KSUWBF942001 Ed PDF
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MAINTENANCE MANUAL
Weigh belt feeders controlled by SCM with KSU console
KSU/WBF.942.001-E.d
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Service
If you need assistance, please call your local service center: Or Hasler International SA F- 38780 Pont-Evêque
Tel. Fax
+33 (0)4 74 16 11 50 +33 (0)4 74 16 11 55
Hasler Suisse Sàrl CH-2000 Neuchâtel
Tél. Fax
+41 (0)32 720 23 00 +41 (0)32 720 23 90
Hasler Deutschland GmbH Tél. D-49525 Lengerich Fax
+49 (0)54 81 80 50 +49 (0)54 81 80 51 10
Before you call … Do you have alarm displays? Are you able to eliminate the cause of the alarm displays?
Ü
Have you modified part of the system, feeder, product or operating mode?
Ü
Ü
Have you tried to remedy remedy the fault in accordance with the operating and service instructions? Please note
Ü
the job number
..............................................
the type of feeder
..............................................
the motor control type
..............................................
“No part of this publication may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopy, facsimile or computer generated distribution without written permission from Hasler Suisse. Tous droits de traduction réservés à Hasler Suisse. Hasler Suisse has made every effort to ensure the accuracy and validity of this document. However, errors and omissions may have occurred. If an error or omission is found, please contact Hasler Suisse at (+41 (0) 32 720 23 00. Information in this manual is correct as of the date of publication. Hasler Suisse assumes no responsibility for damages resulting from misuse of the equipment or negligence on the part of operating personnel.”
Copyright Hasler Suisse Sàrl Rue du Puits-Godet 10a CH-2000 Neuchâtel Prepared and edited by Technical Documentation Hasler Suisse Sàrl Order no.: KSU/WBF.942.001-E.d Date: 21.01.05 Hasler Suisse Sàrl, a Hasler International Sa Company.
KSU/WBF.942.001-E.d
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Table of Contents Programming the Weigh Belt Controller Using the the KSU ....................... .............................................. .......................... ...33 Overview......................................................................................................................3 Introduction ...................... ............................................. .............................................. .............................................. .........................................3 ..................3 Software note .................... ........................................... .............................................. .............................................. .........................................3 ..................3 The Basics ...................... ............................................. .............................................. .............................................. .............................................. .......................... ...44 Changing a variable variable.................... ............................................ ............................................... .............................................. .............................4 ......4 Setting the setpoint ..................... ............................................. ............................................... .............................................. .............................4 ......4 Run feeder ..................... ............................................ .............................................. .............................................. .............................................5 ......................5 Stop feeder .................... ........................................... .............................................. .............................................. .............................................5 ......................5 Selecting gravimetric or volumetric control.............................. control..................................................... .......................... ...55 Definitions................................................................................................................7 Other initial data entries .................... ........................................... .............................................. .............................................8 ......................8 Feeder Calibration................................ Calibration....................................................... .............................................. .............................................. .....................................9 ..............9 Overview......................................................................................................................9 Feeder Calibration............................... Calibration...................................................... .............................................. .............................................. ......................... 11 Introduction ...................... ............................................. .............................................. .............................................. .......................................11 ................11 Feeder Calibration, continued...................................... continued............................................................. ...........................................12 ....................12 Feeder tare chart...................................... chart............................................................. .............................................. .......................................13 ................13 Introduction ...................... ............................................. .............................................. .............................................. .......................................14 ................14 Feeder Calibration, continued...................................... continued............................................................. ...........................................15 ....................15 The span chart ............................................. .................................................................... .............................................. ...................................16 ............16 Programming Operational Variables Variab les....................... .............................................. .............................................. ...................................17 ............17 Power-up sequence..................................... sequence............................................................ .............................................. ...................................17 ............17 Main Menu Menu.................... ........................................... .............................................. .............................................. .............................................. ......................... 18 Introduction ...................... ............................................. .............................................. .............................................. .......................................18 ................18 Accessing the Other Menus Menus....................... .............................................. .............................................. .......................................20 ................20 Alarms ....................... .............................................. ............................................... ............................................... .............................................. ........................... ....23 23 WBF actuators........................... actuators.................................................. .............................................. .............................................. ...................................32 ............32 WBF actuators........................... actuators.................................................. .............................................. .............................................. ...................................33 ............33 New Material Menu Programming ...................... ............................................. .............................................. ........................... ....34 34 New Material Menu Programming ...................... ............................................. .............................................. ........................... ....34 34 Onln Cal Menu Programming Programming ...................... ............................................. .............................................. ...................................36 ............36 Onln Cal menu entries ....................... .............................................. .............................................. ...........................................36 ....................36 Alarm Menu Programming ....................... .............................................. .............................................. .......................................37 ................37 Alarm Sub-menu entries .................... ........................................... .............................................. ...........................................37 ....................37 Alarm Setup menu m enu entries ..................... ............................................ .............................................. .......................................39 ................39 Alarm set-up menu entries, continued ....................... .............................................. .......................................40 ................40 Tuning Menu Programming ..................... ............................................ .............................................. .......................................41 ................41 PID tuning sub-menu entries .................... ........................................... .............................................. ...................................42 ............42 Prefeeder Menu Programming ..................... ............................................ .............................................. ...................................43 ............43 Prefdr PID sub-menu entri entries......................... es................................................ .............................................. ...............................44 ........44 KSU/WBF.942.001-E.d
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Level PI sub-menu entries ............................................ ................................................................... .......................................45 ................45 Hopper Menu Programming .................... ........................................... .............................................. .......................................48 ................48 Scale Menu Programming ..................... ............................................ .............................................. ...........................................53 ....................53 Scale Sub-Menus ............................................. .................................................................... .............................................. ...............................53 ........53 Hopper sub menu entries ...................... ............................................. .............................................. .......................................56 ................56 Input/Output Menu Programming ..................... ............................................ .............................................. ........................... ....60 60 Bit Output sub-menu ...................... ............................................. .............................................. .............................................. ......................... 61 Bit output PSR (Process Status Register) Register) map configuration ..................... ......................... ....62 62 Bit output ASR (Alarm Status Register) alarm bit map configuration..........62 Bit Input sub-menu ..................... ............................................. ............................................... .............................................. ........................... ....63 63 Mechanical Menu Programming ...................... ............................................. .............................................. ...............................68 ........68 Mechanical menu sub-menus.................... sub-menus........................................... .............................................. ...................................68 ............68 Motor Setup sub-menu................... sub-menu.......................................... .............................................. .............................................. ......................... 70 Misc sub-menu ............................................ ................................................................... .............................................. ...................................71 ............71 Scraper sub-menu entries ...................... ............................................. .............................................. .......................................71 ................71 Options sub-menu ...................... .............................................. ............................................... .............................................. ........................... ....72 72 System Menu Programming...................... Programming............................................. .............................................. .......................................73 ................73 Introduction ...................... ............................................. .............................................. .............................................. .......................................73 ................73 System sub menu entries ....................... .............................................. .............................................. .......................................73 ................73 Security sub-menu Security Level settings .................... ........................................... ...................................74 ............74 Security sub-menu Act Control Pt. settings......................................................75 Security sub-menu Ctl Pt. Setup settings ....................... .............................................. ...................................75 ............75 Security sub-menu Ctl Pt. Setup settings ....................... .............................................. ...................................76 ............76 Security sub-menu Ctl Pt. Setup settings ....................... .............................................. ...................................76 ............76 Communication sub-menu entries.....................................................................77 Net Management sub-menu entries .................... ........................................... .............................................. ......................... 78 System Setup Sub-Menu SYSTEM.................................................................. SYSTEM...................................................................... ....80 80 System Setup Sub-Menu SYSTEM, continued.................................. continued..................................................81 ................81 System Setup menu Binding ssub-menu ub-menu ..................... ............................................ .......................................82 ................82 Maintenance Menu Programming ....................... .............................................. .............................................. ........................... ....83 83 Introduction ...................... ............................................. .............................................. .............................................. .......................................83 ................83 Maintenance menu entries................. entries........................................ .............................................. ...........................................83 ....................83 Calib Status sub-menu entries....................... entries.............................................. .............................................. ...............................83 ........83 Maintenance.................................................................................... Maintenance............................................................. .............................................. .......................................84 ................84 Introduction ...................... ............................................. .............................................. .............................................. .......................................84 ................84 KSU WBF application Program Sheet......................................... Sheet................................................................ ........................... ....85 85 KSU WBF application Program Sheet......................................... Sheet................................................................ ........................... ....86 86 KSU WBF application Program Sheet......................................... Sheet................................................................ ........................... ....87 87 KSU WBF application Program Sheet......................................... Sheet................................................................ ........................... ....88 88 KSU WBF application Program Sheet......................................... Sheet................................................................ ........................... ....89 89 KSU WBF application Program Sheet......................................... Sheet................................................................ ........................... ....90 90 KSU WBF application Program Sheet......................................... Sheet................................................................ ........................... ....91 91 KSU WBF application Program Sheet......................................... Sheet................................................................ ........................... ....92 92 KSU WBF application Program Sheet......................................... Sheet................................................................ ........................... ....93 93 KSU/WBF.942.001-E.d
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Programming the Weigh Belt Controller Using the KSU Overview Introduction
This section will take you through the features and usage of the KSU as the user interface to the SCM SmartConnex Weigh Belt feeder controller application.
Software note
This manual is for SCM software version 3.0 and later. This manual is not to be used for earlier versions of SCM software.
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The Basics Changing a variable To change a variable, the variable must be selected from the menu or a sub-menu within that main menu. The pointer will indicate the selected variable. To select, use the down arrow to direct the pointer. Press the enter key.
Entry Type
Action Enter the value and press the
Numeric “Enter” key.
ENTER
NEXT
Alpha
Using the down arrow key reveal the desired entry. Press the “Enter” key to load.
,
Setting the setpoint
This procedure shows you how to enter the setpoint. Step 1 2
3
Action NEW SP
Press the New SP key. Enter the desired setpoint with the keypad. Press the “Enter” key to load.
Note: The setpoint cannot be greater than the Full Scale Setpoint and it should not be larger than the capacity of the machine.
Continued on next page
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The basics, Continued Run feeder
Step
Action Run
Press the "RUN" key.
1 Note: If Alarm Shutdown or Run Disable messages are displayed, the unit will not run. A setpoint is also required.
Stop feeder
Step
Action Stop
1
Press the STOP button.
Selecting gravimetric or volumetric control
Step 1
2
Action For Gravimetric control (normally used to run your process), press the GRAV/VOL key. This will switch the KSU to Gravimetric control. View the top line of the KSU display to verify that condition. To select Volumetric control that fixes the drive command at a set value, press the GRAV/VOL key again. (Normally used for setup or testing only) View the top line of the KSU display to verify that condition.
Continued on next page
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The basics, Continued Order of data entry for WBF machine
In the event of RAM loss due to faulty battery, replacement of the SCM Controller PC Board or software, it may be necessary to reprogram the feeder. The following is the recommended sequence for the programming of any weight based machine. Unlike older Hasler systems, the SCM reads the scale range automatically.
Gravimetric Gravimetri c Feeeder Programming Sequence System Menu General Sub-Menu Choice of units: kg/hr, kg/min. t/hr etc. New Material Menu Set: Max Setpt.
Mechanical Menu Check settings
New Material Menu Perform Static Tare: Zero New Material Menu Perform Belt Tare Scale Menu Perform material calibration
Check settings in other menus Record parameters Run feeder.
Continued on next page
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The basics, Continued Status display
The status line at the top of the screen has 4 display windows.
Gravimetric/ Volumetric
Local/Ratio/Dir Line 1-8
Tare Disa/Alshut Cal/Wait Onln Cal
WBF/LWF, etc.
Definitions
Display Gravimetric Volumetric Local Ratio Direct Line 1-8 Tare DISA Enable/Disable)
Alshut
Wait Onln Cal
Function Sets the Weigh Belt Feeder to run in automatic control using the weigh loss data to set the feeder speed. Sets the feeder to operate at a fixed speed. Setpoint is entered on Overview screen in the selected units of kg/hr etc. Setpoint is entered on the Overview screen in % Setpoint comes from an external source. No change by the operator is allowed. Sets a feeder to run with others selected in a recipe. Indicates that a dynamic tare of the scale is occurring. (not Static Tare) If Enable - means feeder can run of all other condition allow. If Disable - feeder cannot run until I/O interlock is cleared. If showing ALSHUT, an I/O interlock is preventing the feeder from running. The feeder has generated a shutdown alarm from programming and the alarm has not yet been cleared. Trying to Run feeder with the interlock function in the Bit Input not active. The setpoint may also be b e zero "Onln Cal" is displayed when automatic feeder calibration measurements are in progress. Continued on next page
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The basics, Continued Initial data entry procedure for WBF machine Use this procedure to input the initial values from the KSU.
Step
Action Go to System Menu and then the General Sub-Menu and enter desired Display Units, i.e. kg/hr, t/hr.
1
When you select the units of choice, if you are going to use the recipe or Line function of the KSC, you must make the units of operation for the KSC Line and each machine the same or an error message will occur.
2
Go to the New Material Menu and enter Max Setpt
3
Other program variables may be entered in any order.
Other initial data entries You need to check to ensure that the following data values are loaded in addition to those previously mentioned.
Variable
Menu
Setpoint
(Main) or New SP key
Gear Teeth Setpoint
Reduction
Feeder Type
Belt Load Setpoint
Mechanical Menu, Motor Setup SubMenu Mechanical MenuMachine Setup SubMenu Mechanical Menu,
What to Enter Set to a value less than or equal to Max. Setpt. Set to the number of gear teeth of the motor feedback gear. Default is 50 tooth. Compute the total gear reduction and enter it. Set to the type of feeder you
Machine Setup SubMenu
have.
New Material Menu
Set to a value approximately equal to the actual belt loading value. If not read the Linear belt load in the technical data document delivered with the installation.
You will now go to the calibration of your machine. Hasler feeders will require much more programming to use all the features.
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Feeder Calibration Overview
Introduction
In order to validate that the feeder is meeting flow rate accuracy requirements, it is necessary to take material catch samples and compare them to the desired setpoint. If the accuracy is not within specifications you may have to perform a "span calibration". The objective of this procedure is to finely tune the weight reading to increase the accuracy of the feeder.
Weight span calibration calibration overview overview Calibration frequency There is no set time frequency for performing this calibration. If you need to determine that the feeder meets your process accuracy requirements you will need to take actual catch samples and compare them to the desired setpoint. These catch samples samples may be multiple multiple timed samples compared compared to the setpoint or a single large sample of material compared to the displayed totalizer value on the KSU. We will show the concept of Run Charts as a method to help determine det ermine calibration frequency. Calibration of weight span If inaccuracies of the feeder system are determined by taking actual catch samples, a correction value is entered known as "weight span" found on the Scale menu and General scale sub-menu. The span value should range from .90 to 1.1. Calculated span span values outside outside this range range may indicate indicate additional system problems (in this case contact a maintenance technician).
The following procedures define the methods for performing these calibrations. Continued on next page
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Overview, Continued
REF: If the determined span is not within the range of 0.90 to 1.1 or the span results are not repeatable, you may wish to refer to one of the following documents, depending on the type of scale you have, in order to troubleshoot the weighing system.
Span is less than .90 or greater than 1.10 When W ei ght Span
Possible Problem Area Mechanical parameter
Reference Documentation Technical data
Weighing System
SFT Weighing Feeder Mechanics Gravit feeder manual Material test GRAVIT
Feeder material test
Please note that only SFTs with revision "N" and above are supported by the SCM.
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Feeder Calibration Introduction
This section shows you how to perform all of the calibration procedures that permit the feeder to reach its design performance. Tare calibration procedure
To tare the machine, please follow the next procedure.
Step
Action You should properly empty and clean the feeder. To empty the feeder: a) Shut-off material flow onto the belt.
b) Select a setpoint. c) Select Emptying function in the New Material Menu, Menu, and press the enter key. 1 Note: The feeder will stop automatically when the Blt Empty Li is reached. Note: To stop the Emptying function, press the key
d) Clean the feeder.
2
In the New Material Menu, select Static Tare and Press ENTER twice. A static tare value will be accepted and it will be used to validate the dynamic belt tare that is used for running the machine. Press to exit. While in the New Material Menu, select Belt Tare and press the Enter key twice. This starts the dynamic belt tare. The feeder will stop automatically when the dynamic belt tare t are is finished.
3
Note: To stop the tare prior to completion, press the key If belt slip is enabled, the reference data for belt slip is calculated during the dynamic tare process.
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Feeder Calibration, continued
Tare calibration procedure, continued
Step
Action
4
The feeder will begin to run and when the tare cycle is finished, the feeder will stop.
5
Record the value of for future reference as shown in the Tare variable in the Scale Menu, Main Deck Sub-Menu.
6
Record the data point on the Zero/Tare Run Chart. This will be the Static Tare value so some inaccuracies will likely be observed.
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Feeder Calibration, continued, Continued Feeder tare chart
This tare chart is used to record the static and/or dynamic tare values, i.e. the "Tare" parameter in the "Main Deck" sub-menu of the "Scale" menu. The calibration date is at the bottom. The start value is an average that is placed at the initial tare value to make it easy to plot subsequent values. It is recommended that the static tare values are written vertically in line with the point to which they relate. Add the points to this chart horizontally after every tare procedure (Static or Belt). The variance will define the normal process deviations that one expects. If a future tare
value falls outside this normal range, it may indicate a problem with the weighing system.
Zero Change Histogram
Start value
Date:
Initial:
Feeder ID: ________________
Continued on next page
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Feeder Calibration, continuedContinued Introduction
You can use this simple approach to quickly check the flowrate of your feeder and verify its accuracy. Weight Span Calibration by the Totalizer Totalizer method Use this procedure to verify the accuracy of the totalizer from the feeder. Any adjustments will be made to the Scale Weight Span on the Scale Menu, Main Deck Sub-Menu.
Step
Action
1
The necessary material quantity for the material tests is determined as follows: n Accuracy to be achieved = e.g. 0.5 % n Resolution (measurement increment step) of the scale used for the check weighing (customer) = e.g. 20 Kg n The weighing accuracy of the check weigh scale must be 2 x higher n
than the accuracy to be achieved. Measurement increment step * 100 * 2 / accuracy to be achieved = necessary material quantity (batch size). In our example: 20 * 100 * 2 / 0.5 = 8000 Kg minimum
2
Obviously, the more the material quantity exceeds the calculated value, the better the weighing accuracy. On the other hand, the min. material test time must not be less than 3 minutes, nor the time t ime required for the band to perform a complete revolution.
3
If the material transport route after the weigh belt feeder includes equipment such as screw conveyors, belt conveyors, chutes etc., the dead zones of this equipment must be filled by operating the installation.
4
Prepare a container (truck), large enough to hold the material quantity calculated under point 1
5
Weigh or detare the empty container. If it's a truck, weigh the empty truck, without the driver and take into account the distance between the check weigh scale (customer) and the material test site. A heavy duty truck consumes approx. 30 to 50 litres of fuel per hour. At a fuel density of 0.88kg/l, one hour of running already accounts for an error of 0.55% on a 8000kg batch.
6
Reset the KSU totalizer to zero.
7
Make sure that the container is in place and that it's totally empty.
8
Put the feeder in Gravimeteric mode by pressing the GRAV key.
9
Select a setpoint between 20 and 100% of the nominal flowrate.
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Feeder Calibration, continued
Weight Span Calibration by the Totalizer Totalizer method, continued
Step
Action
10
Start the machine until the desired batch size has been reached, then stop.
11
12
Weigh the container. If it's a truck, weigh it without the driver and take into account the fuel consumption (see point 5). Define the net material weight, subtracting the previously weighed empty weight from the now measured gross weight. Read the totalizer = Totalizer KSU. Calculate the new span setting from the following equation: New Span, (Scale Menu, Main Deck sub-menu) = = Current Span*( Container Weight/Totalizer Weight(KSU))
13
14
To confirm the calculated result, perform at least one more material test with the same setpoint and recalculate the error.
15
If the 2nd error calculation differs considerably from the 1 st result, make a 3rd material test.
16 17
KSU/WBF.942.001-E.d
E.g.: Current span = 1.004, Container weight =9,900 kg, the totalizer reads 10,000 kg. New span = 1.004 * ( 9900/10000) = 0.994
Add up the samples and divide by the number of samples taken to get the average sample value. Enter new span into in Scale Menu, General Scale submenu.
18
You have calibrated the feeder. You can now run the feeder in production.
19
Record the new span value on the Span Run Chart.
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Feeder Calibration, continuedContinued The span chart
This chart is used to record the span values, i.e. the values of the "Span" parameter of the "Main Deck" sub-menu of the "Scale" menu. The calibration date is at the bottom. The start value is the reference value, i.e. 1.000. It is recommended that the span values are written vertically in line with the point to which they relate. Add the points horizontally to this chart after every span calibration procedure. The variance of span values will define the normal process deviations that one expects. If a future value falls outside this normal range, it may indicate a problem with the weighing system. The span target should be between 0.90 and 1.10.
Span Change Histogram 1.20
1.15
1.10
1.05
1.000 Start value 0.95
0.90
.085
0.80
Date:
Initial:
Feeder ID: ________________
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Programming Operational Variables
Overview Introduction
This section describes the primary or operator display screens for the KSU. Note: The data you program into these pages is retained in the event of power failure by a battery on the Controller PC Board. Without power, the data should be retained for approx. 7 years. Battery failure would be indicated by some changed variables after power down-power up cycle. See document SCM Commissioning manual for information on battery replacement. Power-up sequence
When power is applied to the controller, the following screen appears for a few seconds after a series of bars is displayed and then the Feeder Overview Screens appear.
KSU Lon Display SW 9700-20930 v1.4
KSU/WBF.942.001-E.d
Example of display
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Main Menu Introduction
This section shows the variables that appear on the Overview menu list. Feeder overview screens flow chart
The flow chart below shows the order of the Feeder Overview Screens. NEXT
Press the Home Key to get to the Main menu. Use the key to scroll through the other data values in this menu. The examples shown are in Kg but other engineering units may be selected. The data values v alues show in the following order:
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Main Menu, Continued Main menu entries The table below defines the Overview menu entries.
Entry
Definition This is the operating setpoint for the feeder in the
SP
NEW SP
selected units. It can be changed using the key on condition that the KSU console is configured for this function. MF
DC
This is the calculated MassFlow by the controller in the selected units. This is the command signal to the Motor Drive Unit that determines how fast the motor will turn. It is the output in percentage from the controller to the Motor Drive Unit 0-100%by= the 0 rpm to Mot. maximum rated motor speedwhere as entered Max Spd value in the Mechanical Menu, Motor Setup Sub-Menu.
BELT LD
KSU/WBF.942.001-E.d
This value is the weight of material per length of weigh belt.
BLT SP
This is the speed of the belt in m/s.
MOT SP
This is the motor speed in rpm.
TOTAL
This is the totalized amount of material delivered by the feeder since the totalizer was last zeroed, in the selected units.
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Accessing the Other Menus Introduction
This section details how how to access the menus. Menus marked with an ** are only shown when that option in the Mechanical menu has been selected.
These menus are accessed using the • • • • • • • • • • •
MENU
and
NEXT
keys.
NEW MATERIAL ONLN CAL** ALARM TUNING PREFEEEDER** HOPPER** SCALE INPUT/OUTPUT MECHANICAL SYSTEM MAINTENANCE
Program parameters within the Menus are accessed using the key. The following menus also include sub-menus.
The
C
ENTER
key as a previous function in the menu navigation.
Some sub-menus or variables in some menus may be hidden or locked if the Security level is not set to “Maint”. Also some selections in the Mechanical menus will affect what other menus are presented. New Material menu - No sub-menu. Onln Cal menu - No sub-menu. Alarm Menu - Limits Sub-Menu - Peripheral Limits Sub-Menu - Setup Sub-Menu
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_______________________ _______________________ _______________________ _________________ ______ ____________ Tuning Menu - PID Tuning Sub-Menu Prefeeder menu - Prefdr PID Sub-Menu - Level PI Sub-Menu - Prefdr Config Sub-Menu Hopper Menu - Config Sub-Menu - PID Sub-Menu - Density Sub-Menu Scale Menu - Main Deck Sub-Menu Sub-Menu - Secondary Deck Sub-Menu** - Hopper Sub Menu** - SFT Scale Sub-Menu - Diagnostics Sub Menu** - Analog Ld. Cell Sub-Menu** Input/Output Menu - Bit Output Sub-Menu - Bit Input Sub-Menu - Analog Out Sub-Menu - Analog In Sub-Menu - Manual Mode Sub-Menu Mechanical Menu - Machine Setup Sub-Menu - Motor Setup Sub-Menu - Misc. Sub-Menu** - Scraper Sub Menu** - Options Sub-Menu** System Menu - Security Sub Menu - Communication Sub-Menu - General Sub Menu - System Setup Sub-Menu - SW Versions Sub-Menu
Continued on next page
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Accessing the Other Menus, Continued Accessing and changing a variable in a menu
Step 1
Action
Select the desired parameter within the Menu using the key.
NEXT
Press the ENTER key to access or or change change the parameter. A Screen similar to the one below will appear:
MAX SETPT
120,000 t/h
¦
New= 2
If the entry requires a language entry, the screen will be similar to this:
Control mode LOCAL New=
Use the 3
KSU/WBF.942.001-E.d
NEXT
key to see other choices for New =
Confirm the new value or choice using the
ENTER
key.
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Alarms Introduction
This section details how to access the alarms. Alarm definitions, probable cause and possible corrective action is also provided. Accessing the alarm screen Use this procedure to handle alarms.
Step
Action When the alarm led
) blinks, or the first line of the Feeder
1 Overview screen blinks, press the ALARM key. The following screen will then appear. A code number will be displayed in addition to the message. This code number is used to set operational conditions for each kind of alarm.
2
Pressing the key a second time disables the "AlarmRelay" data (can be used for a PSR 19 audible alarm) and the alarm LED remains fixed.
3
Pressing a third time clears the alarm This key functions regardless of where you are in the Feeder Overview screens or Menus.
Continued on next page
KSU/WBF.942.001-E.d
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Alarms, Continued Alarm message table with cause and remedy Use this table to resolve alarm problems. Also this table will be needed when setting up the Alarm Set-Up menu where you can select how a specified alarm behaves. The number is used as the alarm code.
No.
Alarm
8
Battery LOW
10
Massflow HIGH
11
Massflow LOW
12
Drv Cmd HIGH
13
Drv Cmd LOW
20
21 24 25
KSU/WBF.942.001-E.d
Cause
Remedy
Replace batteries on CPU board of SCM Check massflow conditions Massflow is greater than setpoint by the Check the MF Err+ limit in the Limits Sub-Menu Alarm limit of the Alarm Menu. Check massflow conditions Massflow is lower Check the MF Err- limit than setpoint by the in the Limits Sub-Menu Alarm limit of the Alarm Menu. Check the material load on the feeder Drive command has Check the DC Alarm+ exceeded Drive limit in the Limits SubCommand High limit Menu of the Alarm Menu. Check the material load on the feeder Drive command has Check the DC Alarmgone below the Drive limit in the Limits SubCommand low limit Menu of the Alarm SCM batteries have failed
Menu. Check LON connections LON communication and operation using the LON Comm FAIL failure LON IO Setup Utility program. Check for data exchange Host Link Fail Host link inactive. to the host Interlock Fail Downstream interlock Check interlock Downstream interlock Check interlock Interlock Time timed out
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Alarms, Continued
Alarm message table with cause and remedy, continued
No.
Alarm
26
Setpoint LOW
27
Setpoint HIGH
39
Incorrect # SFT
42
Temp Too High
Cause Setpoint is less than the Low Setpoint Alarm entry Setpoint is greater than the Max SP Number of SFTs found during a poll don’t agree with the number of SFTs required Aux temperature limit exceeded Aux board getting no speed feedback
47
Bad pickup
48
Aux OutPut Off
Aux board reporting alarm
50
Net DI Timeout
LON digital input timeout
51
Net DO Timeout
LON digital output timeout
52
Net AI Timeout
LON analog input timeout
53
Net AO Timeout
LON analog output timeout
54
Network Overld
LON Node loading too high Could not open
55
KSU/WBF.942.001-E.d
Port Open FAIL
requested port
Remedy Raise the setpoint Lower the setpoint Check SFTs and the wiring, Repoll Check SCM internal temperature. Cheek feeder tachometer and actual motor rpm. Check the Auxiliary Board Check LON device Check whether a LON link is configured for the assigned digital input Check LON device Check whether a LON link is configured for the assigned digital output Check LON device Check whether a LON link is configured for the assigned analog input Check LON device Check whether a LON link is configured for the assigned analog output Check analog I-O for too low deadband Check host communication port configuration.
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Alarms, Continued
Alarm message table with cause and remedy, continued
No.
Alarm
56
Bad SFT Status
58
Feeder not Rdy
59
Start Ignored
Feeder unavailable
60
A/D Fail
61
Emergency
A/D converter error Emergency input enabled
64
Mat. wt. HIGH
65
Mat. wt. LOW
66
Scale failure
67 68
Scale OVERRANGE Scale UNDERRANG
Cause
Remedy
SFT Status shows alarm. Machine not ready to run, but asked to.
Check wiring. Change SFT Check setpoint, check alarms present. Feeder unavailable, check alarms and messages. Check load cell wiring. Check position of emergency mode switch Reduce material weight
on the weigh belt. Material weight is too Weight exceeds load cell high capacity. Increase material weight on the weigh Material weight is too belt. low Weight is less than 0 SFT weighing system Check the SFTs and has failed related equipment Reduce weight on the Weight is above scale scale capacity Increase weight on the Weight is less than 0 scale
80
Belt Drift
Belt drift is beyond limits
81
Belt Slip
Belt slip is detected by Belt Index detector
KSU/WBF.942.001-E.d
Check belt position machine on Check for slip. Check the Blt Slp Lim setting in the Limits Sub-Menu of the Alarm Menu.
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Alarms, Continued Alarm message table with cause and remedy, continued
No. 84
86
89
Alarm
Belt Tare Error
91
OLC out of tol.
93
97
KSU/WBF.942.001-E.d
Remedy
Check belt slip sensor, the wiring and the Belt slip sensor not Belt Index Fail metal plate inserted in responding the belt. Check motor speed Motor speed sensor sensor Speed pickup Fail not responding Check wiring. Speed correction factor outside tolerance 90 – 110 tolerance limits. Speed correction factor Speed corr Check the "Speed Corr" is out of range setting in the Mechanical Menu
90
92
Cause
SettlingChamber High SettlingChamber Low
Hop. too Low
Motor Setup Sub-Menu. Clean the belt and perform another tare. Check the "Belt Len" Belt tare factor is out setting in the of range Mechanical Menu Machine Setup SubMenu. Check hopper weighing and feeder and repeat TAM. On line calibration correction is out of Check the "OLC limit" expected range setting in the Alarm Menu Periph Limits Sub-Menu. Settling chamber level Check level in settling too High chamber Settling chamber level Check level in settling chamber too Low Level of material below the "Hopper Min" limit Hopper level too low set in the Alarm Menu Periph Limits SubMenu.
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Alarms, Continued
Alarm message table with cause and remedy, continued
No.
Alarm
98
Hop. too High
99
Hop. empty
100
Hop. spill
101
Belt Load LOW
102
Belt Load HIGH
103
Belt Buildup
200
Belt Mot. Fback
201
Belt Mot. Therm
KSU/WBF.942.001-E.d
Cause
Remedy
Level of material below the "Hopper Max" limit Hopper level too high set in the Alarm Menu Periph Limits SubMenu. Add material to hopper Hopper low level Check the hopper low sensor is active level sensor, map number 22 Remove material from the hopper. Hopper level sensor high is active
Check the hopper high level sensor, map number 23 Increase material weight on the weigh belt. Belt loading is too low Check the "Lo Belt Ld" setting in the Limits Sub-Menu of the Alarm Menu. Reduce material weight on the weigh belt. Check the "Hi Belt Ld" Belt loading is too setting in the Limits high Sub-Menu of the Alarm Menu. Clean the belt and Excess tare on repeat no-load secondary deck calibration sequence. FBR (FeedBack Run) return signal not present when motor is Check belt motor tach. requested to run or (actuator 1) return signal present when motor requested to be stopped Feeder belt motor Check motor for high thermal switch is active
temperature, reset the thermal switch.
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Alarms, Continued
Alarm message table with cause and remedy, continued
No.
Alarm
Cause
Remedy
202
Belt Mot. Over
Motor overspeed.
Check motor and drive, check load on belt.
204
205
208
209
212
213
214
KSU/WBF.942.001-E.d
FBR (FeedBack Run) return signal not present when motor is Check pre-feeder motor Pref Mot. FBack tach. requested to run or (Prefeeder Motor) (actuator 4) return signal present when motor requested to be stopped Prefeeder motor Check motor for high Pref Mot. Therm thermal switch is temperature, reset the (Prefeeder Motor) active thermal switch. FBR (FeedBack Run) return signal not Pref pg. FBack Check proportioning present when motor is (Prefeeder gate drive. requested to run or Proportioning (actuator 0) return signal present Gate) when motor requested to be stopped Pref pg. Therm The motor thermal Check proportioning (Prefeeder protection switch has gate drive, reset thermal Proportioning switch. opened Gate) Both limit switches Pref sg. LSW active at the same time on the prefeeder slide Check limit switches (Prefeeder Slide Gate) gate. Limit switch awaited but not active when Check limit switch open Pref sg. LSWO and gate position. gate requested to open (Prefeeder Slide (actuator 11) or active when gate Gate) requested to close Limit switch close Check limit switch awaited but not active Pref sg. LSWC closed and gate when gate requested (Prefeeder Slide position. to close or active when Gate) (actuator 11) gate requested to open
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Alarms, Continued
Alarm message table with cause and remedy, continued
No.
Alarm
Cause
Feedback not present when vibrator is requested to run or Pref vib. FBack (Prefeed 216 feedback present when vibrator) vibrator requested to be stopped Thermal switch active. The vibrator thermal Pref vib. Therm. 217 (Prefeed vibrator) protection switch has opened Feedback not present when motor is 220
221
224
225
228
KSU/WBF.942.001-E.d
requested to run or feedback present when motor requested to be stopped Thermal switch active. The motor thermal Scraper Therm (Scraper protection switch has Motor) opened Feedback not present when motor is requested to run or Hop fed. FB (Upstream Hopper Feeder Motor) feedback present when motor requested to be stopped Thermal switch active. Hop fed therm The motor thermal (Upstream Hopper protection switch has Feeder Motor) opened Feedback not present when motor is Hop Pg. FBack requested to run or (Upstream Hopper feedback present when Proportioning Gate) motor requested to be stopped Scraper FBack (Scraper Motor)
Remedy Check prefeeder vibrator. (actuator 3)
Check prefeeder vibrator and reset thermal switch. Check chain scraper motor and drive system. (actuator 6) Check chain scraper motor and drive system, reset thermal switch. Check hopper feeder motor and drive system. (actuator 14) Check hopper feeder motor and drive system, reset thermal switch. Check hopper feed gate motor (actuator 2) and drive system.
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Alarms, Continued
Alarm message table with cause and remedy, continued
No.
Alarm
Cause
229
Hop pg. Thermo (Upstream Hopper Proportioning Gate)
Thermal switch active. The motor thermal protection switch has opened
230
Hop Pg. LSW (Upstream Hopper Proportioning Gate)
The gate has reached one of the security limit switches
232
Hop sg1 LSW (Upstream Hopper Inlet Gate)
233
Hop sg1 LSWO (Upstream Hopper Inlet Gate)
234
Hop sg1. LSWC (Upstream Hopper Inlet Gate)
236
Hop sg2 LSW (Upstream Hopper Outlet Gate)
237
Hop sg2 LSWO (Upstream Hopper Outlet Gate)
238
Hop sg2 LSWC (Upstream Hopper Outlet Gate)
KSU/WBF.942.001-E.d
Both limit switches active at the same time. Limit switch open not active when gate V1 requested to open or active when gate requested to close Limit switch close not active when gate V1 requested to close or active when gate V1 requested to open Both limit switches active at the same time. Limit switch open not active when gate V2 requested to open or active when gate requested to close Limit switch close not active when gate V2 requested to close or active when gate V2 requested to open
Remedy Check hopper feeder motor (actuator 2) and drive system, reset thermal switch. Check hopper feeder motor (act. 2) and drive system. Check limit switches of gate V1 (actuator 13) Check limit switches of gate V1 (actuator 13)
Check limit switches of gate V1 (actuator 13) Check limit switches of gate V2 (actuator 9) Check limit switches of gate V2 (actuator 9)
Check limit switches of gate V2 (actuator 9)
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WBF actuators Introduction This diagram shows all of the options associated with the Weigh Belt Feeder. The
table below gives the actuator number references together with details of the configuration of associated commands, inputs and outputs.
CD LSO LSO
2
LS LSC C
13 LSO LSO CD FR TH POS
CD
CD FR TH DC
14
LSC LSC
9
LSO LSO
LS LSC C
HL
LL
CD
LSO LSO
LS LSC C
11
0 LSO LSO CD FR TH POS LSC LSC
3 CD FR TH
CD FR TH DC
MP
4
HL
CL
CD FR TH DC
1 CD FR TH
6
KSU/WBF.942.001-E.d
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WBF actuators Information This table gives the actuator number references together with details of the
configuration associated commands, inputs and outputs as shown on the diagram on theofprevious page.
Actuator / sensor Feeder proportioning gate
No. 0
CD Prefd gate cmd
FBR 15
TH 16
DC
Feeder belt
1
VSD On
14
34
Hopper feed proportionin proportioning g gate
2
Hopper feed cmd
If SCM out ana => nothing
24
25
Feeder hopper vibrator Feeder prefeeder Scraper Hopper inlet gate V2 Hopper outlet gate
3 4 6 9 11
Prefd mot. cmd Prefd mot. cmd Scraper cmd Hf gate2 cmd Pf gate cmd
15 15 35
16 16 36
Silo outlet gate V1 Hopper feed
13 14
Hf gate1 cmd Hopper feed cmd
24
25
LSO 17
LSC 18
POS Prfdr pg pos
26
27
Hop pg pos
30 19
31 20
28
29
Prefeeder
HopFedCmd
Settling chamber high level float (HL) Settling chamber float analog level measurement.
13
Hopper Hi-Low level WBF outlet inlet material presence detector (MP)
22 38
Key:
CD FBR TH DC LSO LSC POS
KSU/WBF.942.001-E.d
Niveau flot
= Command = FeedBack Run = Actuator motor thermal switch = Actuator analog signal command = Limit Switch Open = Limit Switch Closed = Analog input position
Page 33 / 93
23
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New Material Menu Programming Introduction The New Material Menu is helpful when the type of materials being fed is
changed frequently. The menu includes such parameters as Belt Load setpoint, etc. New Material menu entries The table below defines the New Material Menu entries.
Entry
Definition
SETPOINT
Absolute feeder setpoint if "Ratio" control mode is selected.
MAX SETPT
This is the maximum allowable mass flow setpoint to be entered.
MAX LINE SP
Maximum line setpoint displayed if this mode of operation is the selected. represents represents total of the flows of all feedersValue connected to thethe line. Used in fully analog line control.
BELT LD SETPOINT Nominal load on the feeder weigh deck per unit length (kg/m). BELT LD
This is the actual belt loading or weight of material on the belt per unit length of belt.
EMPTYING
Press ENT to empty the weigh belt The feeder will be automatically stopped when the " Blt Empty Lim" specified in the Mechanical Menu Machine Setup SubMenu is reached. This function assumes that the flow of material can be halted by the controller or manually.
STATIC TARE
Press ENT to perform a static tare of the empty belt. This function can only be executed before a dynamic tare of the empty belt, and is accepted without limits over the whole of the load cell measuring range.
To get an accurate static tare, the weigh belt must be clear of product and clean.
KSU/WBF.942.001-E.d
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_______________________ _______________________ _______________________ _________________ ______ ____________ New Material menu entries, continued
Entry BELT TARE
Definition Dynamic Empty Belt Tare Function: This key begins the process of determining the empty weigh belt weight profile. Note: If the Belt Slip feature is functional (Slip Index), the Dynamic Tare function also generates the reference value used to compute belt slip during normal operation.
CONTROL MODE
This entry selects the control mode for the controller.
The selections are available by pressing the key. The following options are available: Local
NEXT
Feeder's setpoint is programmed via the keypad. Setpoint is entered by pressing the NEW SP
key. The following units are used: t/h, kg/h or %. Setpoint modification depends on the configuration of the SETP SRC and PROP SRC parameters in the CNTRL PT SETUP Sub-Menu. Ratio.
The proportional setpoint value of the feeder in % is entered using the New SP key. The actual setpoint is displayed at the Feeder Overview Screen in the selected units. Resulting operating setpoint setpoint * proportional setpoint. = absolute
Line1-Line8: the feeder setpoint is given by the Host. The KSC Smart Commander can handle up to 8 lines.
Setpoint modification depends on the configuration of the SETP SRC and PROP SRC parameters in the CNTRL PT SETUP Sub-Menu of the SYSTEM => SECURITY Menu.
KSU/WBF.942.001-E.d
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Onln Cal Menu Programming Introduction
This section sets the Hasler feeder for OnLine calibration. This menu is only accessible if the Onln Cal options have been selected in the Mechanical Menu Options Sub-Menu. Onln Cal menu entries
Entry
Definition
START OLC
Select this variable and press twice on the ENT key to run on line calibration.
STOP OLC
Select this variable and press twice on the ENT key to stop on line calibration. This is the quantity of material needed (fed) to do the On Line Calibration. This value is expressed in % of Hopper_Nominal_Weight. This is the quantity of material totalized during the automatic calibration sequence. This is the amount of material which must remain in the hopper at any time to ensure acceptable performance of the downstream prefeeding device. This entry is the time needed to the weight in the hopper to stabilize after the inlet closes. This is the period –in seconds-which the calibration process runs when the Start OLC is set. Error calculated during the last calibration cycle. This value is the 1 – ratio delta hopper weight (OLC_Start_Weight – actual Hopper_Weight) divided by OLC_Tot. This indicates the deviation of the actual weight indication used for the belt feeder process. This is the cumulated correction of all subsequent On_Line_Calibration.
OLC QTY
OLC TOT MIN LEVEL
STAB TIME CORR TIME OLC CORR
OLC CUM
KSU/WBF.942.001-E.d
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Alarm Menu Programming Introduction The Alarm menu serves to set the limiting parameters such as Massflow Error,
slippage, drive control limiting values etc. Alarm Sub-menu entries Three submenus are initially presented.
Entry LIMITS PERIPH LIMITS SETUP
Definition Permits the setting of alarm limit values. Sets limits for peripheral devices. Defines how alarms are to be used and presented. Use the chart under alarm section to obtain the necessary alarm code numbers.
Alarm limit menu entries The table below defines the Alarm Limit Menu entries.
Entry
Definition
MF ERR+
This parameter sets the maximum allowable deviation of massflow from setpoint before an alarm occurs. The default value is 10%.
MF ERR--
This parameter sets the minimum allowable deviation of massflow from setpoint before an alarm occurs. The default value is -10%.
LO BELT LD
Minimum deviation of the actual load on the belt relative to the nominal load of material on the belt.
HI BELT LD
MAXIMUM deviation of the actual load on the belt
DC ALRM+
relative to the nominal load of material on the belt. If the Drive Command signal exceeds this value, an alarm occurs. The default value is 100%.
KSU/WBF.942.001-E.d
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Alarm Menu Programming, Continued Alarm limit menu entries, continued
Entry DC ALRMBLT SLP LIM
Definition Alarm 13 is generated when the drive command signal falls below this value. The default is 0.0 %. Limiting belt slip value generating a Belt Slip alarm. Entered in %.
SLIP VAL.
This is the current belt slip value. If greater than the Belt Slip Limit, a Belt Slip alarm occurs if the feature is enabled.
MIN SETPT
Parameter indicating the minimum value for massflow setpoint entry.
Peripheral Limits meunu entries The table below defines the Alarm Peripheral Limits Menu entries.
Entry
Definition
HOPPER MIN
Is the level (in % of Hopper Nominal Weight) which triggers the Hop. too Low alarm 97. Is the level (in % of Hopper Nominal Weight) which triggers the Hop. too High alarm 98. This is the limit allowed for the cumulated value of the OLC. If at the end of a calibration the new OLC_Cumulated should exceed the limit, an "OLC out of tol" alarm 91 is generated and the calibration is aborted. This situation would indicated that a serious
HOPPER MAX OLC LIMIT
problem affects the weighing system (weighing system defect, maladjusted, clogged with too much material, etc…) which prevent the feeder to work properly.
KSU/WBF.942.001-E.d
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Alarm Menu Programming, Continued Alarm Setup menu entries Use this menu to set-up the alarm functions for this controller.
Entry
Definition
ALARM DELAY This is the time a process alarm can be present before the alarm relay is activated. The default value is 30 seconds. STARTUP DELAY
This is the amount of time the process alarms are ignored after a start command. The default value is 60 seconds.
ACT. TIMEOUT The time during which the alarms are delayed while the feeder is running. The default value is 5 seconds. STOPPED BY
This is a Read Only display. This display is used to indicate why the feeder has stopped. The possibilities are: Board Reset: Controller pc is reset. Run Disable: Run Enable Input stopped feeder. Stop Bit: Feeder stopped by external stop input bit Alarm Shutdn: Alarm Shutdown Input stopped feeder. Loc Display: The KSU stopped the feeder. Ext Display: : Stopped KSC Smart Commander. Zero SP: No setpoint, enter a setpoint. Drive Cmd Low: Drive command signal is zero Motor Failure: the drive motor or drive has failed.
SHUTDOWN
Disables shutdown on alarm for all alarms configured, but interlock and emergency alarms remain active. The function is restored after SCM controller power down.
ALRM NO
With an alarm entered with in thistheposition, its functionality cannumber be changed following parameters.
KSU/WBF.942.001-E.d
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Alarm Menu Programming, Continued Alarm set-up menu entries, continued
Entry
ALRM MODE
Definition
i gnored. Ignore: When posted, the specified alarm is ignored. Timed: Displayed alarm message that may disappear of its own accord if the condition having generated the alarm is resolved during the time delay. If the alarm is still present at the end of the time period, the horn (fatal alarm output) is sounded. Immed: The alarm condition to be posted is immediate. Timed Stop: Displayed alarm message that may disappear of its won accord if the condition having generated the alarm is resolved during the time delay. If the alarm is still present at the end of the time period, the horn is sounded and the feeder is stopped. Immed-Stop: The alarm condition to be posted is immediate. The feeder will stop and a re-start must be issued for the machine to run. Timed Susp: This function is used only when the feeder type "LWB" (Loss in Weight Batcher) is selected, When selected, the feed cycle is suspended at the end of the time delay. Immed-Susp: This function is used only when the feeder type "LWB" (Loss in Weight Batcher) is selected. When chosen, the feed cycle is suspended immediately if the alarm is posted.
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Tuning Menu Programming Introduction
The Tuning Menu contains such parameters as Sample Time, Measured Std Deviation, Motor Gain, etc. Tuning menu entries The table below defines the Tuning Menu entries.
Entry
Definition
MF DISP FILT
Shows the number of seconds of smoothing needed to reach 60% of the change of instantaneous flowrate, used for updating the massflow dislay and the massflow analog output. The default value is 15 s. Instantaneous flow
60 %
Smoothe flow Smoothing time in S
DC CEILING
Sets the maximum motor drive command. The range: 0 to 125%. The default is 100%.
SAMPLE TIME Time between two weight signal acquisitions in ms. The acquired value is the average of all measurements made by the load cell. SFT CUTOFF
WGT AVE PERM TOT PID TUNING
KSU/WBF.942.001-E.d
Value in Hertz of the low pass filter. All frequencies below the value entered are automatically filtered. A value of 0.4-0.6 is considered normal. Number of tachometer pulses used to generate an average belt loading value. (WGT AVE * ESPP) Permanent totalizer. Sets parameters for specific tuning needs of the feeder controller.
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KSU/WBF.942.001 E.d
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Tuning Menu Programming, Continued PID tuning sub-menu entries
Entry
Definition
DEVIATION
Shows the error between the feeder setpoint and the output in percentage terms.
OUTPUT
Shows the value of the sum of the correction values applied to the feeder motor command signal.
PROPORTIONAL
Shows the proportional gain contribution to the feeder controller output.
INTEGRAL
Shows the integral contribution to the feeder controller output.
DERIVATIVE
Shows the derivative contribution to the feeder controller output.
PROP BAND
Sets the proportional band for tuning the feeder
INT TIME
controller Enter 0 to cancel. Sets the integral time of the feeder controller. Enter 0 to cancel.
DER TIME
KSU/WBF.942.001-E.d
Sets the derivative time for the feeder controller. Enter 0 to cancel.
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Prefeeder Menu Programming Introduction
The Prefeeder Menu is used to set the prefeeder parameters for Hasler feeders. Prefeeder menu entries The table below defines the Prefeeder Menu entries.
Entry PREFEDR DC
Definition Actual value of Prefeeder drive command.
PREFDR SPAN This is the value, in % of the prefeeder drive command range, which is needed to get from the prefeeder device a throughput equal to the feeder nominal feedrate. In other words, the feeder's nominal feedrate will be equal to the maximum value of the analog output (10 V or 20 mA) multiplied by the prefeeder DC span. GATE POS
Feeder feed gate position in %
FLOAT LEVEL Settling Chamber float level. FLOAT SP
Settling Chamber float level setpoint. MAX ADJUST The level setpoint can be proportionally adjusted according to the measured weight of material on the weigh deck, this correction being performed by a PI regulator, based on the difference between the measured weight and the nominal weight. The effect of the correction cannot exceed "MAX ADJUST MAX". TIME ON Vibratory actuator or cellular wheel running time in OnOff regulation mode. TIME OFF PREFDR PID LEVEL PI PREFDR CONFIG
Vibratory actuator or cellular wheel shut-down time in On-Off regulation mode. Prefeeder PID configuration sub-menu PI regulator configuration sub-menu. Prefeeder parameter configuration sub-menu.
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Prefeeder Menu Programming, Continued Prefdr PID sub-menu entries
The table below defines the Prefdr PID Sub-Menu entries.
Entry
Definition
DEVIATION
Shows the error between the Prefeeder float setpoint and the measured level displayed in %.
OUTPUT
Shows the value of the sum of the correction values applied to the prefeeder command signal.
PROPORTIONAL
Shows the proportional gain contribution to the prefeeder controller output.
INTEGRAL
Shows the integral contribution to the prefeeder controller output.
DERIVATIVE
Shows the derivative contribution to the prefeeder
PROP BAND
controller output. Sets the proportional band for tuning the prefeeder controller Enter 0 to cancel.
KSU/WBF.942.001-E.d
INT TIME
Sets the integral time of the prefeeder controller. Enter 0 to cancel.
DER TIME
Sets the derivative time of the prefeeder controller. Enter 0 to cancel.
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Prefeeder Menu Programming, Continued Level PI sub-menu entries
The table below defines the Prefeeder Level PI Sub-Menu entries.
Entry
Definition
DEVIATION
Shows the difference between the nominal load and the measured load on the weigh deck, displayed in %.
OUTPUT
Shows the value of the sum of the P and I correction values applied to the prefeeder command signal.
PROPORTIONAL
Shows the proportional gain contribution to the prefeeder PI regulator output.
INT
Shows the integral contribution to the prefeeder PI regulator output.
BP
Sets the proportional band for tuning the prefeeder PI regulator. Enter 0 to cancel.
INT TIME
Sets the integral time of the prefeeder PI regulator. Enter 0 to cancel.
KSU/WBF.942.001-E.d
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Prefeeder Menu Programming, Continued Prefdr Config sub-menu entries The table below defines defines the Prefdr Config Config Sub-Menu entries.
Entry
Definition
PREF ALGRTHM
Select {none, belt load, Ch. Level, On Off} this defines which type of regulation is to be performed.
USE SPEED
When "Use Speed" is enabled, prefeeder regulation is computed in two stages. First, a correction is calculated based on the difference between the belt's actual and nominal load. A second correction based on the variation in speed is then computed and added to the first correction factor.
MOTOR TYPE Select the drive type { Standard = actuator 4 }, { 0 }, Prop gate = actuator { Vibratory = actuator . 3 } LIN SEG
Segment number to display and / or modify 0 to 9.
LIN DC IN
PID output segment setpoint. Warning: if a value of zero is entered, the next segments will not be taken into account. If segmentation is used, the last segment must have a value of 100% to enable the valve to fully open.
LIN DC OUT
Desired proportionig gate command output value. Warning: if a value of zero is entered, the next segments will not be taken into account. If segmentation is used, the last Lin DC In segment must have a value of 100% and Lin DC Out = 100% to enable the valve to fully open.
CLOSE POS
Position of proportionig gate when feeder stopped. To fully close enter a value to or read greater than 0.2 % the but gate, always greater thanequal the value in "Gate Pos" when it is closed. If equal to zero, the proportioning gate will remain in its last position.
KSU/WBF.942.001-E.d
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Prefeeder Menu Programming, Continued Prefdr Config sub-menu entries The table below defines defines the Prefdr Config Config Sub-Menu entries. SLIDE GATE
FLOAT VIBTHR
Select {disable, enable} this defines if a slide gate is present or not. Generally used in conjunction with a proportioning gate as feeding device. The slide gate is placed before the prop. Gate to avoid material pressure 11 }. when closed. {actuator .11 Select {none, dig. High, analog} defines which type of level sensor is used in the settling chamber. Level at which the vibrator mounted on the feed hopper is actuated.
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Hopper Menu Programming Introduction The Hopper menu sets some hopper parameters for Hasler feeder. Hopper Menu entries The table below defines the Hopper Menu entries.
Entry
Definition
HOPPER WT
The net weight of material in the hopper. HOPPER MOT DC Control voltage of the hopper feeding drive. HOP PG P0S HOP DC SPAN
HOPPER LOW HOPPER HI LEVEL SP NOM WEIGHT
This value is the percentage of hopper feed proportioning gate position in percent open. This is the value, in % of the hopper feed drive command range, which is needed to get from the hopper feed a throughput equal to the feeder nominal feedrate. In other words, the feeder's nominal feedrate will be equal to the maximum value of the analog output (10 V or 20 mA) multiplied by the hopper motor DC span. Is the level (in % of Hopper Nom Weight ) which triggers the filling of the hopper. Is the level (in % of Hopper Nom Weight) which stops the filling of the hopper. This value defines the level of material to be maintained constant by the hopper feed regulation. This value defines the maximum hopper contents.
CONFIG
Hopper feed regulation mode, gate (etc.) configuration sub-menu
PID DENSITY
Hopper feed PID configuration sub-menu Material density configuration sub-menu.
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Hopper Menu Programming, Continued Config sub-menu entries The table below defines the Config Sub-Menu entries.
Entry
Definition
PREF ALGRTHM
Select {none, level, limits} This is a configuration value which define the regulation type of hopper process. - None: there is no no hopper filling regulation. regulation. Hopper is only weighed. - Level: the hopper feeding feeding is regulated to maintain the hopper level defined by Hopper_Level_Setpoint. - Limits: the hopper feeding is controlled by two level threshold, Hopper_High_Level and Hopper_Low_Level
MOT TYPE
Select { Standard = actuator
14
} or { Prop. gate =
2
actuator } to the type of hopper feeding device so the SCM candefine handle it appropriately. LIN SEG
Segment number to display and / or modify 0 to 9.
LIN DC IN
PID output segment setpoint. Warning: if a value of zero is entered, the next segments will not be taken into account. If segmentation is used, the last segment must have a value of 100% to enable the valve to fully open.
LIN DC OUT
Desired value for the proportionig gate command output. Warning: if a value of zero is entered, the next segments will not be taken into account. If segmentation is used, the last Lin DC In segment must have a value of 100% and Lin DC Out = 100% to enable the valve to fully open.
CLOSE POS
Position of proportionig gate upon feeder shut--down. To fully close the gate, enter a value equal to or greater than 0.2 % but always greater than the value read in "Hop Pg Pos" when it is closed. If equal to zero, the proportioning gate will remain in its last position.
SLIDE GATE1
Select {disable, enable} this defines if a slide gate 13. {actuator } is present or not. The slide gate is placed before the prop. Gate to avoid material pressure on the gate.
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Hopper Menu Programming, Continued
Config sub-menu entries, continued
The table below defines the Config Sub-Menu entries. SLIDE GATE 2 Select { disable, enable } This defines if a second slide 9 gate {actuator . } is present or not. This second slide gate is placed directly at the hopper inlet. Because the feeding device (generally a prop. Gate) is not always placed immediately at the hopper inlet, and that there is usually a relative long transfer time to the hopper, this gate ensure that the hopper inlet is really closed when performing an On Line Calibration. SG2 STOP DEL Delay between installation shut-down and closure of SG2.
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Hopper Menu Programming, Continued PID sub-menu entries The table below defines the PID Sub-Menu entries.
Entry
Definition
DEVIATION
Shows the error between the Hopper material level setpoint and the measured level, displayed in %.
OUTPUT
Shows the value of the sum of the correction values applied to the hopper feed command signal.
PROPORTIONAL
Shows the proportional gain contribution to the hopper feed controller output.
INTEGRAL
Shows the integral contribution to the hopper feed controller output.
DERIVATIVE
Shows the derivative contribution to the hopper feed controller output.
PROP BAND
Sets the proportional band for tuning the hopper feed controller Enter 0 to cancel.
INT TIME
Sets the integral time of the hopper feed controller. Enter 0 to cancel.
DER TIME
Sets the derivative time of the hopper feed controller. Enter 0 to cancel.
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Hopper Menu Programming, Continued Density Sub-menu entries The table below defines the Density Sub-Menu entries.
Entry
Definition
AP DIST
Shows the distance between the On-Off material presence sensor MP (Input map 38) and the last weigh deck delivery roller, in other words, the position of the weigh deck delivery roller in meters. Material presence sensor
Minimum (m) NOM COEFF
Correction coefficient for adjusting the weigh deck weight measurement and that of the hopper. If this entry is set to zero, the density measurement compensation is disabled.
REG NOMWT Nominal weight of material in the hopper computed according to the density measured on the weigh deck.
If Nom Coeff = 0, the value of this parameters is equal to the hopper nominal weight, otherwise it is equal to the net weight from the weigh deck multiplied by Nom Coeff.
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Scale Menu Programming Introduction
The Scale Menu is used to program the Scale parameters such as Scale Range, Tare, Span for Calibration and SFTs. Scale Sub-Menus Sub-Menus This menu comprises several sub-menus.
Entry
Definition
MAIN DECK
Takes the user to the weight belt feeder weigh deck scale menu for calibration and reading weight information
SECONDARY DECK
Menu used to set all parameters for a second (optional) weigh deck installed ahead of the inlet section.
HOPPER
Sets all weighing-related parameters of the hopper used
SFT SCALE
with a Hasler feeder. This sub-menu is used for configuring all the load cells connected to the SCM controller.
DIAGNOSTICS This sub-menu is used to diagnose problems of communication with the load cells. ANALOG LD CELL
This sub-menu serves to programme the analog cells connected to the controller via suitable converter(s).
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Scale Menu Programming, Continued Main Deck sub-menu entries The table below defines the Main Deck Menu entries.
Entry
Definition
NET WT
This is the net weight of material in the hopper if the feeder system has been properly tared. Gross - Tare = Net Weight (in kg).
This is a read only variable. TARE
This is approximately the gross weight on the weigh deck with the belt in place but without material. This value can be entered in engineering units from the keypad as well as being entered automatically by doing the Static Tare function from the NEW MATERIAL Menu. This value should be close to the actual dynamic tare values used for normal operation but it may not agree exactly.
Do not enter a known value into this variable unless a dynamic tare cannot be performed. GROSS WEIGHT This is the gross amount of weight on the scale in kg. This is a read only variable. SPAN
This is the weight measurement correction coefficient. Also used to enter the reference of a lever arm used in the weighing system. The lever arm is then computed from the ratio of load cell lever arm / weighing idler lever arm. You should expect that the number displayed in units 1.0000.
SCALE RANGE
KSU/WBF.942.001-E.d
This is the gross range of the scale in kg.
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Scale Menu Programming, Continued Secondary Deck sub menu entries These entries are only used when a secondary weigh deck is installed ahead of
the inlet section.
Entry NET WT GROSS WEIGHT TARE
SCALE RANGE DECK GAP STATIC TARE
Definition Net weight on SFT under secondary weigh deck. Gross weight on SFT under secondary weigh deck. Actual tare weight returned from the Static Tare function. Record this value for reference. This value should be close to the actual dynamic tare values used during operation. This is the maximum range of the scale in kg (SFT). Distance between first and secondary weigh elements. Press ENT to perform a static tare of the empty belt for the weigh deck installed upstream of the feed hopper. This function can only be executed before a dynamic tare of the empty belt, and is accepted without limits over the whole of the load cell measuring range.
To get an accurate static tare, the weigh belt must be clear of product and clean.
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Scale Menu Programming, Continued Hopper sub menu entries
These entries are used for hopper weighing systems. Entry
Definition
HOP NET WT
Actual hopper net or material weight.
HOP GR WT
Gross weight as indicated in the feeder hopper.
TARE WT
Tare weight taken when the tare is completed
FILT TIME
This value is the amount of filter applied to the hopper weight acquisition display. This value represents the number of seconds used in each update. The default value is 5 seconds.
HOPPER TARE
Permits tare function to be performed on an empty feeder hopper Only to be used when hopper empty.
HOP SCLE RNG
This gives the nominal capacity of hopper load cells.
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Scale Menu Programming, Continued General SFT Scale sub- menu entries
Entry SFTs
Definition
Please note that only SFTs with software version "N" and above are supported by the SCM.
This variable displays the addresses of all active SFTs on this feeder. Example = -1- - - - - - - - - If any of the following are displayed, an error is indicated. " ? " = Invalid response from SFT " - " = No SFT at that address " T " = SFT no longer responds to controller " f " = SFT communicates but has failed internally SFT REQUIRED
This variable selects the number of SFTs required for this feeder. For a single WBF without options one (1) or two (2) SFT is normal. If some number other than the required SFT’s is present, the controller will switch to Vol and an alarm will occur.
SFT SELECTED
This variable selects the address of the SFT, whose parameters will be displayed.
SFT ADDRESSED
This variable reads is the SFT sensor is recognised with its address and used or if not. This variable displays the gross weight of the SFT selected.
SFT WEIGHT SFT RANGE
This gives the nominal capacity of the load cell.
Continued on next page
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Scale Menu Programming, Continued SFT scale menu entries continued
Entry
Definition
SFT TYPE
This variable displays the the range of the selected SFT. The Scale range is given by the last numbers indicated in kilos.
SFT STATUS
This display indicates the operating status of the SFT. Normally shows the number 1 or 3. where 181 = SFT operating in synchronous mode where 183 = SFT is synchronous mode address leader and is operating in synchronous mode. Status numbers other that that shown may indicate a faulty SFT. Contact Hasler Suisse’s service department.
SFT S/W REPOLL SFT
KSU/WBF.942.001-E.d
Software for SFTs By pressing the ENTER key twice, the SCM controller detects all the SFTs connected to, the weight transmission channels. When this is done, the SFTs will be addressed to the SFT connector number on the SCM to which they are attached. This function is only used when putting a new load cell into service.
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, continued Diagnostics sub-menu entries
This sub-menu serves only to diagnose communications with the SFTs.
Entry MESSAGES FAILED TIMEOUT NAK RETRY
Definition Messages sent via SFTs. Message not understood by the SCM. Message reception time delay exceeded. Command sent to SFT not acknowledged. Resent command to SFT.
ERR_ADRR
SFT address number having generated the error.
ERR_CMD
Command sent has generated an error.
RESET
Reset counters to zero.
Analog Ld Cell sub-menu entries,
This sub-menu is used only to calibrate the analog cell weighing references.
Entry
Definition
SFT SELECTED
Selects the analog cell for which the parameters are to be read.
CAL. WGT
Standard weight used for calibrating the analog cell weighing system.
CAL.LEV.RAT
Lever arm ratio i.e., reference weight lever arm / load cell lever arm.
NULL PT CALIBRATION
Storage of null point Storage of reference point with standard weight. In principle, analog cell calibration is performed as follows: 1. Run NULL PT with no material and no standard standard weight.
2. Place the standard weight in the feeder and run CALIBRATION.
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Input/Output Menu Programming Introduction
The Input/Output Menu is used to set the assignment for the four submenus:
REF: For a description of how to wire SCM I/O you will need to refer to the SCM Commissioning manual. See document SCM-APSR.943.001-e.a for information on the ASR (alarm status register), PSR (process status register) word and numerical codes for Input/Output functions, which gives the numbers of programmable functions not included in the proposed lists. Input/Output sub-menu entries The table below defines the Input/Output Menu entries.
Entry
Definition BIT OUTPUT Configures digital outputs. BIT INPUTS Configures digital inputs ANALOG OUT Configures analog outputs. ANALOG IN Configures analog inputs. MANUAL MODE
Manually tests each of the actuators configured on the weigh belt feeder, in such a way that all the digital and analog inputs and outputs used by the actuator are tested in a single operation. Continued on next page
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Input/Output Menu Programming, Continued Bit Output sub-menu
Entry
BOUT NUM [1-16]
B. FUNC.
Definition
This entry sets the node for the specific output bits 1-16. Entry 1 is for SCM Relay #1, entry 2 is for Relay #2, and entry #3 is for relay #3 (this configuration may differ according to LON links). Numbers from 4-16 are for external LON outputs The entry sets the function assigned to the selected output bit to do one of the following: None, Feeder Run, Any Alarm, Hard Alarm, Drive Ena, Mass Mode, PSR Map, ASR Map, Tare Ongoing, pf mot cmd, pf gate cmd, scrap. cmd, h.f. cmd, hf gate1 cm, hf gate 2 cmd, cmd,
BOUT STATE
Current state of output 0 = low, 4 = high.
MAP NUM.
Enter the PSR or ASR bit map number to be assigned to the output.
POLARITY
Select Normal or Reverse. Select Reverse to reverse the polarity of an output.
EXT TOT INC
Sets the weight increment of each external totalizer pulse
Continued on next page
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Input/Output Menu Programming, Continued Bit output PSR (Process Status Register) map configuration
This list thatPSR shows what numbers to enter in an theoutput Map Number to useisaaspecific –Process function data bit as function.(Num)
See document SCM-APSR.943.001-e.a for information on the PSR word and numerical codes.
Bit output ASR (Alarm Status Register) alarm bit map configuration configuration
This is a list that shows what numbers to enter in the Map Num to use a specific ASR – Alarm data bit as an output function.
See document SCM-APSR.943.001-e.a for information on the PSR word and numerical codes. Continued on next page
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Input/Output Menu Programming, Continued Bit Input sub-menu
Entry
Definition
B. FUNC.
The entry sets the function of the selected input bit to do one of the following:
BIN NUM [1-24] This entry sets the node for the specific input bits 1 to 24. Entry 1 is for SCM physical input "signal 3", entry 2 for the "signal "signal 4" input and entry 3 for "signal 5" input, (this configuration may differ according to LON links). Numbers from 4-24 are for external LON inputs. i nputs.
None, Start, Stop, Interlock, Run Enable, Alarm Ack, Alarm Clr, Start/Stop, Vol Mode, Emergency, Ext. Alarm, Aux/Main., Tot inhibit, Start OLC, Stop OLC, Belt Drift, Belt mot. FB, Belt mot. Th, Input map. map. BIN MAP.
For entering the numbers of functions not included in the above list.
POLARITY
Select Normal or Reverse. Select Reverse to reverse the polarity of an input.
BIN STATE
Current state of output 0 = low, 4 = high, 3 = unassigned input
Continued on next page
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Input/Output Menu Programming, Continued I/O Analog Out sub-menu
Entry
AOUT NUM [1-8] A. FUNC.
Definition
Sets the I-O number from 1-8.
This entry sets the variable assigned to the analog output. None Massflow
Actual average flow rate
Setpoint
Actual setpoint applied to the feeder
Net weight
Actual weight on the weigh deck
Drive Cmd.
Feeder motor setpoint
Motor speed Actual feeder motor rpm Prefdr
Prefeeder motor setpoint
Actual load per meter of feeder trans length Belt loading Actual Belt speed Actual feeder belt speed Hopper wt Actual weighed hopper weight HopFed Cmd Hopper feed motor setpoint Float level Float level of the settling chamber AOUT VAL%
Shows the percentage of output based upon scaling. 100% = 20mA or 10 Vdc.
AOUT MAX
Sets the maximum value for the analog output (in percent).
AOUT MIN
Sets the minimum value for the analog output (in percent).
AOUT DBAND
Sets the amount of deadband for the selected input in percent of full scale. To avoid overloading LON communications, the auto-initialized value of 1 % is
AOUT UNITS
suitable for most applications. This entry sets the type of analog output of the SCM aux. board".
This function is not assigned to the selected output number, it is only assigned to the analog output controlling the variable drive connected to the SCM terminal block. Volts: 10 VDC = 100% or mA : 20 mA = 100%
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Input/Output Menu Programming, Continued Example of analog output configuration Configuration analog output 3 connected to output (LON Setup software connection) of of theSCM Wago module withnumber feeder flowrate within a rangeXfrom 4 to 20 mA:
Step
Action
1
Check that the Wago module used for the output is a 0 (4)- 20 mA module. Select output number 3 using the Aout Num(1-8) function. Set A. Func to Massflow Set Aout Max to obtain the desired max analog output value of 20mA, i.e. 100%. Set Aout Min to obtain the desired minimum analog output value of 4mA, i.e. 20 %. Adjust the precision of analog output correction by means of the Aout Dband function To avoid overloading LON communications, the autoinitialized value of 1 % is suitable for most applications.
2 3 4 5 6
Continued on next page
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Input/Output Menu Programming, Continued I/O Analog Out sub-menu
Entry
AIN NUM (1-8) A. FUNC.
Definition Sets the I-O number from 1-8. This entry sets the variable assigned to the analog input. None Setpoint
Absolute feeder setpoint
Prop setpoint
Proportional feeder setpoint
Float level
Settling Chamber float level.
Hop level Analog value representing the weight of the hopper (where there is no hopper load cell Prfdr pg pos. Copies the prefeeder proportioning gate position Hop pg pg pos. pos. Copies the the hopper inlet proportioning proportioning gate position AIN VAL%
Shows the percentage of input based upon scaling. From 0 % for 0 V or 0 = mA to 100 % for 10 V or 20mA.
AIN ZERO PT
Shifts the zero point of the analog input upward Enter value as a percentage of maximum range. If a 0 – 20 mA Wago module is used in a 4 – 20 mA configuration, enter 20% in this variable.
MIN VALUE
Minimum reference value in percent of the assigned variable. Set to 100% for measuring float level on Powdrit feeder.
MAX VALUE
Maximum reference value in percent of the assigned variable. Set to 0 % for measuring float level on Powdrit feeder.
RATIO DB(%)
Requires the input to change by more than this entry value to permit the value to change its variable value. The entry is in %. To avoid overloading LON communications, the autoinitialized value of 2 % is suitable for most applications.
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Input/Output Menu Programming, Continued Manual Mode sub-menu
Entry
ACTUATOR
Definition
This variable defines the type of motor actuator to activate: Belt Prefeeding Prefeeder gate Scrapper Hopper mot. Hop gate 1 Hop gate 2
SETPOINT
Defines feeder and supply actuator speed or opening setpoints. value between maximumEnter speedaor opening. 0 and 100 % for 0 to
START
Starts the actuator after confirming with "ENT".
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Mechanical Menu Programming Introduction
The Mechanical Menu sets up the mechanical parameters for the feeder. E.g.: Feeder Type, Gear Teeth, Reduction, etc. Mechanical menu sub-menus This is a listing of submenus used with the weigh belt feeder.
Sub-menu
Definition
MACHINE SETUP Selects parameters to program characteristics of the feeder. ACTUATOR MISC
the
physical
Selects parameters to program the physical characteristics of the motor and motor drive. Miscellaneous parameters for configuration.
SCRAPER
Sets the feeder material scraper options.
OPTIONS
Enables and disables certain functions.
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Mechanical Menu Programming, Continued Machine Setup sub-menu entries entries
The table below defines the Machine Setup Menu entries.
Entry
Definition
FDR TYPE.
Selects either, GRAVIT, POWDRIT feeder.
BELT LEN
Defines the belt length for the feeder.
PULLEY DIA
Drive pulley diameter.
REDUCTION
This is the total gear reduction between the motor and the drum. This value is found from the Engineering Spec Sheets or by multiplying the gear reductions shown on the nameplates of the different reduction levels
WHEEL DIA DIA
Diameter of the speed measuring wheel appears if wheel position is selected in the Mechanical Menu, Motor Setup Sub-Menu, Pickup Locat. entry
TRANS LEN
Transport length used to determine transport delay times.
DECK LEN
Deck length used to determine weight to belt loading computation.
BLT EMPTY LI
Lower belt load limit in % of full belt load (BLT LD SETP) to stop the machine.
NOM BLT SPD
The computed value of nominal belt speed that would be expected when the Max Spt and Belt Load Setpoint are entered.
SERVMAN IDX
This numerical entry selects one of many service variables whose value will be displayed in the Servman Val variable. See document SCM-APSR.943.001-e.a. SCM-APSR.943.001-e.a.
SERVMAN VAL
This is the value for the selected Serviceman Index. See document SCM-APSR.943.001-e.a. SCM-APSR.943.001-e.a.
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Mechanical Menu Programming, Continued
Motor Setup sub-menu
Entry
Definition
MAX MOT SPD
Sets the maximum motor rpm for 100% drive command. See motor nameplate for proper entry.
MIN MOT SPD
Sets the minimum motor rpm to be run.
MAX MOT PWR
Enter the rated motor power here. Units are watts.
PCKP LOCAT
Specified for the speed pick-up location. Motor, Drum (Idler Roller), Wheel.
Use for standard Gravit feeder machines PICKUP TEETH
This parameter allows you to enter the number of teeth on the speed pick-up. pick-up. Refer to feeder Spec sheet for number of teeth. Most current Hasler feeders use a 50 tooth gear. Older Hasler units used a 60 tooth gear. Check before entering any value.
SPEED CORR
During the tare cycle, the actual belt speed is compared with the requested belt speed. Any difference is displayed as an error here. Perfect correlation is 100%.
ACT MOT PWR
Shows the motor power consumption, essentially used with Ktron auxiliary boards.
ACTUAL TEMP
Shows the temperature of the inside of the SCM casing in deg. C.
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Mechanical Menu Programming, Continued Misc sub-menu
Entry
Definition
START DIST
The distance covered while the feeder stays in Volumetric control after being started in Gravimetric control. Unit = metre length of belt.
INTLK TIME
The time interval if exceeded in which a Start command will be cleared if the Interlock is not released to permit a start.
TARE LEN
The length of the belt in % of one belt length over which a tare is to occur. 100% is one belt length. Avoid values that are not whole multiples of 100%.
EMPTY LEN
The length of the belt in % of one belt length over which the batcher will run to empty the belt.
DRFT LEN
The distance the belt travel after the Belt Drift detector is contacted formust an alarm to occur
Scraper sub-menu entries
Entry
Definition
SCRAP ON
Defines the amount of time the scraper is running. (actuator 6)
SCRAP OFF
Defines the amount of time the scraper is off. (act. 6)
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Mechanical Menu Programming, Continued Options sub-menu
Entry PREFEEDER
Definition Enables / disables prefeeder system programming Actuators
SECOND DECK
14
,
2
,
9
,
13
.
Enables / disables second weigh bridge programming.
BELT INDEX
Enables / disables belt index detector function.
SLIP INDEX
Enables / disables belt slip index detector function, using a second detector.
Note: This feature can be used if the velocity sensor is installed on the idler roller. This variable must be set to prior to doing a Dynamic Tare so that the slip reference data can be generated. ONLN CAL F. SPD START.
HOPPER EMPTY/STOP SCRAPER INTKL READY
Enables / disables the auto tare function. Enables / disables feeder start-up at nominal speed. Nominal speed is maintained until material is present on the weigh bridge. Enables / disables programming.
upstream
weighing
hopper
Enable/Disables Empty/Stop programming data Enables / disables scraper programming. Actuator
6
Enables/Disables the Interlock function that prevents a start from occurring if an interlock is present. If disabled, the feeder can receive the run request but will only start when the interlock signal is i s present.
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System Menu Programming Introduction
This section shows the submenus and menus for system set-up. System sub menu entries This entry is used to select the proper menu for system set-up.
Entry
Definition
FDR BEING VIEWED Feeder number to which the KSU display is logically attached.
This feature permits the single KSU to talk to other SCM devices rather than the one it is connected to without rewiring. Enter the number of the peripheral with which you wish to communicate and press Enter, the KSU say “Reconnecting KSU – please wait” whilewill undergoing re-assignment. SECURITY
Sets KSU menu access permissions and selects the control mode for this SCM. There are three possible levels of security: Oper: = Operator Mgr: = Manager Maint. = Maintenance
COMMUNICATIONS Provides the communications set-up for a Host PC and related elements. A NET MANAGEMENT sub-sub menu is also shown. GENERAL
Determines the basic set-up of the SCM and KSU.
SYSTEM SETUP
This menu is used to configure the SCM on the LON network.
SW VERSIONS
Displays controller software versions E.g.: CTRL SW 2900.0030 VERSION
4.02 (software version number)
AUX BD S/W 20920-J
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System Menu Programming, Continued Security sub-menu Security Level settings
This sub-menu sets KSU programming programming access levels.
Level Oper
Programming Access The operator may perform the following tasks: Menu
Task
MAIN MENU
Setpoint, Clear Totalizer
NEW MATERIAL
Emptying
ONLN CAL
START OLC, STOP OLC
This level also limits certain menus and data within menus from being either seen or changed without unlocking the console. Mgr
This is considered to be the manager level. This level can change the following parameters plus those of the Oper. Level. Menu
Task
NEW MATERIAL
Belt Load Setpoint, Max Spt
ONLN CAL
OLC Qty
ALARMS
All parameters
TUNING
MF DISP FILT., DC CEILING, INT TIME
Maint This level gives unlimited access to all variables.
Note: The security switch or key lock (if installed) allows security levels to be changed but full access to all levels can only be enabled with the "Maint" command.
Note: If the KSU security switch is closed, all accessible functions and parameters in the different levels can be executed.
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System Menu Programming, Continued Security sub-menu Act Control Pt. settings
This entry is used to select the source of the commands and setpoints operating the SCM controller.
Choice
Definition
Main
In the majority of cases this operating mode is used when commands are issued to the controller from the Host PC or KSC. This mode is configured using Ctrl Pt Setup
Auxiliary
This mode is used as a semi-manual mode when the commands originate from different locations, e.g.: Local KSU and digital input. This mode is configured using Ctrl Pt Setup
Maint
This mode is generally used by the maintenance technicians, it is generally configured for all commands to come from the Local KSU. This mode is configured using Ctrl Pt Setup
Security sub-menu Ctl Pt. Setup settings
This entry is used to configure the different operating modes described above, for the absolute setpoint, the proportional setpoint and commands. S
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SET SRC l l o lo c a U K S
KSU rem K S C C / H o s st t I / / O
A l l
KSU Local
KSURemote
KSC or Host
Inputs / Outputs
All options
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System Menu Programming, Continued Security sub-menu Ctl Pt. Setup settings This parameter is used to configure the different operating modes described
above. S
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PROP SRC l lo c a l o U K S
KSU rem K S C / H o s st t
Local KSU
Remote KSU
KSC or Host
I / / O
A l l
Inputs / Ouputs
All options
Security sub-menu Ctl Pt. Setup settings This parameter is used to configure the different operating modes described above.
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System Menu Programming, Continued Communication sub-menu entries This entry is used to select the proper menu for communications system set-up.
Entry
Definition
HOST PROT
Sets the protocol for communication with a Host PC: None, Modbus, A-B, Siemens, Config, Maint.
Use security level for configuration. X4 PORT
Sets the structure for the K-Link communication port to the Smart Commander or PLC. Select either: RS232, or RS485. The X4 port is a 10 position terminal strip on the SCM that is used for low speed data communication.
The Host Prot and X4 Port values will also depend upon the type of communication personality module used for external data transfer. If ProfibusDP personality module is used, the port will automatically assign the host protocol and X4 configuration suitable for ProfibusDP. If an Ethernet card is used, the Ethernet protocol will be assigned, etc. CONF PROT
MAINT ADDR
Sets up the way in which the DB-9 Config port is used. This serial port is the male DB-9 connector on the SCM. Select None, Maintenance, Config or Printer. KSC or Modbus Host address.
CONF PORT
Selects the port for RS232 communication: DB-9 connector or IR Port (IrDA)
REFRESH RATE
Time between two messages send on host, only with daughterboard.
NET MANAGEMENT
Used to examine LON elements.
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System Menu Programming, Continued Net Management sub-menu entries This entry is used to select the proper menu for Lon Management set-up.
Entry
UTIL FLOAT
Definition Disables or enables LON Alarms Used for LON debug Used for LON debug
NODE LOAD
% of LON loading for that particular node.
DIAG NODE
Defines the LON node currently under test to which the entries of this menu will be sent.
NET ALARMS UTIL INTEGER
XMIT ERR
Number of transmission errors.
TRANS TO
Number of transmissions.
RCV TR FULL LOST MSGS
timed-out
communications
Message reception buffer saturated. Number of lost messages.
or
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System Menu Programming, Continued
General sub-menu entries Use this menu to select basic SCM functions.
Entry
Definition
RUN TIME
The time in hours the feeder has run since last stopped.
UNITS
This parameter is used to select the units to be used by the controller. The options are as follows: Kg/hr, kg/min, lb/hr, T/hr, g/hr, g/min.
MACH TYPE
lb/min,
metric t/hr, Eng.
Select the type of machine that this SCM will connect to: SCM_Generic, SCM_LWF, SCM_WBF, SCM_PID, SCM_LWB, SCM_WBB, SCM_SFM, SCM_SFB.
Changing this entry will clear the memory. FDR ADDR
Shows the address of this SCM. It can be changed by entering another value. The new value cannot be the same as any other in the network.
Changing the SCM LON address number will clear the LON links to the SCM. LANGUAGE
Defines the language, i.e.: English, Français, Deutsch, Italiano, Portugese, Espanol.
CLEAR MEMORY
Clears feeder entries from the memory zone. Corresponds to the "Parameter Memory" zone of the Loader application.
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System Menu Programming, Continued System Setup Sub-Menu SYSTEM
This menu is used to configure the LON network, address an SCM and connect variables to functions and is generally used for troubleshooting. SmartConnex LON IO setup utility software is recommended for settingup a LON network
Entry
Definition
FIND NODES
This is a function that will scan the LON network for un-configured (zero addressed) nodes. When a new node is found, its type is displayed in the NODE TYPE parameter. If a new node is found, a command is automatically sent to force the node to identify itself. This command may be repeated as much as needed to force the command to be executed.
Note: A node that is added to the LON network will be forced to an address of “0”. NODE TYPE
This is a string that displays the type of the node that was found. If no node was found, “None” will be displayed.
DEST ADDR
This is an integer that is the destination address of the last node found. When FIND NODES locates a zero addressed node, entering a nonzero number here will assign that address to the new node.
WINK ADDR.
If you enter the address of a node on the network, a wink command will be sent to that node. This function is used to check the index of the node to be found by flashing the red LED on the LON node for a few seconds. This does not work for zero addressed nodes. If you want to wink the next zero addressed (unconfigured) node, use the FIND NODES command
UNBIND ADDR Disconnects all variables from a given device address.
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System Menu Programming, Continued System Setup Sub-Menu SYSTEM, continued
Entry
REMV ADDR
Definition If you wish to remove an addressed node from the system, simply enter it’s address here and the node will be disconnected and removed (LON device address reset to zero). If you do a FIND FIND NODES command after removing a node, you will find the newly removed node at address “0”. The device can now be removed physically from the LON network. To complete the process, set the REMV ADDR to “0” and press ENT. Note: Before you can remove a node, it must be unbound.
REPL ADDR
Assigns a dead node address to a newly installed LON device.
LAST RESULT This string contains the result of the last function invoked. It will be set to “OK” if everything executed normally, otherwise an error message will be displayed. di splayed. BINDING
This sub-menu is used to attach variables to functions in the SCM.
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System Menu Programming, Continued System Setup menu Binding sub-menu
Use this menu to connect variables to functions.
Entry
Definition
BIND ADDR. 1
These four parameters describe the two ends of a variable binding. In the BIND ADDR fields, the addresses of the source and destination nodes are set. In the BIND VAR, the index of the source and destination variables is set.
BIND VAR 1
See above.
BIND ADDR 2
See above.
BIND VAR 2
See above.
BIND NOW
This function binds the variables described in the BIND VAR and BIND ADDR parameters.
UNBIND NOW
This function unbinds the variables described in the BIND VAR and BIND ADDR parameters. Since unbinding actually only requires that one end be described, it is sufficient to enter only one end of a binding in the BIND ADDR 1 and BIND VAR 1 parameters before invoking this function.
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Maintenance Menu Programming Introduction
This section provides some diagnostics for weigh belt feeder applications. For maintenance technicians only. All the status functions are given below for the purpose of noting readings.
Maintenance menu entries
Entry CALIB STATUS
Definition Gives the status of the various feeder tares and calibrations
STATE MACHINES
Gives the step number of the cycle in progress for the different tare and regulation functions
BELT MVT
Provides information on speeds and effective index positions.
BELT PARMS BELT TARE DEBUG 3
Provides information on weight spaces, belt, belt index, slip index. Provides information on segmented tare. Gives the gross feedrate used by the PID regulator.
INPUT/OUTPUT Gives the physical position of inputs and outputs on the SCM. SIMULATION
Allows weighed hopper weight simulation to be performed.
Hopper simulation does not stop the normal operation of the feeder's other actuators. Calib Status sub-menu entries
Entry WB
Definition A display reading “----“means non calibrated. “O.K.” indicates that weigh deck calibration has been correctly performed.
BELT
A display reading “----“means non calibrated. “O.K.” indicates that tare of empty belt has been correctly performed.
HOPPER
A display reading “----“means non calibrated. “O.K.” indicates that hopper calibration has been correctly performed.
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Maintenance Overview Introduction
The section covers all SCM menus, sub-menus and entries associated with the KSU. Those entries not described in this document are only intended to be used by Hasler technicians. A series of forms are also included for noting the SCM controller parameters.
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KSU WBF application Program Sheet Introduction
This table is provided to enable you to record your controller programming parameters. It is suggested that copies be made for your records. WBF program sheet MENU NEW MATERIAL
Pa Para rame mete terr desc descri ript ptio ion n
Pa Para rame mete terr desc descri ript ptio ion n
Para Parame mete terr de desc scrip ripti tion on
Value
SETPOINT MAX SETPT MAX LINE SP BLT LD SETPT BELT LD
Read only
EMPTYING
Function
STATIC TARE
Tare
BELT TARE
Calibration
CONTROL MODE
Source of Prop. Setpoint
START OLC
Calibration
STOP OLC
Stop Auto calibration
ONLN CAL
OLC QTY OLC TOT
Read only
MIN LEV. STAB TIME CORR TIME OLC CORR OLC CUM
ALARM LIMITS MF ERR + MF ERR LO BELT LD HI BELT LD DC ALRM + DC ALRM BLT SLP LIM SLIP VAL.
Read only
MIN SETPT
Read oly
PERIPH LIMITS HOPPER MIN HOPPER MAX OLC LIMIT
SETUP ALARM DELAY STARTUP DELAY ACT. TIMEOUT STOPPED BY SHUTDOWN ALARM NUM ALARM MODE
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KSU WBF application Program Sheet WBF program sheet TUNING MF DISP FILT DC CEILING SAMPLE TIME(mS) SFT CUTOFF WGT.AVG PERM TOT
Read only
PID TUNING DEVIATION
Read only
OUTPUT
Read only
PROPORTIONAL
Read only
INTEGRAL
Read only
DERIVATIVE
Read only
PROP BAND INT TIME DER TIME
PREFEEDER PREFDR DC
Read only
PREFDR SPAN GATE POS
Read only
FLOAT LEVEL
Read only
FLOAT SP MAX ADJUST TIME ON TIME OFF PREFDR PID DEVIATION
Read only
OUTPUT
Read only
PROPORTIONAL
Read only
INTEGRAL
Read only
DERIVATIVE
Read only
PROP BAND INT TIME DER TIME
LEVEL PI DEVIATION
Read only
OUTPUT
Read only
PROPORTIONAL
Read only
INTEGRAL
Read only
PROP BAND INT TIME
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KSU WBF application Program Sheet WBF program sheet PREFDR CONFIG PREF ALGRTHM USE SPEED MOTOR TYPE LIN SEG LIN DC IN LIN DC OUT CLOSE POS SLIDE GATE FLOAT VIBTHR.
HOPPER HOPPER WT HOP MOT DC HOP PG POS HOP DC SPAN HOPPER LOW HOPPER HI LEVEL SP NOM WEIGHT CONFIG HOP ALGRTHM MOT TYPE LIN SEG LIN DC IN LIN DC OUT CLOSE POS SLIDE GATE1 SLIDE GATE2 SG2 STOP DEL
PID DEVIATION
Read only
OUTPUT
Read only
PROPORTIONAL
Read only
INTEGRAL
Read only
DERIVATIVE
Read only
PROP BAND INT TIME DER TIME
DENSITY FLAP DST NOM COEFF REG NOMWT
Read only
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KSU WBF application Program Sheet WBF program sheet sheet SCALE MAIN DECK NET WT.
Read only
TARE
Tare
GROSS WT
Read only
SPAN SCALE RANGE
Read only
NET WT.
Read only
GROSS WT
Read only
TARE
Tare
SECONDARY DECK
SCALE RANGE DECK GAP
Read only
STATIC TARE
Tare
HOP NET WT
Read only
HOP GR. WT
Read only
HOPPER
TARE WT FILT. TIME HOPPER TARE
Tare
HOP SCLE RNG
Read only
SFTs
Read only
SFT SCALE
SFT REQUIRED SFT SELECTED SFT ADDRESSED SFT WEIGHT
Read only
SFT RANGE SFT TYPE
Read only
SFT STATUS
Read only
SFT S/W
Read only
REPOLL SFT
DIAGNOSTICS MESSAGES
Read only
FAILED
Read only
TIME OUT
Read only
NAK
Read only
RETRY
Read only
ERR_ADDR
Read only
ERR_CMD
Read only
RESET
ANALOG LD. CELL SFT SELECTED CAL. WGT CAL.LEV.RAT. NULL PT.
Tare
CALIBRATION
Calibration
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KSU WBF application Program Sheet WBF program sheet sheet INPUT/OUTPUT BIT OUTPUT BOUT NUM [1-16] B.FUNC. BOUT STATE
Read only
MAP NUM. POLARITY EXT TOT INC
BIT INPUT BIN NUM [1-24] BIN FUNC. BIN MAP. POLARITY BIN STATE
Read only
ANALOG OUT AOUT NUM [1-8] A.FUNC. AOUT VAL%
Read only
AOUT MAX AOUT MIN AOUT DBAND AOUT UNITS
ANALOG IN AIN NUM [1-8] A.FUNC. AIN VAL% AIN ZERO PT MIN VALUE MAX VALUE RATIO DB(%)
MANUAL MODE ACTUATOR SETPOINT START
Read only
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KSU WBF application Program Sheet WBF program sheet sheet MECHANICAL MACHINE SETUP FDR. TYPE BELT LEN PULLY DIA REDUCTION WHEEL DIA TRANS LEN DECK LEN BLT EMPTY LIM NOM BLT SPD SERVMAN IDX SERVMAN VAL
MOTOR SETUP MAX MOT SPD MIN MOT SPD MAX MOT PWR PICKUP LOCAT. PICKUP TEETH SPEED CORR ACT.MOT PWR
Read only
TEMPERATURE
Read only
MISC. START DIST INTLK TIME TARE LEN EMPTY. LEN DRFT LEN
SCRAPER SCRAP. ON SCRAP. OFF
OPTIONS PREFEEDER SECOND DECK BELT INDEX SLIP INDEX ONLN CAL F.SPD START HOPPER EMPTY/STOP SCRAPER INTLK->READY
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KSU WBF application Program Sheet WBF program sheet sheet SYSTEM FDR BEING VIEWED SECURITY SECUR LEV ACT CTRL PT. CTRL POINT SETUP CONTROL PT SETP SRC PROP SRC CMD SRC
COMMUNICATION HOST PROT X4 PORT CONF PROT CONF PORT NET MANAGEMENT NET ALARMS
Read only
UTIL INTEGER
Read only
UTIL FLOAT
Read only
NODE LOAD
Read only
DIAG NODE
Read only
XMIT ERR
Read only
TRANS TO
Read only
RCV TR FULL
Read only
LOST MSGS
Read only
GENERAL RUN TIME UNITS MACH TYPE FDR ADDR LANGUAGE CLEAR MEMORY
SYSTEM SETUP FIND NODES NODE TYPE DEST ADDR WINK ADDR UNBIND ADDR REMV ADDR REPL ADDR LAST RESULT BINDING BIND ADDR 1 BIND VAR 1 BIND ADDR 2 BIND VAR 2 BIND NOW UNBIND NOW
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KSU WBF application Program Sheet WBF program sheet sheet SW VERSIONS CTRL SW VERSION
Read only Read only
AUX BD S/W
Read only
WB
Read only
BELT
Read only
HOPPER
Read only
DENS STATE
Read only
BELT STATE
Read only
OLC STATE
Read only
HOP STATE
Read only
PREF STATE
Read only
TAR STATE
Read only
BELTSPEED
Read only
MOT SPD
Read only
BELTPOS
Read only
BIPOS
Read only
SIPOS
Read only
MAINTENANCE CALIB STATUS
STATEMACHINES
BELT MVT.
SIDIV SIRATIO
Read only
BELT PARMS BI DEB. SI DEB. ESP0
Read only
ESPP
Read only
DIVI
Read only
XBMX
Read only
XB
Read only
CUR. TARE
Read only
W-DECK
Read only
W-DIS.
Read only
WA-DECK
Read only
WA-DIS.
Read only
NB.REV.
Read only
BELT TARE
KSU/WBF.942.001-E.d
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KSU WBF application Program Sheet WBF program sheet sheet DEBUG 3 MF RAW
Read only
INPUT/OUTPUT DIGITAL IN DIG IN 1
Read only
DIG IN 2
Read only
DIG IN 3
Read only
DIG IN 4
Read only
DIG IN 5
Read only
DIG IN 6
Read only
DIG IN 7
Read only
DIG IN 8
Read only
DIG OUT 1
Read only
DIG OUT 2
Read only
DIG OUT 3
Read only
DIG OUT 4
Read only
DIG OUT 5
Read only
DIG OUT 6
Read only
DIG OUT 7
Read only
DIGITAL OUT
SIMULATION HOPSIMMODE
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