Kugelmann K-TRONIC 2 User manual

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Art.Nr.: 10046693 11/15/2016 | Version 1.2 | EN
Kugelmann Maschinenbau e.K.
Gewerbepark 1-5
87675 Rettenbach a.A.
GERMANY
www.kugelmann.com
[email protected]om
+49 (0) 8860 | 9190-0
Kugelmann Maschinenbau is a family-run Allgäu business with its main emphasis and
tradition in municipal technology. With passion, we manufacture reliable and pioneering
machines - we love what we do.
ORIGINAL OPERATING INSTRUCTIONS
Control system
K-TRONIC 2

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Copyrights and trademarks 11/15/2016 2/150
Copyrights and trademarks
© Kugelmann Maschinenbau e.K.
Gewerbepark 1-5
87675 Rettenbach a.A. (Germany)
Tel.: [phone] / 9190-0
Fax: [phone] / 9190-19
Mail: [e-mail]
Web: www.kugelmann.com
All company names and designations used in this manual may also be registered trademarks
of the respective manufacturing companies and shall not be used commercially or otherwise.
Errors and omissions excepted.
All rights reserved. No part of this manual shall be reproduced or copied in any form (printing,
photocopying, storing or distribution in electronic form) without prior written consent of
Kugelmann Maschinenbau e.K.
We are constantly developing our products to offer our customers maximum convenience.
Therefore, we ask for your understanding that the manual can deviate from the product in some
regards.

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2 Content
1 Title............................................................................................................. 1
2 Content........................................................................................................3
3 General information.....................................................................................7
3.1 Service information......................................................................................................................7
3.2 EC Declaration of Conformity.......................................................................................................8
4 Operating instructions..................................................................................9
4.1 Target group.................................................................................................................................9
4.2 Use............................................................................................................................................... 9
4.3 Conventions used.......................................................................................................................10
4.4 Change history........................................................................................................................... 10
5 General description....................................................................................12
5.1 Components of the control system............................................................................................13
5.2 User interface............................................................................................................................ 14
5.3 Display view............................................................................................................................... 16
5.4 Meaning of buttons................................................................................................................... 18
5.5 Overview....................................................................................................................................19
5.6 Designated use...........................................................................................................................20
5.7 Obvious misuse..........................................................................................................................20
5.8 Wear parts................................................................................................................................. 21
6 Safety instructions......................................................................................22
6.1 General safety instructions........................................................................................................ 22
6.2 Commissioning...........................................................................................................................23
6.3 Use............................................................................................................................................. 24
6.4 Maintenance..............................................................................................................................25
6.5 Designations.............................................................................................................................. 26

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7 Commissioning...........................................................................................27
7.1 Wiring diagram.......................................................................................................................... 27
7.1.1 Cable harness fixed installation....................................................................................... 28
7.1.2 Cable harness overhung installation................................................................................30
7.2 Switch on / off control system................................................................................................... 33
7.3 Select user menu....................................................................................................................... 34
7.4 Open detail menu...................................................................................................................... 35
7.5 Setting of date and time............................................................................................................ 37
7.6 Configuration of drive signal......................................................................................................39
7.6.1 Drive signal teach in.........................................................................................................40
7.6.2 Manual entry of drive signal............................................................................................ 41
7.6.3 Drive signal over certain distance....................................................................................42
7.7 Check and setting of sensors..................................................................................................... 43
7.8 Configuration of characteristic curves....................................................................................... 45
7.9 Configuration of spreading material..........................................................................................48
7.9.1 Setting of possible spreading materials...........................................................................48
7.9.2 Teach in spreading materials........................................................................................... 49
7.9.3 Choice of spreading materials to be used during operation............................................52
7.10 Output rates.............................................................................................................................53
7.11 Spreading operation................................................................................................................ 55
7.12 Setting of spreading width.......................................................................................................56
7.12.1 Configuration of spreading width.................................................................................. 56
7.13 Recommissioning.....................................................................................................................59

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8 Operating instructions................................................................................61
8.1 Switch on/off working headlights.............................................................................................. 62
8.2 Switch on/off rotating beacon................................................................................................... 63
8.3 Function key setting...................................................................................................................64
8.4 Double spreading density.......................................................................................................... 66
8.5 Maximum spreading rate...........................................................................................................67
8.6 Operator level 1 and 2............................................................................................................... 70
8.7 Path-dependence and manual operation.................................................................................. 71
8.8 Key tone..................................................................................................................................... 75
8.9 Output counter.......................................................................................................................... 76
8.9.1 Configuration of output counter..................................................................................... 77
8.9.2 Reset output counter.......................................................................................................80
8.10 Emptying the spreader............................................................................................................ 82
8.11 Display increments of output rates..........................................................................................85
8.12 Simulation speed..................................................................................................................... 87
8.13 Configuration of spreading width parameters.........................................................................88
8.14 Warning list..............................................................................................................................90
8.15 Error list................................................................................................................................... 91
8.16 Options.................................................................................................................................... 95
8.17 Serial numbers......................................................................................................................... 99
8.18 Speed when spreader stops...................................................................................................100
8.19 Daily statistics........................................................................................................................ 102
8.20 Complete statistics.................................................................................................................103
8.21 Boost function........................................................................................................................104
8.22 Update................................................................................................................................... 107
8.23 Reset to factory settings........................................................................................................ 109
8.24 Slave.......................................................................................................................................111
8.25 Requirements for carrier vehicle........................................................................................... 113

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9 Operating instructions - Options...............................................................114
9.1 Electrical adjustment of spread pattern.................................................................................. 114
9.1.1 Configuration of electrical adjustment of spreading pattern........................................ 115
9.1.2 Servo motor turned....................................................................................................... 119
9.1.3 Mechanical limits...........................................................................................................122
9.2 Automatic spreading image..................................................................................................... 124
9.2.1 Configuration of automatic spreading image................................................................ 126
9.2.2 Setting of automatic spreading image...........................................................................130
9.3 Electrical monitoring of spreading process..............................................................................131
9.4 Spreaders with pre-wetted salt equipment............................................................................. 131
9.4.1 Configuration of brine equipment.................................................................................132
9.4.2 Switch on/off brine spreading....................................................................................... 136
9.4.3 Changing the brine proportion...................................................................................... 138
9.4.4 Brine calculation............................................................................................................ 138
9.5 Motor unit................................................................................................................................141
9.5.1 Configuration of motor unit...........................................................................................141
9.5.2 Start motor unit............................................................................................................. 143
9.5.3 Switch off motor unit.....................................................................................................144
10 Storage...................................................................................................146
11 Technical Data........................................................................................ 147
12 Disconnecting the system....................................................................... 148
Warranty.....................................................................................................150

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3 General information
This chapter gives you information on the following:
•Chapter 3.1 "Service information", page 7
•Chapter 3.2 "EC Declaration of Conformity", page 8
3.1 Service information
Customer service:
Tel.: [phone] / 9190-90
Fax: [phone] / 9190-49
E-Mail: [email protected]

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3.2 EC Declaration of Conformity
in terms of the EC Machinery Directive 2006/42/EC and
the EMC Directive 2014/30/EU
We herewith declare that the control system designated below complies with the
relevant essential health and safety requirements of the respective EC Machine
Directives and the EMC Directive due to its design and construction, and in the
version supplied by us.
If the control system is modified without our consent, this declaration shall cease to
apply.
Designation: Control system K-Tronic 2
Relevant EC machinery directives:
DIN EN ISO 15431 / 16330/292-1 / 292-2 / 60204-1 / 12100 / 13849-1 / 13849-2
Rettenbach a.A., October 2016 Josef Kugelmann

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4 Operating instructions
This chapter gives you information on the following:
•Chapter 4.1 "Target group", page 9
•Chapter 4.2 "Use", page 9
•Chapter 4.3 "Conventions used", page 10
•Chapter 4.4 "Change history", page 10
4.1 Target group
These operating instructions are intended for skilled persons who are responsible for
the following work at the control system:
•Commissioning
•Control system
•Operation
•Use
At least once a year, all personnel must be trained in the operation of the control
system in accordance with the guidelines of the business liability insurance. The use
of the control system by untrained or unauthorized persons is prohibited.
4.2 Use
These operating instructions contain all necessary data and information for safe
operation and commissioning of the spreader.
Make sure that all persons responsible for the operation of the control system or
persons working in the immediate environment of the control system are familiar
with the operating instructions as well as the safety information in this manual.
These operating instructions are part of the product and have to be kept in a safe
place. In case of resale or transfer of the control system to third parties, these
operating instructions have to be included.
All information, illustrations and technical data correspond to the technical state at
the time of printing. Subject to technical modifications.

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4.3 Conventions used
This manual uses the following typographic conventions:
Symbol Signal
word Meaning
Danger
Indicates an imminent dangerous situation, which - in case of
non-observance of the safety instructions - will entail death or
grievous bodily harm.
Warning
Indicates a possibly dangerous situation, which - in case of non-
observance of the safety instructions - may entail death or
grievous bodily harm.
Caution
Indicates a possibly dangerous situation, which - in case of non-
observance of the safety instructions - may result in minor
injuries or damage to property.
Notice Contains useful information with respect to proper handling of
the machine.
4.4 Change history
Date Version Modification
10/14/2016 1.1 First edition
11/15/2016 1.2 Error and warning codes added

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5 General description
This chapter gives you information on the following:
•Chapter 5.1 "Components of the control system", page 13
•Chapter 5.2 "User interface", page 14
•Chapter 5.3 "Display view", page 16
•Chapter 5.4 "Meaning of buttons", page 18
•Chapter 5.5 "Overview", page 19
•Chapter 5.6 "Designated use", page 20
•Chapter 5.7 "Obvious misuse", page 20
•Chapter 5.8 "Wear parts", page 21

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5.1 Components of the control system
Please see the following illustration for components of the control system:
Pos. No. Part
10 Turning knobs
20 Membrane keyboard
30 Side plate (lh)
40 Side plate (rh)
50 ON / OFF push-button
60 Housing front shell
70 Distance frame front
80 Distance frame rear
90 Clamping sheet
100 Circuit board
110 Plug connector plate
120 EXM board
130 Housing rear shell
140 Fixture
150 Spherical head
160 Counternut
170 Locking nut

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5.2 User interface
Pos. No. Function
10 Rotating beacon / Flasher
20 Working headlight
30 Function key 1
40 Actual value button
50 Turning knob spreading material left
60 Turning knob for setting the spreading width
70 Turning knob spreading material right
80 ON / OFF
90 Button for spreading material
100 Function key 2
110 Function key 3
120 Spreading operation / Pause
130 Display

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Pos. No. Function
10 Socket master - connecting cable
20 Serial interface RS232
30 Cable support
40 USB port 1
50 USB port 2 (not occupied)

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5.3 Display view
Rotating beacon ON / OFF
see Chapter 8.2 "Switch
on/off rotating beacon",
page 63
Working headlight ON / OFF
see Chapter 8.1 "Switch on/
off working headlights",
page 62
Double spreading density ON / OFF
see Chapter 8.4 "Double
spreading density",
page 66
SPREADING / PAUSE see Chapter 7.11 "Spreading
operation", page 55
Operator level LEVEL1 / LEVEL2 see Chapter 8.6 "Operator
level 1 and 2", page 70
Maximum spreading rate ON / OFF see Chapter 8.5 "Maximum
spreading rate", page 67
Teach in ON / OFF
Motor unit ON / OFF see Chapter 9.5 "Motor
unit", page 141

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Electrical monitoring of spreading
process ON / OFF
see Chapter 9.3 "Electrical
monitoring of spreading
process", page 131
Brine spreading ON / OFF
see Chapter 9.4.2 "Switch
on/off brine spreading",
page 136
Spreader works path-dependent /
manually
see Chapter 8.7 "Path-
dependence and manual
operation", page 71
Electrical adjustment of spread
pattern
see Chapter 9.1 "Electrical
adjustment of spread
pattern", page 114
Outside temperature display
Percentage of pre-wetted salt
during brine spreading [%]
see Chapter 9.4.3 "Changing
the brine proportion",
page 138
Driving speed
Output counter left chamber see Chapter 8.9 "Output
counter", page 76
Output counter brine reservoir see Chapter 8.9 "Output
counter", page 76
Output counter right chamber see Chapter 8.9 "Output
counter", page 76
Spreading material and spreading
rate [g/m²] left chamber
see Chapter 7.10 "Output
rates", page 53
Spreading material and spreading
rate [g/m²] right chamber
see Chapter 7.10 "Output
rates", page 53
Spreading width [m]
see Chapter 7.12 "Setting
of spreading width",
page 56

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5.4 Meaning of buttons
Button Meaning
Function key 1
•Confirm and continue to next menu mask
Spreading / Pause button
•Previous menu mask
Turning knob left/middle/right:
•Turning respective turning knob to continue to the next/previous
menu option.
•Turning respective turning knob to confirm the respective menu
option.
•Pressing and turning the turning knob to skip whole numbers for
settings
•Turning the turning knob to skip in steps of 0.01 for settings
Rotating beacon / Flasher button
•Exit menu
Turning knob left/right
•Start / Confirm
Function key 3
•Switching on respective option
Function key 3
•Switching off respective option
Function key 1
•Information on respective menu option
Function key 2
•Settings
Working headlight button
•Save

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Rotating beacon / Flasher button
•Reset output counter right chamber
Working headlight button
•Reset output counter brine
Function key 1
•Reset output counter left chamber
5.5 Overview
The control system K-Tronic 2 consists of two major electronic components:
Pos. No. Part Function
10 Master Operating unit in the driver’s cab
20 Slave Switching electronics at the rear of the spreader

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5.6 Designated use
Use the control system only for spreaders manufactured by Kugelmann
Maschinenbau e.K.
Use the control system only with the plug-and-socket connections provided for this
purpose and with the respective original cables.
Any kind of use that deviates from the procedure set forth herein is considered
contrary to its designated use. The operator of the control system is liable for any
damages arising from such action.
Use and reconditioning of the control system may only be carried out by trained and
competent personnel.
To operate the equipment within the limits of its designated use, please note the
following:
•These operating instructions as well as all other enclosed documentation.
•The relevant accident prevention regulations.
•The generally recognized rules relating to technical safety requirements and
occupational health.
•The operating instructions of the carrier vehicle.
5.7 Obvious misuse
It is not allowed to operate machines with the control system which were not
designed and manufactured by Kugelmann Maschinenbau e.K.
Do not use or store the control system outside or uncovered.
The control system shall not be used as handle.