K-Tron KCM Docu. Inc. Stops

TECHNICAL INSTRUCTION
KCM Protocol
Read this manual prior to operating or

servicing the equipment. This manual
contains all safety labels and warn-
ings.
0590020612-EN Rev. 1.0.0

Service:
If you need assistance, please call your local service center or
K-Tron (Switzerland)
Industrie Lenzhard Tel. (062) 885 71 71
CH-5702 Niederlenz, Fax (062) 885 71 80
K-Tron (U.S.A.)
Rt. 55 and Rt. 553 Tel. (856) 589 -9083
Pitman, NJ 08071, Fax (856) 589 - 5664
Web: http://www.ktron.com
Before you call, gather the following information…

« Do you have alarm displays? What are they exactly?
« Are you able to eliminate the cause of the alarm displays?
« Have you modified part of the system, product or operating mode?
« Have you tried to remedy the fault in accordance with the operating and
service instructions?
« Record the six digit project or job number located on the machine and
in the project manual.
– Example: 403214
Use of the manual:

« This arrow is used for identifying one-step actions or actions that have
no specific order.
1. Numbers in a list identify tasks that have sequences you have to follow.
V This icon indicates a general cautionary note.
Indicates an electrical hazard.
Reference to another manual section.
Marks helpful information.
Indicates that tools are needed for the task.
Specifies where information or a situation must be checked.
Indicates where power is applied or removed.
Don’t place hands or other body parts into machine.
Order no.: 0590020612-EN “K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part of
operating personnel. Further, reference is made to the purchase order, acceptance or other document that contains
the express K-Tron disclaimer of warranties for a statement of the provisions limiting or disclaiming certain warranties
Date:2005/09/02 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
Original: 0290020608-EN ANY OTHER WARRANTY, EXPRESS OR IMPLIED, WITH RESPECT TO THE EQUIPMENT.”
If an error or ommission is found, please contact: documentation@ktron.com.
KIT Project No: 241
Table of Contents
1 Safety Notes ...................................................................................................................... 1

1.1 Safety symbol definitions .................................................................................................... 1
1.1.1 Related safety/electrical icons ............................................................................................ 1
1.2 Proper use .......................................................................................................................... 2
1.3 Organizational measures .................................................................................................... 2
1.4 Operator responsibilities ..................................................................................................... 2
1.5 Safety-conscious operation ................................................................................................ 3
1.6 Safety devices .................................................................................................................... 3
1.7 High voltage ........................................................................................................................ 3
1.8 Additional equipment .......................................................................................................... 4
1.9 Removal from service ......................................................................................................... 4
1.10 Customer service and repairs ............................................................................................. 4
1.11 Warranty ............................................................................................................................. 4
1.12 Applied safety signs and placards ...................................................................................... 4
1.12.1 Selected safety signs on machines .................................................................................... 4
2 Data Structures, Formats and Data Types for SmartConnex-II .................................... 5

2.1 Overview ............................................................................................................................. 5
2.2 Data descriptions ................................................................................................................ 6
2.2.1 Data types ........................................................................................................................... 6
2.2.2 Application types ................................................................................................................. 6
2.3 Data and formats ................................................................................................................ 7
2.3.1 KCM global variables: Process ........................................................................................... 7
2.3.2 KCM global variables: Alarms ............................................................................................. 8
2.3.3 KCM global variables: Scale parameters ............................................................................ 9
2.3.4 KCM global variables: Digital I-O ...................................................................................... 10
2.3.5 KCM global variables: Analog I-O ..................................................................................... 11
2.3.6 KCM global variables: Modbus I-O ................................................................................... 11
2.3.7 KCM global variables: HCU Loader Params ..................................................................... 12
2.3.8 HcuSelParamNum Definitions .......................................................................................... 12
2.3.9 KCM global variables: Communications ........................................................................... 14
2.3.10 KCM global variables: Miscellaneous ............................................................................... 14
2.3.11 KCM variables: LWF ......................................................................................................... 16
2.3.12 KCM variables: LWB ......................................................................................................... 18
2.3.13 KCM variables: PID .......................................................................................................... 21
2.3.14 KCM variables: SFM ......................................................................................................... 22
2.3.15 KCM variables: VOL ......................................................................................................... 24
2.3.16 KCM variables: WBF ........................................................................................................ 24
2.4 Service variable index ....................................................................................................... 25
3 I-O Functions ................................................................................................................... 26

3.1 Global I-O functions for all applications ............................................................................ 26
3.1.1 Global digital inputs .......................................................................................................... 26
Docu-No.: 0590020612-EN Rev. 1.0.0 KCM Protocol Page 1

3.1.2 Global analog setpoint input .............................................................................................26
3.1.3 Global digital outputs ........................................................................................................ 27
3.1.4 Global analog outputs ....................................................................................................... 27
3.2 LWF I-O ............................................................................................................................ 28
3.2.1 LWF digital inputs ............................................................................................................. 28
3.2.2 LWF analog setpoint input ................................................................................................28
3.2.3 LWF digital outputs ........................................................................................................... 28
3.2.4 LWF analog outputs .......................................................................................................... 29
3.3 WBF I-O ............................................................................................................................ 29
3.3.1 WBF digital inputs ............................................................................................................. 29
3.3.2 WBF analog setpoint input ................................................................................................29
3.3.3 WBF digital outputs ........................................................................................................... 29
3.3.4 WBF analog outputs ......................................................................................................... 30
3.4 PID I-O .............................................................................................................................. 30
3.4.1 PID digital inputs ............................................................................................................... 30
3.4.2 PID analog setpoint input .................................................................................................. 30
3.4.3 PID analog process input .................................................................................................. 30
3.4.4 PID digital outputs ............................................................................................................. 30
3.4.5 PID analog outputs ........................................................................................................... 31
3.5 VOL I-O ............................................................................................................................. 31
3.5.1 VOL digital inputs .............................................................................................................. 31
3.5.2 VOL analog setpoint input ................................................................................................. 31
3.5.3 VOL digital outputs ............................................................................................................ 31
3.5.4 VOL analog outputs .......................................................................................................... 31
3.6 SFM I-O ............................................................................................................................ 32
3.6.1 SFM digital inputs ............................................................................................................. 32
3.6.2 SFM analog setpoint input ................................................................................................32
3.6.3 SFM digital outputs ........................................................................................................... 32
3.6.4 SFM analog outputs .......................................................................................................... 32
3.7 LWB I-O ............................................................................................................................ 33
3.7.1 LWB digital inputs ............................................................................................................. 33
3.7.2 LWB analog batch setpoint input ...................................................................................... 33
3.7.3 LWB digital outputs ........................................................................................................... 33
3.7.4 LWB analog outputs .......................................................................................................... 34
4 Command Functions ...................................................................................................... 35

4.1 Overview ........................................................................................................................... 35
4.2 Command tables for action functions ................................................................................ 35
4.2.1 Global command table ...................................................................................................... 35
4.2.2 HCU Loader command table ............................................................................................ 35
4.2.3 LWF command table ......................................................................................................... 36
4.2.4 WBF command table ........................................................................................................36
4.2.5 PID command table .......................................................................................................... 36
4.2.6 VOL command table ......................................................................................................... 36
4.2.7 LWB command table ......................................................................................................... 37
4.2.8 SFM command table ......................................................................................................... 37
5 Condensed Process Status Variables .......................................................................... 38

5.0.1 Introduction ....................................................................................................................... 38
Page 2 KCM Protocol Docu-No.: 0590020612-EN Rev. 1.0.0

5.1 Condensed process status variable table ......................................................................... 38
5.1.1 Condensed global process status variable table .............................................................. 38
5.1.2 Condensed LWF process status table .............................................................................. 39
5.1.3 Condensed WBF process status table ............................................................................. 39
5.1.4 Condensed PID process status table ............................................................................... 40
5.1.5 Condensed VOL process status table .............................................................................. 40
5.1.6 Condensed LWB process status table .............................................................................. 40
5.1.7 Condensed SFM process status table .............................................................................. 41
6 Expanded Process Status Word - PSW ........................................................................ 42

6.0.1 Introduction ....................................................................................................................... 42
6.1 Expanded PSW tables ...................................................................................................... 42
6.1.1 PSW word mapping .......................................................................................................... 42
6.1.2 Global PSW Map .............................................................................................................. 42
6.1.3 LWF PSW Map ................................................................................................................. 44
6.1.4 WBF PSW Map ................................................................................................................. 44
6.1.5 PID and VOL PSW Map ................................................................................................... 44
6.1.6 SFM PSW Map ................................................................................................................. 45
6.1.7 LWB PSW Map ................................................................................................................. 45
7 Alarm Status Variables-ASW ......................................................................................... 46

7.0.1 Introduction ....................................................................................................................... 46
7.0.2 ASW word mapping .......................................................................................................... 46
7.1 Alarm status word tables-ASW ......................................................................................... 47
7.1.1 Global ASW alarm status table ......................................................................................... 47
7.1.2 LWF alarm status definitions ............................................................................................ 50
7.1.3 VOL alarm status definitions ............................................................................................. 50
7.1.4 WBF alarm status definitions ............................................................................................ 51
7.1.5 LWB alarm status definitions ............................................................................................ 51
7.1.6 PID alarm status definitions .............................................................................................. 52
7.1.7 SFM alarm status definitions ............................................................................................ 52
8 Condensed Alarm Status Words-ASR .......................................................................... 53

8.0.1 Introduction ....................................................................................................................... 53
8.1 Tables of condensed alarm status words ......................................................................... 53
8.1.1 Global ASW condensed alarm status table ...................................................................... 53
8.1.2 LWF condensed alarm status definitions .......................................................................... 54
8.1.3 VOL condensed alarm status definitions .......................................................................... 54
8.1.4 WBF condensed alarm status definitions ......................................................................... 54
8.1.5 LWB condensed alarm status definitions .......................................................................... 55
8.1.6 PID condensed alarm status definitions ........................................................................... 55
8.1.7 SFM alarm status definitions ............................................................................................ 55
9 KSL Line Functions ........................................................................................................ 56

9.0.1 Introduction ....................................................................................................................... 56
9.1 KSL line variable listing ..................................................................................................... 56
9.1.1 KSL numeric parameters .................................................................................................. 56
9.1.2 KSL line command table ................................................................................................... 57
10 KCM Built-In *.kgr Files .................................................................................................. 58

10.1 Protocols supported .......................................................................................................... 58
10.2 Communication settings ....................................................................................................59
10.3 Variable locations and mapping ........................................................................................ 60
10.3.1 Floating point reads from the KCM ................................................................................... 60
10.3.2 Condensed process status and alarm status reads .......................................................... 61
10.3.3 Heartbeat, single word read .............................................................................................. 62
10.3.4 Single word writes for control ............................................................................................ 62
10.3.5 Command register ............................................................................................................ 62
10.3.6 Command functions .......................................................................................................... 63
10.3.7 Floating point writes to the KCM ....................................................................................... 64
11 Index ................................................................................................................................. 65

Safety Notes 1
Safety symbol definitions 1.1
1 Safety Notes
Installation, commissioning and programming of the specified

equipment should only be undertaken by qualified personnel.
1.1 Safety symbol definitions
V This is the safety alert symbol. It is used to alert you to the potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
V CAUTION used without the safety alert symbol indicates a poten-

CAUTION tially hazardous situation which, if not avoided, may result in prop-
erty damage.
V CAUTION indicates a potentially hazardous situation which, if not

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

! WARNING avoided, may result in death or serious personal injury.
V DANGER indicates an imminently hazardous situation, which if

! DANGER not avoided, will result in death or serious injury.
1.1.1 Related safety/electrical icons
This icon is used to indicate an electrical hazard. It is located on cov-

ers and doors. Only qualified personnel are allowed to remove these
covers or open the doors.
This symbol shows where an electrical ground or PE is to be placed.

1 Safety Notes
1.2 Proper use
1.2 Proper use
V Only operate the KCM in conjunction with the feeder equipment

from K-Tron.
V Only operate the KCM in accordance with the specified technical
data.
V Do not operate where there is a risk of explosion.
V Do not use the equipment in a manner not intended by the manu-
facturer.
1.3 Organizational measures
V Observe the safety notes for the connected feeding devices.

V In addition to the operating instructions, always comply with gen-
erally prescribed safety regulations governing accident prevention
and environmental safety.
V Always keep the metering device operating instructions within
easy reach. Ensure that they are always complete and legible.
1.4 Operator responsibilities
V Ensure that only qualified and trained personnel work with the
KCM.
V Establish personnel responsibilities for operation and mainte-
nance.
V Ensure that personnel have read and understood the operating in-
structions to all installation components, particularly these safety
notes.
V The operator must have damaged or missing components re-
placed immediately.
V The operator of the KCM is responsible for compliance with the le-
gally prescribed accident and safety regulations.

Safety Notes 1
Safety-conscious operation 1.5
1.5 Safety-conscious operation
V Any changes (including changes to operational behavior) which

affect safety must be immediately reported to the responsible
member of staff.
V Perform all operations with safety in mind.
V Do not make any internal adjustments to the KCM while the feeder
is in operation.
1.6 Safety devices
V The electrical safety devices must not be altered. This increases

the danger of accidents.
V Never operate the KCM with the housing open.
V Replace damaged cables and connections immediately.
V Only operate the feeding equipment if all safety devices are in-
stalled and fully functional.
V Check that the safety devices on the KCM and on the feeding
equipment operate properly daily.
V Never open or remove covers or hoods while the feeding equip-
ment is in operation.
V If accessing KCM internal components, allow 10 seconds to lapse
prior to opening the enclosure. This ensures safe discharge of high
voltage components.
1.7 High voltage
Warning! Danger!
! DANGER V High voltage of 230 Vac may be present on the line power cables
of the KCM.
V Switch off the power to the KCM for 3 minutes before:
– any disassembly, maintenance and repair work
– replacing the motor.
V Only qualified electricians may work on the KCM.
V Protect the KCM against moisture entrance.

1 Safety Notes
1.8 Additional equipment
1.8 Additional equipment
V Modifications to the KCM are prohibited.

V The operator is responsible for complying with all safety regula-
tions related to operation with the feeding equipment.
1.9 Removal from service
V Disconnect the KCM from the power supply before removal from
! CAUTION service.
V The operator is responsible for the proper removal of the KCM
from service.
1.10 Customer service and repairs
V The KCM may only be repaired by

– your authorized K-Tron customer service center
or
– qualified personnel, trained by K-Tron.
V Only use original K-Tron parts for repairs.
1.11 Warranty
V See project specifications and sales agreements for warranty in-

formation.
1.12 Applied safety signs and placards
1.12.1 Selected safety signs on machines
Fig. 1.1 Power applied sign

Data Structures, Formats and Data Types for SmartConnex-II 2
Overview 2.1
2 Data Structures, Formats and Data

Types for SmartConnex-II
This document presents the numeric and digital data that is available
via the KCM Smart K-Link connectivity function. The KSL needs to be
at ver. 4 software.
2.1 Overview
Two sections are presented. The first section presents a summary ta-
ble of the variables that may be selected in Smart K-Link and the sec-
ond shows the index settings used when binary or bit data is selected.
Command, Alarm and Process Status functions fit this later category.
Please use the following notation when using these variables.
Data Type: Numeric - Float, Strings or Integer Data Types,

Digital - Bit Arrays
Typically used variables: Marked in Bold typeface.
For PLC register assignments, use:

Float, string, bit array: 2 registers
Integer: 1 register
Access information:’R’ means Smart K-Link output only,’R/W’ means

the variable is both an input and output value.
Units of time are generally in seconds unless otherwise specified.
Using string data may require setting of an ASCII data block in the
PLC. Then select ASCII in the Poll Record Table.
It is recommended to use floating point rather than integer math. This

will eliminate the need for scaling.

2 Data Structures, Formats and Data Types for SmartConnex-II
2.2 Data descriptions
2.2 Data descriptions

There are different types of data that can be exchanged amount de-
vices. This will help you to identify them.
2.2.1 Data types
Data types are broken into three major categories:

·Commands
·Status
·Variable or process data
Commands are requests for an action to be taken by the controller.

These mnemonics begin with the letter ’C’. Status information is a re-
port on the operating condition of the controller. These values can be
bit mapped or brought back as full 16 bit arrays for a total of 256 bits.
What is left is the process data or such things as setpoint and mass-
flow.
For clarification of mnemonics, use this list.
2.2.2 Application types

Application Function
LWF Loss-in-Weight Feeder
WBF Weigh Belt Feeder
PID Proportional, Integral, Derivative Controller
LWB Loss-in-Weight Batch Feeder
SFM Smart Flow Meter Controller
VOL Volumetric feeder controller

Data and formats 2.3
2.3 Data and formats

This section provides a listing of data that is passed from various ap-
plications to the supervisory control system. You will select them using
the SmartConfig PC application when defining variables and their
placement in the PLC memory map. This listing shows the variables
for all machines where applicable.
2.3.1 KCM global variables: Process
Name Units Type R or R/W Description
ActualTemperature deg C float R Internal temperature of the KCM.

CondProcStat binary R 32 bit definition of the KCM operating sta-
tus.
DriveCommand percent float R Value of operating drive command from the
controller.
GrossWeight weight float R Weight on the scale.
GrossWeight2 weight float R Weight on the secondary weighing device
on a WBF or SFM.
HeartBeat integer R Integer value that increments to 9999 then
rolls over and resumes the count. Indicates
basic operation of the KCM.
Massflow rate float R Output of the feeder in weight/time units.
MotorPower watts float R Actual power used by the motor.
MotorSpeed rpm float R Current motor speed.
NetWeight weight float R GrossWeight-TareWeight.
NetWeight2 weight float R GrossWeight2-TareWeight2.
Setpoint rate/ float R/W Target operation of the feeder.
weight
TareWeight weight float R/W Weight of feeder on scale.
TareWeight2 weight float R/W Weight of feeder on the secondary scale.
Totalizer weight float R/W Accumulative weight delivery of the feeder.

2.3.2 KCM global variables: Alarms
AlarmDelay seconds integer R/W Time, in seconds, for the alarm to persist
before a hard alarm can occur.
AlarmMode integer R/W Alarm action:
Ignore = 0, Alarm immediate = 1, Alarm
timed = 2, Alarm Stop immediate = 3, Alarm
Stop timed = 4
AlarmNumber integer R/W Number of the actual alarm- see ASR list.
AlarmStartupDel seconds integer R/W Time, in seconds, upon machine start-up
when the process alarms are suppressed.
AlarmStat[16] binary R Alarm status, see alarm status listing.
CondAlarmStat binary R Condensed alarm status, see listing.
DrvCmdHiLimit percent float R/W Limit for drive command for when drive
command exceeds the value, an alarm oc-
curs.
DrvCmdLoLimit percent float R/W Limit for drive command for when drive
command fallls below the value, an alarm
occurs.
MassflowHiLim percent float R/W Limit for massflow for when massflow ex-
ceeds the value, an alarm occurs.
MassflowLowLim percent float R/W Limit for massflow for when massflow falls
below the value, an alarm occurs.
StpBitClrAl integer R/W When set, the stop bit clears alarms:
0 = stop bit does not clear alarms
1 = stop bit will clear alarms

2.3.3 KCM global variables: Scale parameters
NumSFTReq integer R/W Number of SFTs located at the feeder.

SampleTime seconds float R/W Sample time interval of weight sampling.
ScaleGrossRange weight float R/W Weight range of scale.
ScaleSpan float R/W Span correction factor.
SelectedSFT integer R/W Address of the viewed SFT.
SFTAddress integer R/W SFT addressed?
0 = no, 1 = yes
SFTConfig string R Shows operation of connected SFTs.
SftCutOff Hz float R/W SFT low pass filter.
SFTRawWeight weight float R Weight direct from SFT.
SFTStatus binary R Operational condition of SFT.
SFTType string R Shows SFT weight range.

2.3.4 KCM global variables: Digital I-O
DgInSelFun integer R/W Selects function for the digital input.

DgInSelNum integer R/W Selects the input to be used by number.
DgInSelPol integer R/W Sets the polarity for the input:
0 = normal, 1 = inverse
DgInSelValue integer R Shows the digital input state:
0 = off, 1 = on/active
Note:
low voltage on input = active/on
DgOutSelFun integer R/W Selects function for the digital output.
DgOutSelMap integer R/W Selects a specific output function to be
mapped to a register.
DgOutSelNum integer R/W Selects the output to be used by number.
DgOutSelValue integer R Shows the digital output state:
Output conducting = on
Output not conductng = off

2.3.5 KCM global variables: Analog I-O
AnInSelDB percent float Deadband setting for this analog input.

AnInSelMax percent float R/W Scaling for the analog maximum value.
AnInSelMin percent float Scaling for the analog minimum value.
AnInSelSrc integer Analog input source:
0 = CPU(0-10kHz), 1 = CPU(Analog), 2 =
External
AnInSelValue percent float Actual value of the analog signal.
AnOutSelDB percent float Deadband setting for this analog output.
AnOutSelFun integer Analog output function select.
AnOutSelMax percent float Scaling for the analog maximum value.
AnOutSelMin percent float Scaling for the analog minimum value.
AnOutSelNum integer Selection of the desired analog output for
the KCM:
CPU = 0, EXT1 = 1, EXT2 = 2, EXT3 = 3
AnOutSelValue percent integer Actual value of the analog signal.
2.3.6 KCM global variables: Modbus I-O
ExtIOBinding integer R/W

ExtIONodeSel integer R/W
ExtIOTypes integer R [0 to 3]
ExtIOTypeSel integer R/W

2.3.7 KCM global variables: HCU Loader Params
HcuActCycle integer R Describes where in the loading cycle the

HCU controller is.
Motor Timer(1), Load Delay(2), Loading(3),
Line Clear(4), Discharge Delay(5), Dis-
charge(6).
HcuActTime seconds integer R/W Shows the active time for the specified cy-
cle.
HcuCommand integer R/W HCU command to: None(0), Run(1),
Stop(2), Clear Alarms(3), or Discharge(4)
HcuSelParmNum integer R/W Number of parameter loaded
HcuSelParmValue float R/W Shows the parameter value for the param-
eter number selected
HcuStatus integer R HCU status to: None(0), Alarm(1), Rec-
Full(3), Buf Full(4), Comm Fail(5), OK(6)
2.3.8 HcuSelParamNum Definitions
Number Description
1 Load Timer
2 Line Clear Timer
3 Discharge Timer
4 Filter Delay Timer
5 Filter Pulse Timer
6 Motor Timer
7 Load Delay Timer
8 Discharge Delay Timer
9 Receiver Proximity Sensor
10 Buffer Hopper Proximity Sensor
11 Supply Hopper Proximity Sensor
12 Remote Start Timer
13 Remote Stop Timer

Number Description
14 Discharge Valve Switch

15 Differential Pressure Switch
16 Discharge Request Switch
17 Digital Input Set-Up (Xor Mask)
18 Operating Mode
19 Filter Clean Mode
20 Discharge Mode
21 Not used.
22 HCU Software Version
23 Supply Hopper Low Alarm Timer
24 Differential Pressure High Alarm Timer
25 Load Cycle Alarm Counter
26 Discharge Valve Alarm Timer
27 ON/OFF Counter
28 Run Time
29 Software Version of HSU

2.3.9 KCM global variables: Communications
ConfigBaud integer R/W Baud rate for the KCM config port.
ConfigMode integer R/W Sets the KCM config port function.
HostFile integer R/W Sets whether the built-in or downloaded kgr
file is used by the host function in the KCM.
HostProt integer R/W Defines the host protocol to be used.
KPort1Baud integer R/W Baud rate for K-Port1.
KPort1Prot integer R/W Defines the protocol for K-Port1.
KPort2Baud integer R/W Baud rate for K-Port2.
KPort2Prot integer R/W Defines the protocol for K-Port2.
2.3.10 KCM global variables: Miscellaneous
AutoSpanLimit integer R/W Sets the limit on auto span calculation us-
ing the auto-calibration function.
AuxBoardType integer R Defines the aux board type.
CalibCorrel percent float R Variance of flow during the calibration cy-
cle.
CalibCorrLimit percent float R/W Sets the limit for variance of flow during the
calibration cycle without canceling activity.
CalibDriveCmd percent float R/W Drive command used during the auto-cali-
bration cycle.
CalibMatFed weight float R Amount of weigh the controller states was
delivered during the autocalibration cycle.
CalibTime seconds integer R/W Time for the auto-calibrate cycle.
CheckWeight weight float R/W Measured amount of product delivered dur-
ing the autocalibration cycle.
ChkWEnum integer R Subscroll listing showing calibration status
codes.
ControlType integer R Type of controller application used.

DeviceID integer R KCM feeder type by a numeric code

LWF = 60, WBF = 61, SFM = 62, PID = 63,
VOL = 64, LWB = 65
DgInFun[16] integer R/W Function for the digital input selected.
DgInPol[16] integer R/W Polarity of the input function selected.
DgOutFun[16] integer R/W Function of the digital output selected.
DgOutMap[16] integer R/W PSR or ASR map value of the selected dig-
ital output.
DgOutPol[16] integer R/W Polarity of the output function selected.
DrvCmdCeiling percent integer R/W Sets the limit on how high drive command
can go. It is a stop limit.
EmptyDC percent integer R/W The drive command used to empty the
feeder.
Encoder teeth integer R/W Defines the number of pulses per revolu-
tion of the primary velocity sensor.
ExternTotalInc weight float R/W Sets the totalizer increment.
FdrCtrMode integer R/W Sets the mode for setpoint control:
0 = local, 1 = ratio, 2 = direct, 3 = line1, 4 =
line2, 5 = line3 up to 10 = line8
FeederAddress integer R Address of the KCM.
FeederName string R/W Name for the KCM. [14 bytes]
FeederRunTime hours float R Time the feeder has been running in hours.
FeederType integer R/W Sets the type of application used.
FltClearTime msec. integer R/W Built-in loader control, filter clear time.
GearReduction float R/W Primary gear reduction for a feeder.
IDSetpoint integer Value for remembering pictures/graphics.
Used by the KSC.
KLinkTxDelay msec. integer R/W Delays host transmissions to prevent net-
work overloads.
MassflowFiltLen seconds integer R/W Display filter time constant.
MDUStatus binary R Operational status of the drive board. See
document 0490020605 for details.
MaximumFlow rate float R/W Sets the limit for maximum flow.
MinimumFlow rate float R/W Sets the limit for minimum flow.

NominalPower watts integer R/W Sets the maximum motor power to be

drawn.
NominalSpeed rpm integer R/W Sets the maximum, rated motor speed.
NominalVoltage volts integer R/W Sets the limit for DC voltage to the motor.
PreLoadMFeqSP Hz integer R/W
SerVarSubscrl integer R/W Number of the service variable selected.
SerVarValue float R/W Value of the service variable selected.
SetpointRatio percent float R/W The ratio setpoint value.
StoppedBy integer R Condition under which the KCM was last
stopped.
TotalizPreload weight float R/W Totalizer preload value. Use <0> to clear
totalizer.
Units integer R/W Selects the units of operation:
0 = kg/hr, 1 = kg/min, 2 = lb/hr, 3 = lb.min,
4 = metr ton/hr, 5 = en ton/hr, 6 = g/hr, 7 =
g/min
2.3.11 KCM variables: LWF
AdaptGain float R/W Learned gain value for LWF.

AdaptTuning integer R/W Sets adaptive tune function:
0 = off, 1 = on
AveFeedFactor rate float R Average feeding factor.
DensArray integer R/W Turns on the Refill/Density array:
0 = off, 1 = on
FeedFactAlrmLim percent float R/W Sets the bounds on good values of feedfac-
tor.
FeedFactArray1 rate float R Shows the feedfactor value in the lower
portion of the Refill array.
FeedFactArray5 rate float R Shows the feedfactor value in the middle
FeedFactArray9 rate float R Shows the feedfactor value in the upper

GearReductionLo float R/W Sets the higher gear reduction/lowest
speed for K2 feeders with dual speed gear-
boxes.
GearSwitch integer R/W Turns on the dual speed control:
0 = high, 1 = low, 2 = auto high, 3 = auto low
InitialFeedFact rate float R/W Starting feedfactor
LoadEna integer R/W Enables the built-in loader control:
0 = off, 1 = on
LoadMaxTime seconds integer R/W Sets the maximum load time for the built-in
loader control.
LoadCloseTime seconds integer R/W Sets the valve close time for the built-in
loader control.
LoadDischTime seconds integer R/W Sets the time for discharge for the built-in
loader control.
LoadMotorTime seconds integer R/W Sets the motor run time for the built-in load-
er control.
Modulation integer R/W Turns on modulation:
0 = off, 1 = on
MotorCtrlGain float R/W Motor gain set by user.
NetWtHighLimit weight float R/W Maximum high limit on net weight.
NetWtLowLimit weight float R/W Minimum low limit on net weight.
PertValue float R Actual pert value.
PostRefillDelay seconds integer R/W Sets the time for post refill function.
RefArrDevlimit percent float R Maximum allowed variance in feedfactor
from empty to full points on the refill array
curve.
RefillDelTime seconds integer R/W Time for refill to occur before an alarm.
RefillEna integer R/W Turns on/off the automatic refill function:
0 = disabled, 1 = enabled, 2 = if running
RefillLevelMax weight float R/W High weight level that turns off refill.
RefillLevelMin weight float R/W Low weight level that starts the refill.
RefillMode integer R/W Sets the refill mode:
0 = Manual, 1 = Auto, 2 = AutoTerm

ScrewSpeed rpm float R Displays screw RPM when Gear Reduction

is set.
VibDisplSpan float R/W Sets span for vibratory drive.
VibDispVal float R Current vibratory displacement output.
VibKVNumber integer R/W Sets the feeder type to KV1-KV3.
VibSPChgLimit percent float R/W Maximum change allowed in Setpoint be-
fore the control behavior is executed on the
vibratory calibration curve.
VibY0 float R Correction factor for vibratory feeder non-
linearity at 8% Drive Command.
2.3.12 KCM variables: LWB
AdaptGain float R/W Learned gain value for LWF when adaptive
tuning is active.
AdaptTuning integer R/W Sets adaptive tune to on/off:
0 = off, 1 = on
AveFeedFactor rate float R Current average feeding factor.
BatCompMass weight float R Current batch weight delivered.
BatCompPerc percent float R Batch weight delivered in percent of set-
point.

BatCount integer R Number of batches delivered but does not

increment for aborted batches.
BatchTimeGrace seconds integer R/W If this value plus the Maximum Batch Time
is exceeded during batching, a batch time
exceeded alarm will occur.
BatRefMode integer R/W Sets the refill mode type:
0 = undefined, 1 = refill after batch, 2 =
pause batch to refill, 3 = refill while batching
BatSize weight float R/W Batch setpoint.
BatState integer R State of batcher:
BatTime seconds integer R/W Batch time in seconds.
BatTolerance percent float R/W Sets batch tolerance for out of limit final
batch value.
DribDC percent float R/W Drive command in dribble mode.
DribTime sedonds float R/W Time in dribble mode.
FastDC percent float R/W Drive command in normal mode.
FeedFactAlrmLim percent float R/W Sets the bounds on acceptable values of
feedfactor.
FeedFactArray1 rate float R Shows the feedfactor value in the lower
FeedFactArray5 rate float R Shows the feedfactor value in the middle
FeedFactArray9 rate float R Shows the feedfactor value in the upper
GearReductionLo float R/W Sets the higher gear reduction/lowest
speed for K2 feeders with dual speed gear-
boxes.
GearSwitch integer R/W Turns on the dual speed control:
0 = high, 1 = low, 2 = auto high, 3 = auto low
InitialFeedFact rate float R/W Starting feedfactor.
JogEna integer R/W Enables the jog function.
0 = off, 1 = on
LoadEna integer R/W Enables the built-in loader control.
0 = off, 1 = on

LoadMaxTime seconds integer R/W Sets the maximum load time for the built-in
loader control.
LoadCloseTime seconds integer R/W Sets the valve close time for the built-in
loader control.
LoadDischTime seconds integer R/W Sets the time for discharge for the built-in
loader control.
LoadMotorTime seconds integer R/W Sets the motor run time for the built-in load-
er control.
MaxBatSize weight float R/W Maximum allowable batch size.
Modulation integer R/W Turns on modulation:
0 = off, 1 = on
MotorCtrlGain float R/W Motor gain as set by user.
NetWtHighLimit weight float R/W Maximum high limit allowed on net weight.
NetWtLowLimit weight float R/W Minimum low limit allowed on net weight.
PertValue float R Actual pert value.
PostRefillDelay seconds integer R/W Sets the time for post refill function.
Preact1Pulses integer R/W Preact value of motor encoder pulses from
fast to dribble control.
Preact2Pulses integer R/W Preact value of motor encoder pulses from
dribble to stop.
RefArrDevlimit percent float R Maximum allowed variance in feedfactor
from empty to full points on the refill array
curve.
RefillDelTime seconds integer R/W Time for refill to occur before an alarm
RefillEna integer R/W Turns on/off the automatic refill function:
0 = disabled, 1 = enabled, 2 = if running
RefillLevelMax weight float R/W High weight level that turns off refill.
RefillLevelMin weight float R/W Low weight level that starts the refill.
RefillMode integer R/W Sets the refill mode:
0 = Manual, 1 = Auto, 2 = AutoTerm
ScrewSpeed rpm float R Displays screw RPM when Gear Reduction
is set.
StableWtCnt float R/W Number of stable weight readings after
dribble that are required for batch com-
plete.

StopPert float R/W The net weight deviation above which a

PERT will be detected.
VibDisplSpan float R/W Sets span for vibratory drive.
VibKVNumber integer R/W Sets the feeder type to KV1-KV3.
VibSPChgLimit percent float R/W Maximum change allowed in Setpoint be-
fore the control behavior is executed on the
vibratory calibration curve.
2.3.13 KCM variables: PID
AveFeedFactor rate float R Current value of feedfactor.

DerContribFreq Hz integer R Value of frequency component due to De-
rivative control.
DerivLimit Hz integer R/W Limit to the amount of derivative action al-
lowed.
DerivTime seconds float R/W Derivative time interval.
FeedFactAlrmLim percent float R/W Sets the bounds on good values of feedfac-
tor.
InitialFeedFact rate float R/W Starting feedfactor.
InputFiltLen seconds float R/W Process variable input filter.

IntContribFreq Hz integer R Value of frequency component due to Inte-

gral control.
IntegralTime seconds float R/W Integral time interval for control.
ProcessVariable rate float R Current process value.
PropContribFreq Hz integer R Value of frequency component due to pro-
portional control.
PropGain float R/W Amount of proportional gain applied to con-
trol.
PVinMax float R/W Limit on process variable input-maximum.
PVinMin float R/W Limit on process variable input-minimum.
PVInSelect integer R/W Selects the type of process variable input.
SelfTune integer R/W Turns on/off self tuning feature:
0 = off, 1 = on
TotalInhibit integer R/W Turns on/off totalizer function:
0 = off, 1 = on
2.3.14 KCM variables: SFM
AutoReZero integer R/W Turns on/off chute auto re-tare function:

0 = manual, 1 = auto
BlowOff integer R/W Turns on/off blow-off function:
0 = off, 1 = on
BypassFunct integer R/W Turns on/off Auto Bypass function:
.0 = off, 1 = on
BypassInterval float R/W Sets bypass valve operation interval.
BypassValve integer R/W Turns on/off Bypass valve function:
0 = off, 1 = on
CalDC percent integer R/W Overall calibration drive command.
CalDC1 percent integer R/W Calibration drive command at flow 1.

CalDev float R Deviation over the calibration range.

CalMassFlow weight float R Amount of product delivered during calibra-
tion cycle.
CalStep integer R/W Cal step 1-3 taken.
ChuteAngle degrees float R/W Angle of chute to horizon.
ChuteLength meters float R/W Length of chute.
ChuteThresh weight float R/W Weight below which chute weight is consid-
ered <0>.
ChuteWgtSpan float R/W Span value for chute.
DerivTime seconds float R/W Derivative time for control.
DivertWgtSpan float R/W Span value for divert.
DivertThresh weight float R/W Weight below which divert weight is consid-
ered <0>.
InternalFiltLen seconds float R/W Massflow filter value.
MaterialFact0 weight float R A0 flow error correction factor.
MaxMFAlrmLim rate float R/W Upper limit on massflow.
MinMFAlrmLim rate float R/W Lower limit on massflow.
OverallSpan‘ float R/W Overall calibration factor.
PropGain float R/W Amount of proportional gain applied to con-
trol.

2.3.15 KCM variables: VOL
Density weight/ float R/W Density of fed product that is entered for
vol use in calibration.
CalWt1 weight float R/W Calibration weight at Cal Drive Cmd 1.
CalWt2 weight float R/W Calibration weight at Cal Drive Cmd 2.
CalDC1 percent integer R/W Calibration drive command at step 1.
CalDC2 percent integer R/W Calibration drive command at step 2.
Feedfactor rate float R Current value of feedfactor.
PowerOnStart integer R/W Actuates power-on start function:
0 = off, 1 = on
2.3.16 KCM variables: WBF
BeltIdxEna integer R/W Enables belt index function:

0 = off, 1 = on
BeltLength meters float R/W Length of belt.
BeltLoad weight/ float R Beltloading value.
length
BeltLoadSetpt weight/ float R/W Belt loading setpoint used for volumetric
length control.
BeltSlipAlrmLim percent float R/W Limit on belt slip.
BeltSlipValue percent float R Actual belt slippage.
BeltSpeed m/min float R Actual belt speed.
or ft/min
DeckGap meters float R/W Distance between weigh bridges.
DriveDrumDiam meters float R/W Diameter of drive roller.
HiBeltLdAlrmLim weight/ float R/W High belt loading alarm limit.
length
LoBeltLdAlrmLim weight/ float R/W Low belt loading alarm limit.
length
PickupPos integer R/W Location, motor or roller for velocity sensor.

Service variable index 2.4
PreFdrDist meters float R/W Distance of prefeeder to weigh bridge.

PreFdrTune integer R/W Turns on Prefeeder autotune function.
PrefeedDCSpan float R/W Spans the prefeeder drive command value
to set belt loading.
TotalDeadBand weight/ float R/W Sets the lower beltload that turns off the to-
length talizer.
TransportDist meters float R/W Distance from weigh bridge to discharge.
WeighDeckLength meters float R/W Weigh bridge length.
2.4 Service variable index

This section presents service variable index information that is avail-
able on the KSU-II or KCM/KD.
Go to the Machine Menu of the KSU-II or KCM/KD and to the Service
Set-Up sub-menu.
Desc Variable
PreLoad MF=SP Preload MF value with SP upon KCM starts or SP changes
KLink Tx Delay Enable K-Link to delay TxD to prevent network overloads
Empty DC Value of drive command when emptying the feeder. Default is 70%. LWB and LWF only.
Auto Span Limit Limit in actual range of the allowed span deviation from 1.000 to allow a auto-span calculation to
proceed. Default is 0.98-1.02 or an entry of 0.02.
Com1 Read Comm board K-Port 1 reads per second; <=100
Com1 Write Comm board K-Port 1 writes per second:<=10
Com1 Err Comm board K-Port 1 error counter:<= 1/hour
Com2 Read Comm board K-Port 2 reads per second:<=100
Com2 Write Comm board K-Port 2 writes per second:<=10
Com2 Err Comm board K-Port 2 error counter:<= 1/hour
Host Read Host channel reads per second: <=100
Host Write Host channel writes per second: <=10
Host Err Host channel error counter: <= 1/hour
IntCh msgs Internal channel (SFT/MDU) messages per second
IntCh err Internal channel (SFT/MDU) error counter
IntCh Load Internal channel (SFT/MDU) loading in percent: <= 50%
IntCh Node Internal channel (SFT/MDU) last failed node
IntCh Opcode Internal channel (SFT/MDU) last opcode
ResConfPort Resets the config port to defaults
RefArr Dev Lim Maximum allowed variance in Feedfactor from Empty to Full points on the Refill Array curve
Modulation% Screw modulation-percent- amplitude, debug variable.
KCDR-K10S When set to <1> configures K-Port 1 to function with a K-Commander or KDU using extended soft-
ware. When set to <0> returns K-Port 1to normal function.
ReprogCommBd When this variable is set to <1> and KCM power is cycled, automatic reprogramming of the comm
board by the KCM will occur. This value is reset to <0> after the programming activity is complete.

3 I-O Functions
3.1 Global I-O functions for all applications
3 I-O Functions
This section presents I-O mapping for KCM products with parameter
code. These functions will be found in the I-O menu.
3.1 Global I-O functions for all applications
3.1.1 Global digital inputs

A true/on condition results in the desired action.
Name Function List

None=0 No function assigned.
Start=1 Start Machine
Stop=2 Stop Machine
Interlock=3 Downstream interlock for temporary stop of machine.
Run Run enable to stop and prohibit machine from starting.
Enable=4
ALS Input=5 Alarm shutdown input
Al. Ack=6 Alarm Acknowledge
Al. Clr=7 Alarm Clear
Start/Stop=8 One-wire start stop. True = Start/False = Stop
Vol Mode=9 Force to volumetric mode if true.
Loc/Ext=10 Local or external setpoint source. 1= Ext, 0=Local
Ratio/ Ratio or direct mode.1=Direct, 0=Ratio
Direct=11
External Input for an external alarm.
alarm=12
Totalizer Input to clear totalizer.
Clear=13
Data Lock=14 Input to lock data from being changed.
3.1.2 Global analog setpoint input
Name Function List

Setpoint=1 Feeder setpoint.
= (10kHz/Max SP) x Actual SP
or
= (20ma/Max SP) x Actual SP

I-O Functions 3
Global I-O functions for all applications 3.1
3.1.3 Global digital outputs

A true/on condition is the result.
Name Function List

Feeder Output is true if feeder is running
Run=1
Any Alarm=2 Output is true for any alarm situation
Hard Alarm Relay output is true only for any hard alarm condition.
Relay=3
ALS Out- Alarm shutdown output.
put=4
Drive Ena=5 Output is true when the Driver Enable line is active- drive
should run.
Mass Output is true when feeder is in mass mode.
Mode=6
PSR-Map=7 Output is true when the selected PSR bit is true. See PSR
mapping for LWF application.(Process Status)
ASR-Map=8 Output is true when the selected ASR bit is true. See ASR
mapping for LWF application. (Alarm Status)
Totalizer Output for totalizer pulses.
Pulse=9
3.1.4 Global analog outputs
Name Function List

Setpoint=1 Setpoint normalized to maximum rate.
=(20ma/Max Setpoint) x Massflow Setpoint
Massflow=2 Massflow normalized to maximum rate.
=(20ma/Max Setpoint) x Massflow
Net Weight=3 Net Weight normalized to gross range. (This may also be
NetWeight1 for a belt feeder or Chute Net Weight for the
SFM.)
=(20ma/Scale Range) x Netweight

3 I-O Functions
3.2 LWF I-O
3.2 LWF I-O

This section presents I-O variables for Loss-in-Weight feeder applica-
tions.
3.2.1 LWF digital inputs

Add the following to the global digital input listing. A true/on condition
results in the desired action.
Name Function List
Batch
Pause=15
Empty=16 Empty the feeder now
Ref Refill Bypass
Bypass=17
Ref Cmd=18 Refill Command (force refill)
Calib=19 Starts the Auto Calibration routine.
Loader Loader is at its full level.
Level=20
Loader Enables the loader function
Enable=21
3.2.2 LWF analog setpoint input

See global listing.
3.2.3 LWF digital outputs

Add the following to the global digital output listing. A true/on condition
is the result.
Name Function List
Refill=10 Output is true when a refill is called for.
Refill Output is true when the refill time has expired and refill did
Expired=11 not complete.
Loader=12 Runs loader motor.
Blow-off=13 Turns on blow off feature for loader.
HiLoGear=14 Selects either Hi or Lo gear function for K2 feeders.
Dribble=15 Dribble mode active
Batch Com- Batch completed
plete=16

I-O Functions 3
WBF I-O 3.3
3.2.4 LWF analog outputs

Add the following to the global analog output listing.
Name Function List
Drive Cmd=4 Drive command.
=(20ma/100%) x (%Drive Command)
Motor Motor speed normalized to maximum motor speed.
Speed=5 = (20ma/Max motor rpm) x Actual motor speed
Feedfactor=6 Computed feedfactor as a function of the initial value.
=(20ma/Initial Feedfactor) x Average Feedfactor
3.3 WBF I-O

This section presents I-O variables for Weigh Belt feeder applications.
3.3.1 WBF digital inputs

Name Function List

Empty=15 Empty the feeder now
Belt Drift=16 Input for belt drift detection
Belt Index=17 Belt index function input
Dynamic A dynamic tare is to occur
Tare=18
3.3.2 WBF analog setpoint input

See global listing.
3.3.3 WBF digital outputs

is the result.
Name Function List

Tare Run=10 A dynamic tare is ongoing if true.
Prefeeder Enable the prefeeder to run.
Drive
Enable=11

3 I-O Functions
3.4 PID I-O
3.3.4 WBF analog outputs

Name Function List

NW1=3 = (20mA/ScaleRange)*NetWeight 1 (Netweight on the pri-
mary weigh bridge)
NW2=4 = (20mA/ScaleRange)*NetWeight 2 (Netweight on the sec-
ondary weigh bridge if used)
DriveCom- = (20mA/100%) x Percent drive command
mand=5
Motor = (20mA/Max Mot RPM) x Act Mot Speed
speed=6
Belt Load=7 Actual belt loading as a function of Belt Load SP.
= (20ma/Belt Load SP) x Current belt loading
Prefeeder=8 Value of the prefeeder signal. For Soder feeder select Direct
algorithm.
= (20 ma)*(DrvCmd)*PrefeederSpan
3.4 PID I-O

This section presents I-O variables for PID applications.
3.4.1 PID digital inputs

Name Function List
3.4.2 PID analog setpoint input

See global listing.
3.4.3 PID analog process input

This entry is preset.
3.4.4 PID digital outputs

See global listing. A true/on condition is the result.

I-O Functions 3
VOL I-O 3.5
3.4.5 PID analog outputs

Name Function List

PVUInput=3 =(20mA/100%)xPVinput value percent of maximum
Drive Com- = (20mA/100%) x Percent drive command
mand=4
Speed=5
3.5 VOL I-O

This section presents I-O variables for VOL applications.
3.5.1 VOL digital inputs

Add the following to the global digital input listing A true/on condition
Name Function List

3.5.2 VOL analog setpoint input

See global listing.
3.5.3 VOL digital outputs

See global listing. A true/on condition is the result.
3.5.4 VOL analog outputs

Name Function List

mand=3
Speed=4

3 I-O Functions
3.6 SFM I-O
3.6 SFM I-O

This section presents I-O variables for SFM applications.
3.6.1 SFM digital inputs

Name Function List

Bypass Input from the Bypass valve position contact- Bypass position
Fb=15
Normal Input from the Bypass valve position contact- Normal position
Fb=16
3.6.2 SFM analog setpoint input

See global analog setpoint input list.
3.6.3 SFM digital outputs

is the result.
Name Function List

Bypass Bypass valve is in bypass mode if true
Valve=10
BlowOff=11 Blowoff function is active if true
3.6.4 SFM analog outputs

Name Function List
Net Chute=3 Net weigh on the chute
= (20mA/ScaleRange)*NetWeight_Chute
Net Divert=4 Net weight on the divert channel
= (20mA/ScaleRange)*NetWeight_Divert
DriveCom- = (20mA/100%) x Percent drive command
mand=5
speed=6

I-O Functions 3
LWB I-O 3.7
3.7 LWB I-O

This section presents I-O variables for Loss-in-Weight batch applica-
tions.
3.7.1 LWB digital inputs

Name Function List

Ref. Refill Bypass
Bypass=11
Ref. Cmd=12 Refill Command (force refill)
Ext. Al.=13 Customer alarm from external source.
Pause=14 If true, will force a batch pause
Empty15 If true, will initiate a empty function of the batch feeder
FF Calibra- If set to true, will initiate a feedfactor calibration routine.
tion=16
3.7.2 LWB analog batch setpoint input

Name Function List
Batch Size=1 Batch size setpoint.
= (10kHz/Max Batch SP) x Actual Batch SP or
= (20ma/Max Batch SP) x Actual Batch SP
3.7.3 LWB digital outputs

is the result.
Name Function List

Refill=10 Output is true when a refill is called for.
Refill Output is true when the refill time has expired and refill did
Expired=11 not complete.
Loader Runs loader motor.
Run=12
Blow-off=13 Turns on blow off feature for loader.
HiLoGear=14 Selects either Hi or Lo gear function for K2 feeders.
Dribble=15 Output is true if the unit is in dribble mode
Batch Com- Output is true if the unit has reached batch complete
plete=16

3 I-O Functions
3.7 LWB I-O
3.7.4 LWB analog outputs

Name Function List
Net Weight=1 Net Weight normalized to gross range.
=(20ma/Scale Range) x Netweight
mand=2
Speed=3
Batch Size=5 Batch Size
= (20ma/Max Batch Size) x Actual Batch Size
Batch% Com- Percentage of batch complete
plete=6 =(20ma/Batch Size) x Actual Amount Batched

Command Functions 4
Overview 4.1
4 Command Functions
4.1 Overview
This section presents control and status functions for operation of the
KCM system.
Command functions are to be entered as alphanumeric values in

Smart K-Link. They must be entered in upper case letters for a ma-
chine and in lower case letters for line function.
For commands to be activated, a trigger will have to be provided at the

PLC. This trigger can be a rising (HIT) or falling edge (LOT), a high
(HI) or low (LO) level or an action on either transition (XOT). The (HIT)
trigger is preferred for most situations.
4.2 Command tables for action functions
4.2.1 Global command table
Description Mnemonic
Alarm acknowledge CALA
Alarm clear CALC
Stop CSPC
Start CSTC
Clear database invalid bit in PSR CDBI
Stop and preserve alarms CSPA
Clear totalizer CTOC
Enable totalizer-PID only CTON
Disable totalizer-PID only CTOF
4.2.2 HCU Loader command table
HCU Loader clear alarms CHCA
HCU Loader Discharge to OFF CHDF
HCU Loader Discharge to ON CHDO
HCU Loader Run CHRU
HCU Loader Stop CHST

4 Command Functions
4.2 Command tables for action functions
4.2.3 LWF command table
Set MASS mode flag CMAM
Set VOL. Mode flag CVOM
Set tare values from gross weight CTAR
Automatic feed factor calculation CCFF
Empty feeder CETY
Refill start CCRF
4.2.4 WBF command table
Set static tare values from gross weight CTAR
Dynamic belt tare CTR2
Empty feeder CETY
4.2.5 PID command table
Command ramp down of manual output CMRD
Command ramp up of manual output CMRU
4.2.6 VOL command table

Use global commands only.

Command Functions 4
Command tables for action functions 4.2
4.2.7 LWB command table
Set tare values from gross weight CTAR
Clear batch count CCBC
Pause batch run CPAS
Empty feeder CETY
Refill start CCRF
4.2.8 SFM command table
Tare chute & plate sft CTAR

5 Condensed Process Status Variables
5.1 Condensed process status variable table
5.0.1 Introduction
This section presents the process status variables that are presented
for operational analysis. The variable that is read is a 32 bit (2 register
value) with the mnemonic of <CondensedProcStatus>. When the con-
dition is present, the specific bit is set high.
Bit code is the bit location in the CondensedProcStatus word
5.1.1 Condensed global process status variable table
Bit Function
Code
0 KSU-II or KCM/KD display is present
1 Database invalid
2 Alarm Shutdown Input active
3 Disable Input active
4 Line mode active
5 Unused
6 Auto calibration in progress
7 CVAR – Examine changed variable
8 Unused
9 Machine running
10 Drive Enabled
11 Mass/Grav Mode
12 Alarm relay active
13 Alarm Shutdown output active
14 Any hard alarm is present
15 Any soft alarm is present - not timed out
16 Unused
17 Unused
18 Unused
19 Unused
20 Unused
21 Unused
22 Unused
23 Unused

Condensed Process Status Variables 5
Condensed process status variable table 5.1
Condensed global status variable table, con’t
Bit Function
Code
24 KCM initialization complete
25 Unused
26 Unused
27 Feeder emptying
28 HCU loading
29 Waiting to run
30 Smart K-Link Initialization complete
31 Pert function active
5.1.2 Condensed LWF process status table

Please see the global process status table for bits not shown here.
Bit Function
Code
8 Refill window set true
16 Refill Time-out set
18 Built-in Loader function enabled
19 Ratio setpoint mode
20 Direct setpoint mode
21 Refill_Enabled
22 Refill set to Auto mode
23 Refill timer set on (KCM = always true)
5.1.3 Condensed WBF process status table

Bit Function
Code
8 Dynamic tare active

5.1.4 Condensed PID process status table

Bit Function
Code
5.1.5 Condensed VOL process status table

Bit Function
Code
5.1.6 Condensed LWB process status table

Bit Function
Code
8 Refill window set true
16 Refill Time-out set
18 Built-in Loader function enabled
19 Paused
20 Batch complete
21 Refill_Enabled
22 Refill set to Auto mode
23 Refill timer set on (KCM = always true)
26 Dribble active

Condensed Process Status Variables 5
Condensed process status variable table 5.1
5.1.7 Condensed SFM process status table

Please see the global process status table for bits not shown
Bit Function
Code
18 Refill Bypass enabled

6 Expanded Process Status Word - PSW
6.1 Expanded PSW tables
6.0.1 Introduction
This list set is used for expanded PSW mapping for PSW bits 0-95.
Many of these special bits can be mapped to a digital output. These
bit functions are not used for Smart K-Link applications.
6.1.1 PSW word mapping

Here is a list that identifies the PSW word number with the Process ID
code. Each PSW word is 32 bits long.
The bit is set to TRUE at the condition specified.
Word Number Bit Range
Word(0) 0-31
Word(1) 32-63
Word(2) 64-95
6.1.2 Global PSW Map

These process codes are common for all K-Tron machines. This is the
bit number entered into the Smart K-Link PSW word configuration.
PSW(Process number) Description
DB Initialized(0) • Not used

CVAR(1) • Not used
Run(2) • Motor/machine running
Disa(3) • Run disabled by Interlock input or
run enable input
Ena(4) • Drive output enabled
ALS_In(5) • Alarm shutdown input active
ALS_Out(6) • Alarm shutdown output active
AL_Rel(7) • Alarm relay active
Hard_AL(8) • Complement of AL_Rel
Soft_AL(9) • On for any alarm present

Expanded Process Status Word - PSW 6
Expanded PSW tables 6.1
Emptying(13) • Machine is being emptied by Empty

function
Wait(15) • Feeder received a start command
but is waiting
Start_OK(20) • Start input will start feeder
HCU_Alarm(32) • HCU loader alarm
HCU_Rec_Full(33) • Loader receiver is full
HCU_Buf_Full(34) • HCU alarm
HCU CommFail(35) • HCU communication failure to CPU
HCU_Loading(36) • HCU loading status
Hard_interlock(40) • Drive (MDU) hard interlock input sta-
tus
Interlock_In(41) • Interlock input bit status
Enable_In(42) • Run enable input bit status
Vol_Mode_In(46) • Volumetric input bit status
Extern_In(47) • Machine set for External SP bit input
Direct_In(48) • Machine set for Direct SP bit input
Ext_Al_in(49) • External alarm input bit active
Disp_Present(64) • KCM/KD display present
CPU_Init_cpl(65) • CPU initialization complete
Mass_mode(66) • Unit in Grav mode
Calib(67) • Currently running an auto calibrate
routine

6.1.3 LWF PSW Map

Use these additional codes for all LWF machines.
Refill_Bypass_In(45) • Refill bypass bit input is set for LWF

Gear_Sw_Out(51) • Hi (Lo) gear switch output bit state
Blowoff_Out(52) • Filter blowoff function output bit
state
Pert(68) • Unit in PERT condition
Refill(69) • Feeder is refilling by automatic
means
Ref_Timeout(70) • Refill timer has expired
Loader_Full(75) • Loader full input to control
Loading(76) • Loader motor is running
Load_Ena(77) • Loader is enabled to run
6.1.4 WBF PSW Map

Use these additional codes for all WBF machines.
Sec-Deck(14) • Secondary weigh bridge is active

Prefeeder en- • Prefeeder enable output bit state
abled(50)
BeltDrift(53) • Belt drift has been detected
BeltIndex(54) • Belt index function bit state
Dynamic tare ongo- • Dynamic tare is in progress
ing(70)
6.1.5 PID and VOL PSW Map

Use the global PSW map only.

Expanded Process Status Word - PSW 6
Expanded PSW tables 6.1
6.1.6 SFM PSW Map

Use these additional codes for all SFM flowmeters.
BP-Open-In(43) • Bypass valve open input bit status is

true
BP-Close-In(44) • Bypass valve close input bit status is
true
Blowoff_Out(52) • Filter blowoff function bit state.
Bypass(69) • Bypass output bit state
Unstable(71) • Weight is unstable on SFM
6.1.7 LWB PSW Map

Use these additional codes for all LWB machines.
Pause(12) • Batcher has paused.

Gear_Sw_Out(51) • Hi (Lo) gear switch output enabled
Blowoff_Out(52) • Filter blowoff bit state
Refill(69) • Feeder is refilling by automatic
means
Ref_Timeout(70) • Refill timer has expired
Loader_Full(75) • Loader full input to control
Loading(76) • Loader motor is running
Load_Ena(77) • Loader is enabled to run
BatchComplete(78) • Batch has completed
Dribble(79) • Batcher is in dribble mode

7 Alarm Status Variables-ASW
7.0.1 Introduction
This section presents the alarm status variables that provide feedback
on all types of machine alarms. You have 95 bits of alarm reporting. If
you wish to limit the register requirement you may bit map selected
conditions or extract the 32 bit Condensed Alarm Status-ASR word in
two registers. These are in the KCM.
7.0.2 ASW word mapping
Here is a list that identifies the ASW word number with the Alarm ID
code. Each ASW word is 32 bits long
Word Number Bit Range
Word(0) 0-31
Word(1) 32-63
Word(2) 64-95

Alarm Status Variables-ASW 7
Alarm status word tables-ASW 7.1
7.1 Alarm status word tables-ASW
7.1.1 Global ASW alarm status table

These alarm codes are common for all K-Tron machines. This is the
bit number entered into the Smart K-Link ASW word configuration.
Note:
Some global entries will not be used for VOL and PID applications
since SFTs are not employed.
ASR(Alarm number) Description
K-Prom_Fail(1) • Checksum error in parameter mem-

ory
K-Prom_Fail(2) • Checksum error in kgr file area
Power_Glitch(3) • Power dip detected. CPU did not re-
set
Int_Chan_Fail(5) • Internal channel has failed to com-
municate between the CPU and
drive pcbs
Gen_Weight_Fail(6) • SFT(s) failed
• Serial communication to the load cell
interrupted
• f = SFT internal failure. communica-
tion OK
• t = No communication from the SFT
to the controller board
• ?= Not valid answer from SFT
Incorrect_Num_SFT • Number of SFTs found during poll-
(7) ing does not match that required
Bad_SFT_Status(8) • SFT is showing an incorrect status
No_MDU-Found(9) • The drive pcb is not function with re-
spect to the CPU pcb
MDU Failure(10) • Motor drive has failed
MDU_Timeout(11) • CPU pcb not communicating with
the Drive pcb
MDU_Thermal(12) • Drive temperature has exceeded
deg C
MDU_Speed(13) • No speed feedback signal is present
when motor is asked to run

MDU_Current(14) • Motor current limit is exceeded

MDU_SRelay(15) • Safety relay disconnected while run-
ning
MDU_Motor(16) • No current in motor leads when mo-
tor is supposed to run
MDU_Control(17) • Drive problems
MDU_EEPROM(18) • EEPROM checksum failed
MDU_Drive_Fail(19) • MDU drive pcb has failed
MDU_Polarity(20) • Coil polarity is incorrect on the vibra-
tory drive (Vibratory feeder only)
HCU_Removed(21) • HCU was removed
HCU_Alarm(22) • HCU has an alarm
HCU_EEPROM(23) • EEPROM failed
HCU_Driver(24) • The controller's digital output driver
has detected a fault
HCU_Supp_Hp(25) • Material is below the level of the
supply hopper proximity sensor
• Sensor failed
HCU_Filter_DP(26) • The differential pressure across the
filter is too high indicating a clogged
filter
HCU_CycCount(27) If P20 Discharge Mode =01“Fill” mode
then:
• Max. numbers of load cycle exceed-
ed, because Buffer Hopper Low in-
put has been active (on) for more
than the allowed load cycles. The
Buffer Hopper Low signal going in-
active clears the load cycle counter
If P20 Discharge Mode =02 (LWF)
mode then:
• Discharge Request input has been
on for more than the allowed load
cycles. The Discharge Request sig-
nal going inactive clears the load cy-
cle counter

HCU_DischVlv(28) • Discharge valve has failed to either

open or close properly. This alarm is
automatically disabled in P18 Oper-
ating Modes 03 and 04
HCU_Rec_Full(29) • Receiver is still full after discharge.
• Receiver proximity switch too sensi-
tive adjusted or failed
KLinkWrongFile(30) • Protocol of KGR file does not match
that required by the installed com-
munication circuit card
KLink_No_File(31) • No KGR file loaded
KLink_HPortFail(32) • Host communication pcb error
KLink_HPortFail • Host communication pcb could not
Init(33) be initialized
KLink_HPort_IllegBd • Improper pcb installed in the host
(34) port location
KLink_KPort Fail(35) • Check Host circuit card
KLink_KPortFail • Check Host circuit card
Init(36)
KLink_KPort_IllegBd • Host communication pcb is installed
(37) on the wrong port location-(K-Port)
KLink_BadKGR(38) • One or more feeder parameters are
not correct for the specified feeder
Ext_IO_Fail(39) • The MODBUS I-O connection has
failed
External Alarm(40) • Digital input on KCM selected for Ex-
ternal Alarm is active
Aux_interlock(41) • Run Enable digital input has failed
Start_Ignored(42) • Start conditions not fulfilled
MF-High(43) • The current massflow is above the
tolerance entered in <ALARM>
menu parameter <MF ERR+>
MF_Low(44) • The current massflow is below the
tolerance entered in <ALARM>
menu parameter <MF ERR->

DC_Ceiling(45) • Drive command has reached the

limit <DC CEILING>
DC_High(46) • The drive command has exceed the
value <DRV CMD HI> Limit in the
<ALARM> menu
DC_Low(47) • The drive command has dropped
below the value <DRV CMD LO>
Limit in the <ALARM> menu
Check_Brush(48) • DC motor brushes may be wearing
out and ready to fail.
7.1.2 LWF alarm status definitions

Use these in addition to the global values.
FF_Alarm(52) • Feedfactor is either zero or outside

the Feedfactor alarm limit
Scale_Over(53) • Scale is over its range
Scale_Under(54) • Scale is reading under zero
Weight_High(55) • Weight is above the High Limit
Weight_Low(56) • Weight is below the Low Limit
Refill_Time(57) • Refill timer has expired
Loader_Empty(58) • Loader is empty
Low_Gain(61) • Adaptive gain has dropped below
10, the value will be locked at 10 and
a <Low Gain> alarm will display.
7.1.3 VOL alarm status definitions

Use only the appropriate global values.

7.1.4 WBF alarm status definitions

Belt_Slip(52) • Belt is slipping beyond the belt slip

limit
Weight_High(55) • Weight is above the High Belt Load
Limit
Weight_Low(56) • Weight is below the Low Belt Load
Limit
Belt_Drift(57) • The belt is drifting off the machine
Belt_Buildup(58) • Belt is accumulating material be-
yond the limit.
7.1.5 LWB alarm status definitions


Weight_High(55) • Weight is above the High Limit
Weight_Low(56) • Weight is below the Low Limit
Loader_Empty(58) • Loader is empty
BatchTolerance(59) • Batch tolerance limit has been ex-
ceeded
BatchTime2Hi(60) • Batch time limit has been exceeded

7.1.6 PID alarm status definitions


7.1.7 SFM alarm status definitions

Range_Div(53) • Divert channel is over its range

Range_Chute(54) • Chute channel is over its range
Over_Flow(55) • Rate is above the maximum limit
NoFlow(56) • No flow condition has been detected
Valve(57) • Bypass valve has failed

Condensed Alarm Status Words-ASR 8
Tables of condensed alarm status words 8.1
8 Condensed Alarm Status Words-ASR
8.0.1 Introduction
This section presents the various condensed alarm status words for
those who only wish to import a maximum of 2 registers or alarm data.
A list for each type of application will be presented here.
8.1 Tables of condensed alarm status words
8.1.1 Global ASW condensed alarm status table

These condensed alarm codes are common for all K-Tron machines.
This is the bit number entered into the Smart K-Link ASW word con-
figuration. A 32 bit word is used to describe the Condensed Alarm Sta-
tus.
Note:
Some global entries will not be used for VOL and PID applications
since SFTs are not employed.
Ext_Alr(1) • External Alarm active

DC_High, and • Either drive command has exceed-
DC_Ceiling(14) ed the high limit or tried to exceed
the ceiling
DC_Low(15) • Drive command has dropped below
the Low DC limit
Num_SFT(19) • Number of SFTs is incorrect
Internal_Channel_F • Internal channel on which the SFTs
ail(20)
Weight_Fail, • Weighing system failure
Bad_SFT_Status
(21)
Hardware failure(22) • All hardware and KPort or K-Link
problems
MDU(23) • Any related drive problem is identi-
fied here
Interlock(24) • An interlock is active
Start_Ignored(25) • A start input has been ignored
HCU problems(26) • Any HCU problem is grouped here

8 Condensed Alarm Status Words-ASR
8.1 Tables of condensed alarm status words
8.1.2 LWF condensed alarm status definitions

FF_Alarm(0) • Feed factor alarm active

Loader_Empty(3) • Loader is empty of product
Weight_High(5) • Weight is above the high limit
Weight_Low(8) • Weight is below the low limit
Scale_Over(9) • Scale is over-range
Scale_Under(10) • Scale is under-range
MF_High(12) • Massflow is above the high limit
MF_Low(13) • Massflow is below the low limit
8.1.3 VOL condensed alarm status definitions

Use only the appropriate global values.
8.1.4 WBF condensed alarm status definitions

Belt_Slip or • Either belt slippage or belt drift is the

Belt_Drift(0) problem
Belt_Buildup(2) • Belt has buildup that exceeds the
limit
Hi_Belt_Load(8) • Belt loading exceeds the limit
Lo_Belt_Load(11) • Belt loading is below the limit

Condensed Alarm Status Words-ASR 8
Tables of condensed alarm status words 8.1
8.1.5 LWB condensed alarm status definitions

FF_Alarm(0) • Feed factor alarm active

Loader_Empty(3) • Loader is empty of product
BatchTime2High(4) • Batch time has expired
Weight_High(5) • Weight is above the high limit
Weight_Low(8) • Weight is below the low limit
MF_High(12) • Massflow is above the high limit
Batch_Tolerance(13) • Batch is out of tolerance
8.1.6 PID condensed alarm status definitions


8.1.7 SFM alarm status definitions

Range_Div(2) • Divert channel is over its range

Range_Chute(5) • Chute channel is over its range
NoFlow(8) • No flow condition has been detected
Over_Flow(9) • Rate is above the maximum limit
Valve(10) • Bypass valve has failed

9 KSL Line Functions
9.1 KSL line variable listing
9 KSL Line Functions
9.0.1 Introduction
This section shows the variables for KSL Line Function. The mnemon-
ics are indicated by lower case characters.
9.1 KSL line variable listing

Note:
Access information:’R’ means Smart K-Link output only,’R/W’ means
the variable is both an input and output value.
9.1.1 KSL numeric parameters

Here is a listing of KSL line variables.
LineBatchSize weight float R/W Total batch size of line – for batch applica-
tions only.
LineMaxBatchSize weight float R/W Maximum total batch size of line – for batch
applications only.
LineMaxRate rate float R/W Full scale line massflow rate.
LineMassflow rate float R Actual line massflow rate.
LineSetpoint rate float R/W Line target massflow setpoint.
LineBatchComplete- weight float R Actual weight delivered in the total batch.
Mass
LineBatchComplete- percent float R Actual weight delivered in the total batch in
Percent percent of the line batch setpoint.
LineTotalizer weight float R/W Summary weight information.
TempProportion percent float R Proportional percent of the Line setpoint to
the total Line SP.

KSL Line Functions 9
KSL line variable listing 9.1
9.1.2 KSL line command table
Use this table to construct functional commands for the KSL. Please
note that the commands for Line function are lowercase.
Active selected recipe cacr
Batch pause for the line cpas
Recall the recipe crcr
Stop and preserve alarms for the line cspa
Stop and clear alarms for the line cspc
Start, run and clear alarms for the line cstc
Store the recipe cstr
Clear the line totalizer ctoc

10 KCM Built-In *.kgr Files
10.1 Protocols supported
In this section, the pre-loaded kgr files for KCM data communications
are shown. The user is also able to prepare and download custom kgr
files specific to process needs.
The KCM provides Built-In kgr files for each supported protocol. The
Built-In kgr files can be used as a quick-start to test communications
and as a starting point for building custom kgr files. Built-In kgr files
can be extracted, customized and downloaded to the KCM as a cus-
tom kgr file using SmartConfig program.
The select between the Built-In kgr files and a custom kgr file is made
in the KSU Communication menu. Setting the Host File selection in
that menu to <Built-In> selects the Built-In file as described in this sec-
tion. Selecting <KGR> file selects the custom downloaded kgr file that
the user designs.
The KSL supports only Modbus, AB-DF1 and Siemens 3694R proto-
cols.
10.1 Protocols supported

Protocols supported for the Built-In kgr files are:
• Modbus
• Modbus Plus
• Modbus TCP
• AB Allen Bradley DF1
• Siemens 3694R
• DeviceNet
• ProfibusDP
• EthernetIP
Note:
These protocols will require a communication adapter card to be in-
stalled in the KCM.

KCM Built-In *.kgr Files 10
Communication settings 10.2
10.2 Communication settings

Below are the communications settings for each Built-In kgr file proto-
col. These settings appear in the header of the kgr file.
Protocol Baud Bits Parity Stop Details

Bits
Modbus-MB 19200 8 Even 1 MS_Byte_First, Node = 0
AB-DF1 9600 8 Even 1 LS_Byte_First, Node = 0
Siemens 3694 9600 8 Even 1 MS_Byte_First, Node = 0
ProfibusDP MS_Byte_First, In=64 bytes, Out=64 bytes, Node =
0.
Modbus TCP MS_Byte_First, IP address = 10.20.10.100, Net-
(Modbus over Mask = 255.0.0.0, and the Gateway = 0.0.0.0
Ethernet)-
MBTCP
Modbus Plus - MS_Byte_First, Global Database settings = (SR-
MB+ CID=0, NumWords=0, Offset=0), Node=0.
DeviceNet MS_Byte_First, No I/O Blocks, Input bytes=62, Out-
put bytes=40,
Note: DeviceNet address is set by switches
EthernetIP MS_Byte_First, No I/O Blocks, Input bytes=62, Out-
(DeviceNet put bytes=40, IP address = 10.20.10.100, Net Mask
over Ethernet) = 255.0.0.0, Gateway = 0.0.0.0

10.3 Variable locations and mapping

The first group of variables are global floating point reads from the
KCM. That means the registers are the same for all KCM applications.
10.3.1 Floating point reads from the KCM
Byte MB, MB+, AB-DF1, Device- Parameter Name KCM Application Data Type
Number MBTCP regis- Net, ProfibusDP,
ter Siemens, Ether-
net IP register
0 40001 0 Maximum Flow LWF, WBF, PID, SFM Float

0 40001 0 MaxBatch Size LWB, WBB, SFB Float
4 40003 2 Setpoint LWF, WBF, PID, SFM Float
4 40003 2 Batch Size LWB, WBB, SFB Float
8 40005 4 Totalizer All applications Float
12 40007 6 Massflow LWF, WBF, PID, SFM Float
12 40007 6 Batch Complete Mass LWB, WBB, SFB Float
16 40009 8 Drive Command All applications Float
20 40011 10 Motor Speed All applications Float
24 40013 12 Aver Feeding Factor LWF, LWB, PID Float
24 40013 12 Nominal Belt Load WBF, WBB Float
24 40013 12 Chute Net Weight SFM, SFB Float
28 40015 14 Netweight LWF, LWB Float
28 40015 14 Belt Load WBF, WBB Float
28 40015 14 Divert Net Weight SFM, SFB Float
28 40015 14 Prop Contrib Freq PID Float
32 40017 16 Refill Level Max LWF, LWB Float
32 40017 16 Belt Speed WBF, WBB Float
32 40017 16 Chute Gross Weight SFM, SFB Float
32 40017 16 Integ Contrib Freq PID Float

Variable locations and mapping 10.3
Floating point reads from the KCM, con’t
ter Siemens, Ether-
net IP register
36 40019 18 Refill Level Min LWF, LWB Float

36 40019 18 Belt Slip Value WBF, WBB Float
36 40019 18 Divert Gross Weight SFM, SFB Float
36 40019 18 Deriv Contrib Freq PID Float
40 40021 20 Batch Time LWB, WBB, SFB Float
40 40021 20 Process Variable PID Float
44 40023 22 Fast Drive Command LWB, WBB, SFB Float
48 40025 24 Dribble Drive Com- LWB, WBB, SFB Float
mand
10.3.2 Condensed process status and alarm status reads
These bits show the functional condition and alarm status of the par-
ticular KCM. See section 7.1. for more information. These parameters
are two word integer reads.
ter Siemens, Ether-
net IP register
52 40027 26 CondensedProcStatus All applications Bit-

Mapped
56 40029 28 CondensedAlarmSta- All applications Bit-
tus Mapped

10.3.3 Heartbeat, single word read

Read this value to verify data communication and KCM functionality.
ter Siemens, Ether-
net IP register
60 40031 30 Heartbeat All applications Integer
10.3.4 Single word writes for control

Use these registers to set LWF/LWB Refill and SFM/SFB Bypass
valve control. Note the change in address sequence from the ‘reads’.
ter Siemens, Ether-
net IP register
62 41025 1024 Refill Enable/Disable LWF, LWB Integer

62 41025 1024 Bypass Valve SFM, SFB integer
10.3.5 Command register

This table provides a single register write for KCM commands.
ter Siemens, Ether-
net IP register
64 41026 1028 Commands from Com- All applications Bit-

mand table See next mapped
table.

Variable locations and mapping 10.3
10.3.6 Command functions

The Built-In kgr file provides the following bit mapped commands at
byte number ‘64’.
.
Bit Number Mnemonic Definition
0 CALA Alarm acknowledge

1 CALC Alarm clear
2 CSPA Stop and keep alarm
3 CSPC Stop and clear alarms
4 CSTC Start and clear alarms
5 CTOC Clear totalizer
6 CMAM Set gravimetric mode
7 CVOM Set volumetric mode
8 CTAR Set the tare
9 CTR2 Start dynamic tare, WBF, WBB only
10 CCFF Start FF calibration - LWF only
11 CRMD PID Ramp Up - PID only
12 CMRU PID Ramp down - PID only
13 CPAS Batch pause, LWB, WBB, SFB only
14 CTON Enable totalizer
15 CTOF Disable totalizer

10.3.7 Floating point writes to the KCM
Use this table to configure the writes (float-2 register) for the applica-
tion.
ter Siemens, Eth-
ernt IP register
0 41027 1026 Maximum Flow LWF, WBF, PID, SFM Float

0 41027 1026 Maximum Batch Size LWB, SFB Float
4 41029 1028 Setpoint LWF, WBF, PID, SFM Float
4 41029 1028 Batch Size LWB, SFB Float
8 41031 1030 Initial Feeding Factor LWF, LWB, PID Float
8 41031 1030 Nominal Belt Loading WBF, WBB Float
8 41031 1030 Bypass Interval SFM, SFB Float
12 41033 1032 Refill Level Maximum LWF, LWB Float
12 41033 1032 Prefeed DC Span WBF, WBB Float
12 41033 1032 Overall Span SFM, SFB, PID Float
16 41035 1034 Refill Level Minimum LWF, LWB Float
16 41035 1034 Belt Slip Alarm Limit WBF, WBB Float
16 41035 1034 Prop Gain PID Float
16 41035 1034 Chute Weight Span SFM, SFB Float
20 41037 1036 Scale Span LWF,LWB, WBF, WBB Float
20 41037 1036 Deriv Time PID Float
20 41037 1036 Divert Weight Span SFM, SFB Float
24 41039 1038 Batch Time LWB, SFB Float
24 41039 1038 Process Variable PID Float
28 41041 1040 Fast Drive Command LWB, SFB Float
32 41043 1042 Dribble Drive Com- LWB, SFB Float
mand

Index
Index CHDO 35 DriveCommand=5 30, 32

CHRU 35 DriverEna 27
CHST 35 Dynamic Tare=18 29
A Chute 60 E
AB CIF 58 Chute Gross Weight 60 Empty 33
Access information 5, 56 Chute Weight Span 64 Empty=15 29
Al. Ack 26 CMAM 36, 37, 63 Empty=16 28
Al. Clr 26 CMRD 36 EthernetIP 58
Alarm ID code 46 CMRU 36, 63 expanded PSW 42
ALS Input 26 Commands 6 Ext. Al. 33
ALS Output=4 27 condensed alarm status words External alarm=12 26
Any alarm 27 53
F
ASR-map 27 CondensedAlarmStatus 61
CondensedProcStatus word Fast Drive Command 61,
Aver Feeding Factor 60 64
B 38
CPAS 37, 63 Feeder run 27
Batch Complete 33 Feedfactor 29
cpas 57
Batch Complete Mass 60 Feedfactor=4 34
crcr 57
Batch Complete=16 28 Feedfactor=6 31
CRMD 63
Batch Pause=15 28 Feedfactor=7 32
CSPA 35, 63
Batch Size 60, 64 FF Calibration 33
cspa 57
Batch Size=1 33 G
CSPC 35, 63
Batch Size=5 34 global floating point reads 60
cspc 57
Batch Time 61, 64
Batch% Complete=6 34
CSTC 35, 63 H
cstc 57 Hard alarm 27
Belt Drift=16 29
cstr 57 HiLoGear=14 28, 33
Belt Index=17 29
CTAR 36, 37, 63 I
Belt Load 60
CTOC 35, 63
Belt Load=7 30 Initial Feeding Factor 64
ctoc 57
Belt Slip Alarm Limit 64 Integ Contrib Freq 60
CTOF 35, 63
Belt Slip Value 61 Interlock 26
CTON 35, 63
Belt Speed 60
CTR2 36, 63 L
BlowOff=11 32 LineBatchCompleteMass 56
CVOM 36, 37, 63
Blow-off=13 28, 33 LineBatchCompletePercent
Bypass Fb=15 32 D
56
Bypass Interval 64 Data Lock=14 26
LineBatchSize 56
Bypass Valve 62 Data types 6
LineMassflow 56
Bypass Valve=10 32 Deriv Contrib Freq 61
LineMaxBatchSize 56
C Deriv Time 64
LineMaxRate 56
DeviceNet 58
cacr 57 LineSetpoint 56
Divert Gross Weight 61
CALA 35, 63 LineTotalizer 56
Divert Net Weight 60
CALC 35, 63 listing of KSL line variables
Divert Weight Span 64
Calib=15 30, 31 56
Dribble 33
Calib=19 28 Loader Enable=21 28
Dribble Drive Command 61,
CCBC 37 Loader Level=20 28
64
CCFF 36, 37, 63 Loader Run=12 33
Dribble=15 28
CCRF 36, 37 Loader=12 28
Drive Cmd 29
CDBI 35 Loc/Ext 26
Drive Command 60
CETY 36, 37 LWB 6
Drive Command=2 34
CHCA 35 LWF 6
Drive Command=3 31
CHDF 35
Drive Command=4 31

Index
M Ref. Cmd 33
Mass mode 27 Refill Enable/Disable 62
Massflow 60 Refill Expired=11 28, 33
Massflow=2 27 Refill Level Max 60
MaxBatch Size 60 Refill Level Maximum 64
Maximum Batch Size 64 Refill Level Minimum 64
Maximum Flow 60, 61, Refill=10 28, 33
62, 64 Reill Level Min 61
MDU Failure(6) 47 Run Enable 26
Modbus 58 S
Modbus Plus 58 Scale Span 64
Modbus TCP 58 service variable index
Motor Speed 29, 60 information 25
Motor Speed=3 34 Setpoint 26, 60, 64
Motor Speed=4 31 Setpoint=1 27
Motor Speed=5 31 SFM 6
Motor speed=6 30, 32 Siemens 3694R 58
N Start 26
Net Chute=3 32 Start/Stop 26
Net Divert=4 32 Status 6
Net Weight 27 Stop 26
Net Weight=1 34 T
Netweight 60 Tare Run=10 29
Nominal Belt Load 60 TempProportion 56
Nominal Belt Loading 64 Totalizer 60
Normal Fb=16 32 Totalizer Clear=13 26
NW1=3 30 Totalizer Pulse=9 27
NW2=4 30 V
O Variable or process data 6
Overall Span 64 VOL 6
P Vol Mode 26
Pause 33 W
PID 6 WBF 6
Prefeed DC Span 64
Prefeeder Drive Enable=11
29
Prefeeder=8 30
pre-loaded kgr files 58
Process Variable 61, 64
ProfibusDP 58
Prop Contrib Freq 60
Prop Gain 64
PSR-map 27
PVUInput=3 31
R
Ratio/Direct 26
Ref Bypass=17 28
Ref Cmd=18 28
Ref. Bypass 33

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TECHNICAL INSTRUCTION

Read this manual prior to operating or

0590020612-EN Rev. 1.0.0

Before you call, gather the following information…

Use of the manual:

Indicates an electrical hazard.

Reference to another manual section.

Marks helpful information.

Indicates that tools are needed for the task.

Specifies where information or a situation must be checked.

Indicates where power is applied or removed.

Don’t place hands or other body parts into machine.

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

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

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

Docu-No.: 0590020612-EN Rev. 1.0.0 KCM Protocol Page 1

4 Command Functions ...................................................................................................... 35

5 Condensed Process Status Variables .......................................................................... 38

Page 2 KCM Protocol Docu-No.: 0590020612-EN Rev. 1.0.0

6 Expanded Process Status Word - PSW ........................................................................ 42

7 Alarm Status Variables-ASW ......................................................................................... 46

8 Condensed Alarm Status Words-ASR .......................................................................... 53

9 KSL Line Functions ........................................................................................................ 56

10 KCM Built-In *.kgr Files .................................................................................................. 58

Docu-No.: 0590020612-EN Rev. 1.0.0 KCM Protocol Page 3

Page 4 KCM Protocol Docu-No.: 0590020612-EN Rev. 1.0.0

Installation, commissioning and programming of the specified

1.1 Safety symbol definitions

V CAUTION used without the safety alert symbol indicates a poten-

V CAUTION indicates a potentially hazardous situation which, if not

V WARNING indicates a potentially hazardous situation which, if not

V DANGER indicates an imminently hazardous situation, which if

1.1.1 Related safety/electrical icons

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

This symbol shows where an electrical ground or PE is to be placed.

Docu-No.: 0590020612-EN Rev. 1.0.0 KCM Protocol Page 1

1.2 Proper use

V Only operate the KCM in conjunction with the feeder equipment

1.3 Organizational measures

V Observe the safety notes for the connected feeding devices.

1.4 Operator responsibilities

Page 2 KCM Protocol Docu-No.: 0590020612-EN Rev. 1.0.0

1.5 Safety-conscious operation

V Any changes (including changes to operational behavior) which

1.6 Safety devices

V The electrical safety devices must not be altered. This increases

1.7 High voltage

Docu-No.: 0590020612-EN Rev. 1.0.0 KCM Protocol Page 3

1.8 Additional equipment

V Modifications to the KCM are prohibited.

1.9 Removal from service

1.10 Customer service and repairs

V The KCM may only be repaired by

V See project specifications and sales agreements for warranty in-

1.12 Applied safety signs and placards

1.12.1 Selected safety signs on machines

Fig. 1.1 Power applied sign

Page 4 KCM Protocol Docu-No.: 0590020612-EN Rev. 1.0.0

2 Data Structures, Formats and Data

Please use the following notation when using these variables.

Data Type: Numeric - Float, Strings or Integer Data Types,

Typically used variables: Marked in Bold typeface.

For PLC register assignments, use:

Access information:’R’ means Smart K-Link output only,’R/W’ means