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.