terminal block specifications ............................................................................................31
4.6.2 Keying diagrams for specified connectors ........................................................................31
4.7 CPU connection summary ................................................................................................32
4.7.1 CPU DB-9 Configuration port - P1 ....................................................................................32
4.7.2 CPU digital I-O - J8 ...........................................................................................................32
4.7.3 CPU frequency and analog I-O - J9 ..................................................................................32
4.7.4 Internal channel; CPU to Drive - J11 ................................................................................33
4.8 K-Port connection summary .............................................................................................34
4.8.1 K-Port protocols ................................................................................................................34
4.8.2 K-Port protocol table .........................................................................................................34
4.8.3 K-Port details ....................................................................................................................35
4.8.4 K-Port 1 connections - J14 ...............................................................................................35
4.8.5 K-Port 2 connections - J15 ...............................................................................................35
4.9 Host port connections .......................................................................................................36
4.9.1 Host port details ................................................................................................................36
4.9.2 Host connections for AB-DF1 and Modbus using K-Port1 ................................................36
4.10 Drive connection summary ...............................................................................................37
4.10.1 Drive digital inputs- J1 ......................................................................................................37
4.10.2 Drive Internal Channel; Drive to CPU - J3 ........................................................................38
4.10.3 Drive SFT connections - J4/J7/J8 .....................................................................................38
4.10.4 Drive output relays - J5 .....................................................................................................39
4.10.5 AC Interface specific output relays - J9/J6 .......................................................................39
4.10.6 DC motor drive power - J6. ...............................................................................................40
4.10.7 DC motor drive feedback - J2 ...........................................................................................40
4.10.8 Change DC motor shaft rotation .......................................................................................40
4.10.9 Stepper drive specific connections ...................................................................................41
4.10.10 Universal stepper motor drive power - J6 .........................................................................41
4.10.11 LoPo/HiPo stepper motor drive power - J6 .......................................................................41
4.10.12 Stepper motor drive feedback - J2 ....................................................................................42
4.10.13 Stepper drive rotation error ...............................................................................................42
4.10.14 Vibratory drive power - J6 .................................................................................................43
4.10.15 Vibratory drive feedback - J2 ............................................................................................43
4.10.16 Vibratory drive phase angle correction .............................................................................43
4.10.17 AC interface drive power - J6 ...........................................................................................44
4.10.18 AC interface frequency feedback - J2 ...............................................................................44
4.10.19 AC interface analog I-O - J9 .............................................................................................45
4.11 I-O wiring connections ......................................................................................................46
4.11.1 Safety input wiring to KCM Drive - J1 ...............................................................................46
4.11.2 Drive enable input to KCM Drive - J1 ................................................................................46
4.11.3 Digital input #1 and #2 at Drive pc board ..........................................................................47
4.11.4 Drive output relays K1-K3 - J5 ..........................................................................................47
4.11.5 AC interface drive output relay K4 - J9 .............................................................................48
4.11.6 AC interface drive output relay K5 - J9 .............................................................................48
4.11.7 AC interface drive output relay K6 - J6 .............................................................................48
4.11.8 KCM CPU digital outputs - J8 ...........................................................................................49
4.11.9 KCM CPU digital inputs - J8 .............................................................................................49
4.11.10 KCM CPU analog output - J9 ...........................................................................................50
4.11.11 KCM CPU analog input - J9 ..............................................................................................50
4.11.12 KCM CPU frequency input - J9 .........................................................................................51

Docu-No.: 1090020601-EN Rev. 1.2.1 Page5
4.12 Connecting the KCM .........................................................................................................52
4.12.1 General wiring instructions ...............................................................................................52
4.12.2 Recommended wire sizes and maximum lengths .............................................................53
4.13 Power wiring; specific requirements .................................................................................54
4.13.1 Power mains disconnect requirements .............................................................................54
4.13.2 Protective ground ..............................................................................................................54
4.13.3 AC input wiring details to KCM .........................................................................................54
4.13.4 Shielding and cable glands ...............................................................................................55
5 KCM Set-Up .....................................................................................................................56
5.1 Initial set-up for KCM CPU ................................................................................................56
5.1.1 CPU pc board jumper settings ..........................................................................................56
5.1.2 KCM CPU DIP switch setting ............................................................................................57
5.1.3 KCM addressing with CPU DIP switch positions 1-5 ........................................................57
5.1.4 K-Port 1 function via KCM CPU DIP switch positions 6-8 .................................................57
5.1.5 K-PROM configuration ......................................................................................................58
5.1.6 Display backlight control ...................................................................................................58
5.1.7 Setting display brightness .................................................................................................58
5.2 Initial set-up for KCM drives ..............................................................................................59
5.2.1 Drive jumper settings-all drive types listed ........................................................................59
5.3 DC drive set-up .................................................................................................................60
5.3.1 DC drive selection notes: ..................................................................................................60
5.3.2 DC motor selection table by drive type and line voltage ...................................................60
5.3.3 450/1600 Watt DC drive pc board DIP switch settings .....................................................61
5.3.4 Additional jumper settings for 450 watt drive ....................................................................61
5.4 AC drive set-up .................................................................................................................62
5.4.1 AC drive interface pc board DIP switch settings ...............................................................62
5.5 Stepper drive set-up (all types) .........................................................................................63
5.5.1 Stepper motor programming table ....................................................................................63
5.5.2 Stepper drive pc board DIP switch settings ......................................................................63
5.6 Vibratory drive set-up ........................................................................................................64
5.6.1 Vibratory drive pc board DIP switch settings ....................................................................64
5.6.2 Vibratory drive adjustment ................................................................................................64
5.7 GWB Application drive set-up ...........................................................................................66
5.7.1 GWB Hardware overview .................................................................................................66
5.7.2 Setup DC Drive Boards ....................................................................................................67
5.7.3 Setup Vibrator Drive Boards .............................................................................................67
5.7.4 Setup Stepper Drive Boards .............................................................................................68
5.7.5 Setup AC Drive Boards .....................................................................................................68
6 Transportation, Storage, Disposal ................................................................................69
6.1 Notes on transportation ....................................................................................................69
6.2 Notes on storage ..............................................................................................................69
6.3 Notes on disposal .............................................................................................................69
7 Operation .........................................................................................................................70
7.1 Initial operation .................................................................................................................70
7.1.1 KCM-SD LED status display .............................................................................................71

Page 6 Docu-No.: 1090020601-EN Rev. 1.2.1
7.1.2 LED function listing ...........................................................................................................71
7.2 Emergency stop procedure ...............................................................................................72
7.3 Switching ON and OFF .....................................................................................................72
8 Cleaning ...........................................................................................................................73
9 Maintenance ....................................................................................................................74
9.0.1 Required skills/training for maintenance of the KCM ........................................................74
9.0.2 General tools required ......................................................................................................74
9.1 Preventive maintenance ...................................................................................................74
9.2 Parameter Backup ............................................................................................................75
9.3 KCM fuse replacement .....................................................................................................75
9.3.1 Auto-resetting drive fuses .................................................................................................75
9.3.2 Resetting auto-resetting fuses ..........................................................................................75
9.3.3 List of auto resetting fuses ................................................................................................76
9.3.4 Replacing fuses ................................................................................................................76
9.3.5 1600 watt dc motor drive fuse location-0000002610 ........................................................77
9.3.6 450 watt dc motor drive fuse location-0000007405 ..........................................................77
9.3.7 Vibratory drive fuse location-000000684 ..........................................................................77
9.3.8 AC motor drive interface fuse location-000003413 ...........................................................78
9.3.9 Stepper drive interface fuse location-0000005987 ...........................................................78
9.4 Battery replacement ..........................................................................................................79
9.5 KCM service connections .................................................................................................80
9.5.1 Forcing the Config Port to UserIF protocol .......................................................................80
9.5.2 USB ..................................................................................................................................80
10 Troubleshooting .............................................................................................................81
10.1 General information on fault detection ..............................................................................81
10.2 KCM CPU LEDs ...............................................................................................................82
10.2.1 CPU pc board LEDs .........................................................................................................83
10.2.2 K-Port LEDs ......................................................................................................................83
10.3 KCM Drive and Power Supply Details ..............................................................................84
10.3.1 Drive board LEDS .............................................................................................................84
10.3.2 KCM Drive pc board LEDs-all types .................................................................................85
10.3.3 Measuring motor power ....................................................................................................85
10.3.4 Measure and adjust speed frequency signal ....................................................................85
10.4 DC motor drive problems and solutions ............................................................................86
10.5 Vibratory drive problems and solutions .............................................................................87
10.6 Stepper drive problems and solutions ..............................................................................88
10.6.1 Stepper alarm LED flash sequence ..................................................................................89
10.7 AC interface drive problems and solutions .......................................................................90
11 Optional Devices .............................................................................................................91
11.1 Host communication circuit cards .....................................................................................91
11.2 Encoder interface circuit card ...........................................................................................91
11.3 Field power supply ............................................................................................................92

Docu-No.: 1090020601-EN Rev. 1.2.1 Page7
11.4 SFT expander circuit card .................................................................................................93
11.5 Daisy chain connector ......................................................................................................93
12 Appendix .........................................................................................................................94
12.1 Cable length specifications ...............................................................................................94
12.1.1 DC motor cable lengths: 230 Vac .....................................................................................94
12.1.2 DC motor cable lengths: 115Vac ......................................................................................94
12.1.3 Cable lengths for speed feedback signals ........................................................................95
12.2 KCM I/O defaults ..............................................................................................................96
12.2.1 Default KCM Programmable I-O table. .............................................................................96
12.2.2 I-O function selection ........................................................................................................97
12.3 I-O function and KCM state indications ............................................................................99
12.3.1 State indications ...............................................................................................................99
12.4 KCM wiring examples .....................................................................................................101
12.4.1 System wiring examples .................................................................................................101
12.4.2 KCM to KSU-II wiring at K-Port 1/2 .................................................................................101
12.4.3 KCM to KSL wiring at K-Port 1 .......................................................................................102
12.4.4 KCM to KSC wiring at K-Port 1- Digi card .......................................................................103
12.4.5 KCM to KSC wiring at K-Port 1- Moxa card ....................................................................104
12.4.6 KCM to KSC wiring at K-Port 1- K-Tron converter ..........................................................105
12.4.7 KCM to WAGO I-O wiring at K-Port 2 .............................................................................106
12.4.8 KCM to KF2 Host port wiring ..........................................................................................107
12.4.9 KCM to BM-85 Host port wiring ......................................................................................108
12.4.10 450 watt DC drive wiring example - 0000007405 ...........................................................109
12.4.11 KCM without SIB board - dc motor - 0000002610 ..........................................................110
12.4.12 Remote KCM with SIB pcb at feeder ..............................................................................111
12.4.13 Field wound DC motor wiring example ...........................................................................113
12.4.14 Stepper drive wiring example for 0000005987 ...............................................................114
12.4.15 Encoder Line Driver Board .............................................................................................115
12.4.16 Vibratory feeder wiring example - 0000000684 ..............................................................116
12.4.17 AC drive wiring example - 0000003413 ..........................................................................117
12.4.18 KCM interlock wiring example .........................................................................................118
12.4.19 Hi/Lo Auto gear external switching circuit .......................................................................119
12.4.20 KCM to HCU wiring example ..........................................................................................120
12.4.21 KCM to LSR wiring example ...........................................................................................120
12.4.22 Schematic of SIB board-9191601650 .............................................................................121
12.4.23 Belt slip wiring for WBF and WBB applications. ..............................................................122
12.5 Summary of KCM I-O .....................................................................................................123
12.5.1 CPU I-O ..........................................................................................................................123
12.5.2 Common Drive I-O ..........................................................................................................124
12.5.3 SFT Connections for all drives ........................................................................................124
12.5.4 Specific 450/1600 Watt DC Drive connections ...............................................................125
12.5.5 Specific Stepper Drive connections ................................................................................125
12.5.6 Specific Vibratory Drive connections ..............................................................................126
12.5.7 Specific AC Drive connections ........................................................................................126

Page 8 Docu-No.: 1090020601-EN Rev. 1.2.1

Docu-No.: 1090020601-EN Rev. 1.2.1 Page9
SafetyNotes 1
Safetysymbolsdefinitions 1.1
1 Safety Notes
1.1 Safety symbols definitions
▲The explosion-proof control is one of the products with increased
risk of damage, as it is used in hazardous locations. For handling
with this device is therefore an increased duty of care. The front
cover is part of the ignition protection and should not be opened in
an explosive atmosphere.
▲Protect the explosion-proof control from direct sunlight.
Installation, commissioning and programming of the specified
equipment should only be undertaken by qualified personnel.
▲DANGER indicates a extremely hazardous situation which, if not
avoided, could lead to heavy bodily injury or to death.
▲WARNING indicates a potentially hazardous situation which, if not
avoided, could lead to heavy bodily injury or to death.
▲CAUTION with safety alert indicates a potentially hazardous
situation which, if not avoided, could lead to light bodily injuries.
▲CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
▲The safety alert symbol is used to alert to the potential personal
injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.

1 Safety Notes
1.2 Operator responsibilities
Page 10 Docu-No.: 1090020601-EN Rev. 1.2.1
1.1.1 Electrical Hazard Icon
1.1.2 Ground Icon
1.1.3 ATEX Icon
1.2 Operator responsibilities
This sign indicates an electrical hazard. It is located on covers and
doors. Only qualified personnel are allowed to remove these covers or
open the doors.
This sign indicates that a ground/PE connection is required.
Important information to explosion protection.
▲For install and the mounting for explosion-proof equipment
following and observe the standards and directives:
Standards 99/92EG (ATEX 137)
▲Ensure that only qualified and trained personnel work with the
device.
▲Establish personnel responsibilities for operation and
maintenance.
▲Ensure that personnel have read and understood the operating
instructions to all installation components, particularly these safety
notes.
▲The operator must have damaged or missing components
replaced immediately.
▲The operator of the equipment is responsible for compliance with
the legally prescribed accident and safety regulations.

Docu-No.: 1090020601-EN Rev. 1.2.1 Page11
SafetyNotes 1
Properuse 1.3
1.3 Proper use
1.4 Special provisions X
1.5 Organizational measures
1.6 Safety-conscious operation
▲The operation of the device in hazardous areas is only allowed in
areas with classification zone 22.
▲Only operate the device in conjunction with the feeder equipment
from K-Tron.
▲Only operate the device in accordance with the specified technical
data.
▲Avoid larger dust deposits on the device.
▲Protect from direct sunlight.
▲When processing dangerous materials, also comply with the
safety notes which govern the handling of such materials.
▲Any modifications and changes on safety devices are prohibited
▲Do not use the equipment in a manner not intended by the
manufacturer.
▲Do not use the equipment in a manner not intended by the
manufacturer.
▲The equipment must be protected against direct sunlight.
▲Observe the safety notes for the connected feeding devices.
▲In addition to the operating instructions, always comply with
generally prescribed safety regulations governing accident
prevention and environmental safety.
▲Read the operating instructions, in particular these safety notes,
and follow these instructions.
▲Ensure that only authorized personnel enter the working and
danger area of the equipment.
▲Any changes (including changes in the operational behavior)
which affect safety must be immediately reported to the
responsible member of the staff.
▲Always keep safety in mind while working.
▲Before working on the equipment always switch the feeding
equipment off at the main power switch.

1 Safety Notes
1.7 Safety devices
Page 12 Docu-No.: 1090020601-EN Rev. 1.2.1
1.7 Safety devices
1.8 High voltage
1.9 Additional equipment
1.10 Customer service and repairs
▲Never open or remove covers or hoods while the equipment is in
operation.
▲Do not modify the electrical safety devices, for example fuses.
Increased risk of accident.
▲Replace damaged cables and connections immediately.
▲Switch off the power to the equipment. Do not open the enclosure
in an explosive atmosphere. Before accessing internal
components, allow 3 minutes to lapse prior to opening the
enclosure. This ensures safe discharge of high voltage
components.
▲Only qualified electricians may work on the electrical equipment of
the equipment.
▲High voltage may be present on the line power cables of the
device.
▲Switch off the power to the device for 3 minutes before:
– any disassembly, maintenance and repair work
– replacing the drive
▲Protect the device against moisture entrance.
▲Modifications to the equipment are prohibited.
▲The operator is responsible for complying with all safety
regulations related to interoperation with any additional
equipment.
▲Have repairs to the equipment carried out by
– your authorized K-Tron customer service center
or– qualified personnel, trained by K-Tron.
▲Only use original K-Tron parts for repairs.
▲In EX equipment may only manufacturer-approved batteries used.
Replacement from the battery, see section 9.4.

Docu-No.: 1090020601-EN Rev. 1.2.1 Page13
SafetyNotes 1
Removalfromservice1.11
1.11 Removal from service
▲The operator is responsible for the proper removal and disposal of
the equipment from service.

2 Assembly and Function
2.1 Field of application
Page 14 Docu-No.: 1090020601-EN Rev. 1.2.1
2 Assembly and Function
2.1 Field of application
KCM XPC3 stands for K-TRON Control Module and XPC3 for
Explosion-protection of Category 3.
The KCM is a control and a drive module for K-Tron feeders. The KCM
is normally mounted directly on the feeder. It can also be mounted
remotely.The KCM can usedas controller for feeding processes which
require explosion protection in zone 22.
2.1.1 Explosion proof marking
The marking on the device shows the device category. The declara-
tion of conformity shows the zone in which the device may be used.
2.1.2 Zones and device categories (gas)
The owner is responsible for ensuring that the system is installed in
the intended zone. The corresponding category is described in the
declaration of conformity.
Zone Description Use of KCM
Zone 0 An area in which an explosive atmos-
phere, i.e. a mixture of air and flamma-
ble gases, vapours or mists is either fre-
quently or constantly present over an
extended period.
Not allowed
Zone 1 An area in which a dangerous mixture of
air and flammable gases, vapours or
mists sometimes forms during normal
operation, constituting an explosive at-
mosphere.
Not allowed
Zone 2 An area in which a dangerous mixture of
air and flammable gases, vapours or
mists constituting an explosive atmos-
phere usually does not exist or only for
short periods.
Not allowed

Docu-No.: 1090020601-EN Rev. 1.2.1 Page15
AssemblyandFunction 2
Fieldofapplication 2.1
2.1.3 Zones and device categories (dust)
2.1.4 Dust deposits and glow temperature
Zone Description Use of KCM
Zone 20 An area in which a dangerous, explo-
sive atmosphere in the form of a cloud
of flammable dust suspended in the air
is either constantly present, or frequent-
ly or for long periods at a time.
Not allowed
Zone 21 An area in which a dangerous, explo-
sive atmosphere in the form of a cloud
of flammable dust suspended in the air
may form at times under normal operat-
ing conditions.
Not allowed
Zone 22 An area in which a dangerous, explo-
sive atmosphere in the form of a cloud
of flammable dust suspended in the air
may form at times under normal operat-
ing conditions.
Allowed
▲Observe the requirements of the standard IEC/EN 60079-14
Chapter 5.6.3.1 with regard to reduced glow temperature at dust
deposits.
In case of dust deposits of up to 5 mm:
• Glow temperature of the material at a thickness of the layer of dust
5 mm: ≥max. Surface temperature (Tmax) + 75 K.
Tmax = T5 mm - 75 °C
In case of dust deposits greater than 5 mm to max. 50mm:
• The difference to be observed between the glow temperature of the
material and the surface temperature (Tmax) depends on how thick
the dust layer is. The context is shown in Fig. 1 of the standard EN
60079-14 Chapter 5.3.3.2.1
• Avoid Dust deposits > 5mm (see 8 cleaning).
Dust deposits ≥50 mm avoid or complete covered:
• not allowed

2 Assembly and Function
2.1 Field of application
Page 16 Docu-No.: 1090020601-EN Rev. 1.2.1
2.1.5 Abbreviations
• AB = Allen Bradley data comm-DF1 protocol
• Config port = diagnostic serial data port from KCM
• CPU = central processing unit, microprocessor
• DPDT =Relay Double Pole, Double Throw
• Drive = Common representation of all types of drive pc boards (450
watt DC drive, 1600 watt DC drive, AC drive interface, stepper
motor drive, vibratory drive)
• HCU = Pneumatic loader control
• Host Channel = serial data connection to remote host computer
• HSU = Pneumatic loader control programming interface
• HMI = human, machine interface, usually a PC utilizing a
commercial SCADA software package
• Internal Channel = serial data connection to SFTs/ loader controls,
internal motor drives and ActiFlow
• KCM = K-Tron Control Module, feeder controller
• KCM-KD = KCM with local Keypad and graphic display since 2010,
before 4x20 characters display
• KCM-SD = KCM with Status Display only
• KGR = host communication file residing in KCM
• K-PROM = parameter and k-link file storage in the KCM
• KSC = K-Tron Smart Commander, a PC based HMI system for use
with up to 30 feeders
• KSL = K-Tron line interface for up to 8 feeders
• K-Net = KCM serial data connection to KSU-II, KSL, K-Vision or
KSC
• K-Port 1 and K-Port 2 = data ports for a K-Tron specific interface
• KSU-II = Single unit user interface for the KCM
• K-Vision = K-Tron line interface for up to 16 feeders
• LSR = Pneumatic loader control
• LWF = loss-in-weight feeder
• MDU = Motor Drive Unit, Drive Board
• pcb = printed circuit board
• PID = proportional, integral, differential process controller
• SCADA = supervisory, control and data acquisition system
• Smart Connex II = second version of SmartConnex architecture
• SFM = Smart Flow meter
• SFT = Smart Force Transducer
• SPDT =Relay Single Pole, Double Throw
• SPST =Relay Single Pole, Single Throw
• VOL = volumetric feeder controller

Docu-No.: 1090020601-EN Rev. 1.2.1 Page17
AssemblyandFunction 2
Fieldofapplication 2.1
• WBF = weigh belt feeder
2.1.6 Additional programming information
See the following documents for more detailed programming
information.
• Operation for LWF/WBF/PID/SFM/VOL Feeder
• Operation for LWB/WBB/SFB/GWB Feeder
• LWF Programming
• WBF programming
• PID programming
•SFMprogramming
•VOLprogramming
• LWB programming
• WBB programming
• SFB programming
•GWBprogramming
• The K-Tron’s supplied operating instructions describe how to use
the connected feeder.

2 Assembly and Function
2.2 Overview
Page 18 Docu-No.: 1090020601-EN Rev. 1.2.1
2.2 Overview
The KCM is the controller member of the SmartConnex II family. This
family is comprised of a KCM feeder controller, a KSU-II remote
display unit, a K-Vision for up to 16 feeders and a KSC for interface
for up to 30 feeders.
The KCM is comprised primarily of a cpu pc board, and a drive pc
board. Drive choices include a 1600 watt DC drive, a 450 watt DC
drive, a vibratory drive for KV1-KV3 vibratory trays, a stepper drive for
feeders that utilizes a stepper bi-phase motor and lastly, an AC drive
interface pc board for use with variable frequency drives (VFD) or
remote DC drives.
This manual will describe the full familyof KCM components, including
all drive applications supported.
The KCM is available in two packages: full local keypad and 3.5“ color
LCD (KCM-KD) or 4 LED status display (KCM-SD).

Docu-No.: 1090020601-EN Rev. 1.2.1 Page19
AssemblyandFunction 2
Structure 2.3
2.3 Structure
The KCM includes the following components, some which are
optional.
2.3.1 Enclosure
First, the pc board assemblies are housed in an Aluminium profile or
stainless steel housing with a swing-out cast cover. The enclosure is
designed to mount directly to a feeder or be located in a control panel.
All cabling is brought through the side of the housing incorporating
cable glands. The enclosure is Nema 4/IP 65 rated.
Wiring access is made through IP cable glands at the underside of the
KCM.
Fig. 2.1 KCM-KD
Fig. 2.2 KCM-SD

2 Assembly and Function
2.3 Structure
Page 20 Docu-No.: 1090020601-EN Rev. 1.2.1
2.3.2 Circuit assemblies
The KCM CPU pc board is mounted to the rear of the front swing-out
cover. The drive pc board with KCM power supply is mounted to the
bottom heatsink plate of the housing. (Fig. 2.3)
There are two choices for theon-board KCM operational display. First,
a fully functional display and keypad assembly may be mounted to the
rear of the KCM cpu pc board and permit access via the front of the
cover for all operational actions. (Fig.2.1) The second choice provides
only the four status LEDs that indicate machine running and alarm.
(Fig. 2.2) The first case permits operation of the KCM without any
other external components and is suited for simple machine mount
installations where operator interaction is required at the controller.
The second case requires the addition of one or more of the following:
KSU-II, KSC, K-Vision or KSL user interface. The choice depends
upon application. If communications to a host computer or PLC is
required, a Host Communications pc board is mounted to the KCM
CPU pc board. Also connected to the KCM CPU is the K-PROM
memory module that contains all parameter and KGR file data.
Lastly, if the speed signal is differential, a plug-in circuit card permits
the receipt of this signal where normally a single ended input is
received.
KCM element identification
(1) CPU circuit card
(2) Drive circuit card
(3) Host comm. circuit card
(4) K-PROM circuit card
Fig. 2.3 KCM open
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4
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