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Controls

Content Slide
Systems Controls

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Feeder Controls

KCM / KSU / K-Vision / KSC

Pneumatic Conveying Controls


LSR / MPC /PLC

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System Controls

System Controls Services


Sales Support

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Basic/Detailed Engineering and documentation


Manufacturing and installation supervision
Start-up and Commissioning

Documentation for FAT, SAT, Qualification

FAT, SAT including calibration, validation and training

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Overview Controls Configuration

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Overview Controls Configuration

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Overview Controls Configuration

PLC Programming

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PLC (Programmable Logic Controller)

Sequence
Interlocks
Alarm Management
Communications

HMI (Human Machine Interface)

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Overview Controls Configuration

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Supervisory Control Main Screen

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Feeder Controls

SmartConnex
Puts the Brain at the Feeder

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Integrated Package

Simplifies Installation and Operation


Lowers Cost

Comparison
Traditional
HOST bus

K-Vision

HOST bus

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Operator
Interface

SmartConnex

RS485

Control
network

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SmartConnex

Traditional

SmartConnex

SmartConnex Controls

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10/100 Ethernet connection


Protocols: Modbus/TCP, Ethernet/IP (AB) and Profinet-IO

K-Vision

Serial connection (RS485 - 2 or 4 wire selectable or RS232)


Protocols: Allen Bradley DF1, Modbus RTU, Modbus Plus,
Profibus DP or DeviceNet

K-Net RS485 4-wire high speed serial connection with KMB protocol

K-Tron Feeders with KCM, KSHM/KSSM, SCM, K10S


K-Tron Series 4 MPC for Vacuum Receivers and Loaders

SmartConnex Benefits
Realize ROI at all times
1. Purchase

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Fewer components and less wiring mean lower costs

2. Installation

Less wiring and off-the-shelf components

3. Communication

Host connectiviy at all levels

4. Configuration/ Start-up

Simple configuration & less programming needed

5. Operation

Improved short-term accuracy

6. Maintenance

Remote diagnostics and configuration

Controls and Communications

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K-Trons SmartConnexTM
control environment
provides comprehensive
control capability with
maximum flexibility and
connectivity for systems
that include feeders, flow
meters or PID controlled
devices.

Multi-Line Control
KSC Smart Commander is a PCbased interface able to control a
total of 32 devices in up to 8
process lines.

Single-Line Control
K-Vision offers touchscreen
operator interface for single
process lines consisting of up to
16 feeders or PID devices.

Device-Level Control
KCM Control Module combines
machine mounted feeder control
and motor drive modules into a
compact housing, offering
maximum flexibility and excellent
performance.

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Device Level Control

KCM K-Tron Control Module


KCM/SD

(Keypad and Display)

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(Status Display)

KCM/KD

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KCM K-Tron Control Module

Compact unit, installed directly at the feeder


Software for screw feeders, BSP feeders, belt
feeders, Smart Flow Meters and PID available
Host communications via Smart K-Link
Integrated controls for vacuum conveyor or
vertical agitator
Models with and without Display
ATEX 3D

KCM K-Tron Control Module


Software matched to the
controlled device

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Continuous or batch operation


Local or remote mounting
Network interface

Patented screw speed


modulation algorithm

Integrated refill control

Extensive host communication


capabilities

KCM User Interface


3.5 inch color LCD

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Real Time Clock

5 built-in languages

One custom language


file can be uploaded
e.g. Chinese, Japanese,
Korean, Russian

KCM Drive Boards


KCM/../DC

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450 Watt DC Motor Drive Board


1600 Watt DC Motor Drive Board
Vibratory Drive Board
Stepper Motor Drive Board (43,194W)

KCM/../AC

AC Motor Interface Board used with external VSD


(Variable Speed Drive) eg. AC Drive, Servo Drive etc.

KCM Connectivity
Communication Protocols

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Modbus RTU (KCM Slave)


Allen Bradley DF1 (KCM Slave)
Modbus Plus

Modbus/TCP
Ethernet/IP
Device Net

Profibus DP
ProfiNet

KCM Basic Control

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LIW controller adjusts feeder speed to produce a


rate of weight loss equal to the desired feed rate
setpoint

KCM Control Features: Speed Modulation


In general screw feeders produce an irregular

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material flow within one screw revolution,


resulting in a pulsation of the massflow.
Volumetric with constant screw speed

60

70

55
50

Massflow (kg/h)

Drive Command

40

50

35
30

40

25
20

30

Massflow

15
10

20

5
0

10
0

10

15

Time (s)

20

25

30

Drive Command (%)

60

45

KCM Control Features: Speed Modulation


Electronic speed modulation minimizes the
pulsation of the material flow:

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Short-term accuracy improved by a factor of 2


2-Sigma accuracy at a 10 second sampling time improved
tremendously
Ideal for low feed rates (speed < 1 screw rotation per second)
Volumetric with constant screw speed
55

35
30

50

40

25
20

30

Massflow

15
10

Massflow (kg/h)

Drive Command

40

60

45

Drive Command (%)

Massflow (kg/h)

50

60

45

70

Drive Command

55

50

40

20

50

35
30

40

25

Massflow

20
15

5
0

Gravimetric modulated with volumetric phase

60

70

30

volumetric phase

10

20

5
10
0

10

15

Time (s)

20

25

30

10
0

10

15

Time (s)

20

25

30

Drive Command (%)

60

KCM Control Features: ActiFlow

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Serial Channel

ActiFlow
Control Unit

Weighing
System

Hopper

ActiFlow
Device

Coil Power / Position Feedback

Feeder

Motor Power / Speed Pickup

KCM
KCM

KCM Control Features: Refill Algorithm

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The weighing sensor technology (SFT) and KCM refill


algorithm allows K-Tron to supply smaller feeder hoppers
for more frequent refills
12 or more refills an hour

KCM Control Features: Conveying Support


LSR Integration

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LSR = controller for Loader


or Single Receiver
LSR communicates with
KCM via serial link or
hardwired I/O
KCM fully supports the LSR
functions accessible on the
KCM display

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Feeders with KCM

KSU-II K-Tron Single Unit

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Operator Interface for a single


feeder at the same time (for
maintenace purposes)
Can access multiple feeders
on single network
Vacuum-fluorescent display
IP65 housing
ATEX 3D compliant
Screen setup as per connected KCM

K-Tron Feeders with KCM and KSU II

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Single Line Control

K-Vision Basics

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10.4 color touchscreen


Integrated solution
Supports all K-Tron
controls
Supports pneumatic
conveying controls
16 Feeders in one
process line
Easy to use

K-Vision Connectivity

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10/100 Ethernet connection


Protocols: Modbus/TCP, Ethernet/IP (AB) and Profinet-IO

K-Vision

Serial connection (RS485 - 2 or 4 wire selectable or RS232)


Protocols: Allen Bradley DF1, Modbus RTU, Modbus Plus,
Profibus DP or DeviceNet
I/O Board
One analog in, One analog out
Two relay outputs, two digital inputs

K-Net RS485 4-wire high speed serial connection with KMB protocol

K-Tron Feeders with KCM, KSHM/KSSM, SCM, K10S


K-Tron Series 4 MPC for Vacuum Receivers and Loaders

K-Vision
Quad screen mode

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view of multiple pages on one feeder or a


single page on multiple feeders

Multiple language support, including


Chinese and Japanese

Event logging and flexible, easy-to-use


trend graphs

Software updates via serial download or


flash memory exchange

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Quad Screen

Four independent panes of information

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Language Support

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Event logging

Trend graph is color coded


Blue = Setpoint
Green = Massflow
Black = Weight

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Multi Line Control

K-Tron Smart Commander


Multi-line Control, SCADA
package

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KSC software controls up to 32


devices in up to 8 independent
continuous or batch process
lines
animated graphics display of
feeder operation, vacuum
sequencing systems, refill, etc.
Virtually unlimited storage or
recipe and material data
Real-time historical trending
data and alarm management

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Pneumatic Conveying Controls

Pneumatic Conveying Controls

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LSR Loader Single Receiver Controller


MPC Series 4 (Microprocessor Controller)
Up to 24 receivers on 1 vacuum pump

PLC Series 4 Controller


(Allen Bradley or Siemens)

Up to 32 receivers on 4 vacuum pumps

Vacuum Receiver Controllers


LSR Controller

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Operates with either one self


contained loader or single central
receiver with separate blower.

Vacuum Receiver Controllers


MPC Controller

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Controls up to 24 vacuum receivers on one


blower with one back-up blower.
Built-in K-Modbus communication

ATEX Version

Vacuum Receiver Controllers


Series 4 PLC

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Standard Package handling up to


32 receivers and 4 blowers.
Allen-Bradley or Siemens PLC with
Touch Screen HMI
Pre-programmed for full system of
receivers that can be customized
Support for remote access

MPC with LIW Feeders


Series 4 with
LIW Feeders

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MPC

K-Bus RS485 4-wire

Receiver
Panel

Refill
Signal

K-Vision