701-EN DigiDrive Ver 2 Oper

701
Digi-Drive-ver2- Installation and Operation
Digi-Drive®
Ver 2
Installation and Operation
Manual
______________________________________________________________________________
Rev: D Produced by the K-Tron Institute
701
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 the K-Tron Institute. All translation rights
are reserved by the K-Tron Institute . The K-Tron Institute 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 the K-Tron Institute at
(609)589-0500.
______________________________________________________________________________
701
Table of Contents
Topic See Page
Digi-Drive® Motor Control-ver 2 1
Overview 1
Features 3
Internal Components 5
Safety Considerations 6
Digi-Drive® Installation 7
Overview 7
K2V Mounting 8
Quick Start 11
Wiring 15
Operating Configurations, Controls, and Displays 29
Overview 29
Operating Configurations 30
Touchpad Controls 31
Display 33
Set-Up Programming and Calibration 40
Overview 40
Programming 41
Calibration 51
Remote Setpoint Calibration 54
The I/O Option Pc Board 57
Overview 57
Description of I-O Option Pc Board 58
Installation of the I-O Option Pc Board 64
Wiring I-O Functions for the I-O Option Pc 66
Board
Calibration of the I-O Option Pc Board for 72
Analog Inputs
Maintenance and Troubleshooting 75
Overview 75
Preventative Maintenance 76
Troubleshooting 77
Digi-Drive® Specifications 85
Index 87
______________________________________________________________________________
701.1
Digi-Drive® Motor Control-ver 2

Overview
Introduction Digi-Drive® Direct Current Motor Control-ver 2- from K-Tron offers

the process industries the most advanced, accurate and reliable method
of motor speed control available for volumetric feeding applications.
Unlike traditional analog SCR control, Digi-Drive® provides drift-free
precision speed control through advanced closed-loop digital
processing and control techniques. As a result, volumetric feeder
performance is enhanced throughout the full operating range,
producing improved blend accuracy, less wasted product and material,
and higher overall process efficiency.
For the smoothest, most accurate control possible over the feeder's
entire operating range, Digi-Drive® combines precision pulse width
modulation drive control with advanced digital speed sensing.
Fully microprocessor based, Digi-Drive® affords the user a new level of
application and operating flexibility. Feeder setpoint may be expressed
in user-calibrated rate units, motor rpm or % maximum motor rpm, and
may be entered locally via Digi-Drive®'s data entry touchpad, or
remotely by PLC or host computer. Digi-Drive®'s ratioing capability
also permits setpoint entry in percent of an external master rate signal.
Operating ease is assured with Digi-Drive®'s scrollable LED display
and sealed data entry touchpad. Digi-Drive®'s convenient data entry
ramping function eliminates numerical input.
Warning for WARNING!, WARNING!

K2 Medium,
T60 and S100 Since the current T60 and S100 K2V feeders may not have reversible
feeders
motors for switching into different gear ranges as do the smaller K2
feeders, gearing changes must be accomplished manually. If the motor
is reversed in operation, the screws lose engagement with the drive
shaft if material is present in the feed hopper. To prevent screw
disengagement from occurring, the motor rotation must be set to that
indicated on the feeder with Hi Speed operation set for the Digi-Drive®.
Set program variable P3 to "3" to cause start-up to occur in High Speed.
For these machines: DO NOT PRESS HI/LO KEY TO GET LO SPEED
as this will cause a screw disconnect. Only run in HI SPEED. Power
down is required for the Digi-Drive to see the new selection.
Continued on next page

701.2
Overview, Continued
In this chapter
Topic See Page
Features 3
Internal Components 5
Safety Considerations 6
Notes on The version 2 of the Digi-Drive is different from the original as specified
hardware in document DCS#451. The electronic hardware including the option pc
version board in ver 2 is incompatible with the electronic components in the
original Digi-Drive. Interconnection wiring has also changed. If you use
a version 2 unit, be sure to use the wiring details presented in this
manual.
Software The software version described by this manual is version 3.4.

version

701.3
Features
Design
Features
REM Alarm %A
%
S
P CAL
rpm
DISPLAY
LOCAL
REMOTE RUN STOP
Digi Drive
DIGI-DRIVE
Direct Current Motor Control
• Closed-loop digital control with digital speed feedback

• Microprocessor based
• Stable, no-drift control
• High-efficiency pulse wave modulation maintains constant voltage
throughout full operating range
• Modular, optically isolated electronics with plug-in wiring connectors
• Feeder or panel mounting
• 115–230V, 50-60 Hz AC supply
Performance • Continuous digital speed regulation

features • Insensitive to line and temperature variations
• Controls to 1.5 Hp (1.15 KW)DC motors
• No motor chatter at low speeds
• Automatic flow starvation detection
• Automatic speed deviation detection and compensation
• External control and remote indication of high or low speed function
• Either 115 or 230Vac service, internally switch-able
• Momentarily displays value of AC line power on power-up

701.4
Features, Continued
Operating • Digital setpoint entry eliminates potentiometer guesswork

features • Large, .56" LED display with floating decimal
• User selected displays
• Sealed data entry touchpad with tactile key action
• NEMA 4/IP65 watertight construction
• Analog or digital input for remote setpoint operation
• Motor load display in % of rated motor load
• Simple setup and calibration
• Alarm output
• Option pc board is available for analog setpoint control and
additional digital I-O
• Rapid shutdown feature prevents damage to feeder when jammed.

701.5
Internal Components
Internal view
To access the interior of Digi-Drive®, loosen the four front panel
retaining screws and swing open.
Processor Connections
External
Control
Signals
Power
Connections
Programming
Pushbutton

701.6
Safety Considerations
Safety It is important to remember that the Digi-Drive is a high power device.

precautions Therefore:
• Never disassemble or wire the Digi-Drive while AC power is

applied.
• Never change the motor or motor brushes while AC power is

applied to the Digi-Drive.
• Never install a larger fuse than recommended by K-Tron. Do

not short circuit the fuse protection.
Local and National safety rules should always be observed.

701.7
Digi-Drive® Installation
Overview
Introduction Digi-Drive® may be installed in a feeder mount or panel mount

configuration, depending on your needs. Mounting hardware for your
chosen mounting method is included with your Digi-Drive® shipment.
To mount Digi-Drive®, reference the appropriate section.
In this chapter
Topic See Page
K2V Mounting 8
Quick Start 11
Wiring 15
Tools The following tools are required to install and wire this unit.
• small flat blade screwdriver

• #2 Phillips head screw driver
• medium sized flat blade screwdriver
• 22 mm open end wrench
Voltage and The motor determines what voltage and current values the drive must
current provide. Use the following table to decide.
selection
Motor Voltage Motor Current Drive Current Drive Voltage
Rating -P20
90 Vdc ≤ 5.5 Amp DC 6 Amp DC 115 Vac
180 Vdc ≤ 5.5 Amp DC 6 Amp DC 230 Vac
90 Vdc > 5.5 Amp DC 12 Amp DC 115 Vac
≤ 12 Amp DC
180 Vdc > 5.5 Amp DC 12 Amp DC 230 Vac
≤ 12 Amp DC

701.8
K2V Mounting
K2V mounting The Installation Kit Contains Mounting Bracket w/2 Mounting Screws,
2 Anchoring Screws, and Set Screw.
To mount Digi-Drive® on any K2 Modular feeder, follow the steps in

the table below.
Step Action
1 Hold the Mounting Bracket in position at the rear of the
Digi-Drive® case and secure using the Mounting Screws
provided.
2 Affix the assembly to the feeder using the Anchoring Screws
provided.
3 Adjust the Set Screw at the bottom of the Mounting Bracket
as needed to support the assembly.
Feeder Mount ing Bracket

mounted Digi- Anchoring Screws
Drive®
Mount ing Screws
Set Screw

701.9
K2V Mounting, Continued
Panel The Panel Mount Installation Kit contains (2) 7" "E Channel" mounting
mounted Digi- rails and (2) M6 x 1 mm x 16 mm set screws.
Drive®
The following diagram illustrates the dimensional cut-out requirements
in order to mount the Digi-Drive® controller in an enclosure.
122 mm
122 mm
)
ax
(M
m
m
3
R
200 mm

701.10
K2V Mounting, Continued
Panel Follow the procedure below to mount the Digi-Drive® in a cutout per
mounted Digi- the previous section.
Drive® cont.
Step Action
1 Slide the Digi-Drive® into the cutout such the face is tight
against the panel
NOTE: Make sure the four screws that hold the face plate
to the Digi-Drive® case are tightened securely.
2 From the back of the panel, slide the two "E channel"
mounting rails into the side slots in the Digi-Drive® case. See
the illustration below.
Digi-Drive
Rear of Panel
Set Screw
E Channel Slide Rail
3 Using the two set screws supplied with the Panel Mounting
Kit, insert and tighten the screws into the rear of each "E
channel"

701.11
Quick Start
Introduction This section outlines the minimum steps required to connect the Digi-
Drive® to a K2M feeder in order to drive the motor of that feeder. All
Digi-Drive® programming parameters are left at their default values. If
values other than the defaults are required consult the "Programming &
Calibration" section of this manual. The Digi-Drive® ships from the
factory set for Local control and display setpoint in motor RPM.
Quick start
steps
Step Action
1 Open front panel display by loosening four Phillips head
screws. (These screws are captivated so complete removal is
not necessary to swing open the front panel). The graphic
below illustrates the Digi-Drive® with the front display
panel opened.
Digi-Drive
Power Board Case
Assembly
TB2
Display
Ribbon
Cable
TB1
Front Panel
Display
Mounting
Screws
2 Unscrew the two Mounting Screws that hold the Power

Board to the Case Assembly.
3 Disconnect the Processor Connection Cable from the display
board.
4 Carefully pull the Power Board Assembly straight out of the
Case.

701.12
Quick Start, Continued
Quick start
steps cont.
Step Action
5 Strip 6" of jacket insulation from both the motor drive and
power AC cables.
6 Unscrew the strain relief gland nut from all three strain
reliefs. Slide the gland nuts over the AC, motor drive, and
speed pickup cables.
7 Insert power, motor drive, and speed pickup cables through
the strain reliefs as shown below. Feed the wires to the front
of the unit.
Bottom of Case
Hole
Plug
AC
Power
Motor
Armature
Speed
Pickup
8 Re-install the Power Board Assembly.

9 Tighten the (2) power board containment screws with a
minimum of 20 in-lbs of torque. Failure to tighten securely
the power board assembly can result in higher than desired
operating temperatures on the output transistors.

701.13
Quick start
steps
cont.
Step Action
10 Connect the cables as shown below.
TB2 P1 - to Processor
1 2 3 4 5 6 7 8 9 10
SIGNAL
5VDC
COM
Speed
Pickup
TB1
1 2 3 4 5 6 7 8
L2/N
L1
Earth
AC + -
Power Motor
Earth
Field
+ -
Motor
Armature
11 Close the Front Panel Display. Tighten four corner screws.

12 Be sure that the applied line voltage is as stated on the case
and agrees with the internal power switch. Then apply AC
power.
13
D ISPL AY
S
P 0
Press the key to display rpm

701.14
Quick start
steps
cont.
Step Action
14 Ramp up the setpoint to the desired RPM by using the
and/or keys.
15
Press the key. If the screws run at "high speed",

RUN
wires number 5 and 6 on TB1 need to be reversed. The Digi-

Drive® is factory programmed for "Low Speed" mode.
The Digi-Drive® is now operating in its default settings.
In order to access all the features and to utilize the different display
loops and control modes of the Digi-Drive®, refer to the remainder of
this manual.

701.15
Wiring
Wiring
considerations Wiring Digi-Drive® involves:
A) Establishing motor drive and speed pick-up connection

between Digi-Drive® and the K2V feeder.
B) Providing power to the unit
C) Performing I/O wiring required for alarm relay, run
enable input, and/or remote setpoint input.
NOTE: Strain relief for I/O connections supplied loose. Digi-Drive® is

shipped with a hole plug installed.
Recommended wiring sizes and maximum lengths are provided in

the following table:
Function Wire size US. Wire size DIN

Line Power Per Regulation Per Regulation
Feeder Motor 14 AWG ≤ 100 ft 2.5 mm2 ≤ 35m
12 AWG ≥ 100 ft ≤ 500ft 4.0 mm2 ≥ 35m ≤ 150m
I/O 22 AWG ≤ 100 ft 0.5 mm2 ≤ 35m
Speed Pickup 22 AWG ≤ 10 ft 0.5 mm2 ≤ 4m
Wiring
illustration

701.16
Wiring, Continued
Wiring Before establishing power connections, Digi-Drive®-to-feeder wiring

procedure should be performed. With Digi-Drive® and the feeder installed,
perform the steps in the table below. Then add the AC line wiring as the
last step.
Step Action
1 Plan the routing of wiring between Digi-Drive® and the
feeder to which it will be connected, and determine the
required lengths of cable for Digi-Drive®-to-feeder motor
connection.
2 Route wiring according to established accepted practice,
local/federal regulations, and the requirements of your
installation.
3 As shown below, locate the four cable ports with strain
reliefs on the bottom of the Digi-Drive® case. Strip all
cabling to 9" length.

701.17
Wiring, Continued
Wiring
procedure
cont.
Step Action
4 Secure connection of the Motor Drive Cable at Digi-Drive®
Terminal Block 1 (TB1) as shown below.
TERMINAL BLOCK 1
1 2 3 4 5 6 7 8
TB1
Terminal # Description
4 Grou nd
5 Motor Armatu re +
6 Motor Armatu re –
7 Motor Field +
8 Motor Field –
Note: All standard K-Tron K2V Volumetric feeders employ permanent magnet
motors and therefore require connection to TB1 terminals 5 & 6. TB1
terminals 7 & 8 are for Digi-Drive® applications involving the use of wound
field motors.
Note: If, upon start-up, Hi and Lo drive ranges are reversed (Lo drive range
indication when in Hi range and vice versa), simply reverse connections 5 & 6
to restore proper operation.

701.18
Wiring, Continued
Wiring
procedure
cont.
Step Action
5 Secure connection of the Motor Drive Cable at the feeder
motor.
6 Secure connection of the Speed Pickup Cable at Digi-Drive®
Terminal Block 2 (TB2) as follows:
TERMINAL BLOCK 2
1 2 3 4 5 6 7 8 9 10
TB2
8 +5 VDC
9 Speed Signal
10 Common
Note: Attach shield at signal source

701.19
Wiring, Continued
Wiring
procedure
cont.
Step Action
7 Access the Speed Pickup Cable terminal block connector at
the back of the feeder by removing the rear cover. Route the
Speed Pickup Cable through the strain relief and secure
connections to the terminal block as shown on the next page.
8 Once secured, remove any interior slack by gently pulling
the cable back out from the strain relief, and then tighten the
fitting.
9 Check wiring security.
Speed pickup When removing the speed pickup Molex connector from the terminal
replacement- block printed circuit board, use a small screwdriver as shown in the
K2 feeders illustration below. Insert the screwdriver in the connector slot and twist
it in a clockwise direction. Once the Molex connector is free, the
connector can be removed by hand.
Pulling on the Molex connector without first freeing it from the mating
part might break the terminal block printed circuit board.
T erminal
Block Terminal Block
Connector Printed Circuit Board
Screwdriver
Slot
Speed Pickup
Filler Molex Connector Cable
Plate

701.20
Wiring, Continued
Speed pickup The schematic below illustrates the input structure for the speed pickup
schematic signal.
NOTE: The Speed Pickup input was intended for short distances only. A
maximum of 10 feet is allowed between the inputs and signal source.
WARNING: DO NOT APPLY AC VOLTAGE TO THIS INPUT. DOING

SO MAY DAMAGE THE DIGI-DRIVE®.
TB2 5 VDC INSIDE DIGI-DRIVE
5 VDC OUT 8 4.7 Kž
10 Kž
9
1000 pf
SIGNAL COMMON 10 NOISE FILTER
MAXIMUM 10 FEET
Maximum source current from pin 8 is 50 ma at 5 Vdc. Speed signal at

pin 9 must swing < 1.5 Vdc and > 3.5 Vdc for input to function.

701.21
Wiring, Continued
Feeder rear
view Agitator Gear Snap Ring
Rear Drive
Belt
Filler Plate
Idler/Adjusment Speed Pickup
Pulley Terminal Block
Drive Motor
Speed Pickup
Cable Entry
Speed pickup
terminal block +5 VDC
1
Speed Signal
3
Common

701.22
Wiring, Continued
AC line power Using cabling as specified above, provide line power to Digi-Drive® by
routing cabling through strain relief #1 and secure connection as shown
below and tighten strain relief.
Note: Be sure to set variable P20 to the correct value prior to applying
power so that the correct protection is in place. Be sure that the internal
power selection switch is set to the applied line voltage. This switch is
found on the power module unit.
TERMINAL BLOCK 1
1 2 3 4 5 6 7 8
TB1
1 Ground
2 L (L1)
3 N (L2)
115V(230V)
Digi-Drive® allows for three Input/Output functions. They are; Alarm

I/O wiring Relay, Run Enable, and Setpoint Input. The following shows how to
connect an alarm relay.
TERMINAL BLOCK 2
1 2 3 4 5 6 7 8 9 10
TB2
1 Relay Center-tap
2 AlarmRelay (NC)
3 Alarm Relay (NO)
Note: TB2 terminal #2 is used to stop connected equipment under an alarm

condition; TB2 terminal #3 is used for annunciation of an alarm condition.

701.23
Wiring, Continued
I/O wiring The schematic below illustrates the input structure for the Alarm Relay
cont. - Alarm contacts TB2-1, TB2-2, and TB2-3. The internal relay is shown in the
Relay normal closed position, i.e. no alarm conditions exist.
schematic
A C C om m on A C C om m on
IN S ID E D IG I-D R IV E
TB2 TB2 IN S
AC AC
1 1
2 2
3 3
ANNUNCIATOR ANNUNCIATOR
NO ALARM CONDITION ALARM CONDITION
Relay wiring In software version 1.2 and later, variable #15 determines if the relay is
for agitator used as an "Alarm" relay as mentioned above or a "Run" relay which
control can be used to interlock to an agitator drive.
PV15 Variable Function of the Relay

Set to "0" Relay is used for Alarm
Set to "1" Relay is used for "Run"
If "Run" is the selected choice for the output relay, the current
limitations of the relay do not permit direct connection to the power
device being controlled by the relay. The internal relay in the Digi-
Drive® must be used to energize another relay or contactor which in
turn will operate an agitator or bridge breaker or other device. If the
relay output is being used as a logic signal to a PLC or other device, its
contacts can be used directly.

701.24
Wiring, Continued
Agitator Here is a wiring diagram for connecting the output relay set for "Run"
contactor to a larger contactor for control of an agitator. Connections 1-3 are in
wiring the Digi-Drive®,
diagram L1
L2
L1
To Motor
Motor Starter
L2
I/O wiring - To use the Run Enable input feature, connect the wires as shown below.
Run Enable Note that this must be used in conjunction with program variable P14.
To use, P14 must be set to "1".
TERMINAL BLOCK 2
1 2 3 4 5 6 7 8 9 10
TB2
4 Run Enable Input
5 Common
Note: The Run Enable feature is designed for fail safe operation. If the
Run Enable wire becomes broken, the feeder will stop. Digi-Drive® is
supplied with a jumper installed across TB2 terminals #4 and #5,
assuring a Run Enable condition if no external connections are made.
To indicate Run Disable condition, the green Run indicator will blink.

701.25
Wiring, Continued
I/O wiring - The schematic below illustrates the structure of the Run Enable input,
Run Enable TB2-4 and TB2-5.
schematic
NOTE: The Run Enable input was intended for short distances only. A
maximum of 10 feet is allowed between the inputs and signal source.
This input is shown as permitting running of the motor given a

setpoint. Opening the contact will cause the motor to stop.
WARNING: DO NOT APPLY VOLTAGE TO THIS INPUT. DOING SO

MAY DAMAGE THE DIGI-DRIVE®.
5 VDC
EXTERNAL
CONTACTS INSIDE DIGI-DRIVE
4.7 Kž
TB2
10 Kž
4
1000 pf
5 NOISE FILTER
MAXIMUM 10 FEET
RUN ENABLE CONDITION

701.26
Wiring, Continued
I/O wiring - To use setpoint input, connect the wires as shown below.
Setpoint input
TERMINAL BLOCK 2
1 2 3 4 5 6 7 8 9 10
TB2
6 Setpoint Input
7 Common
Note: Attach shield at signal source
NOTE: Frequency input for remote setpoint (5 VDC square wave with
50% duty cycle, 20 KHz max, (can be scaled)). Used in Remote Direct
and Remote Ratio Control Modes.
I/O wiring - The schematic below illustrates the input structure for the Remote
Setpoint input Setpoint signal.
schematic
NOTE: The Remote Setpoint input was intended for short distances only. A maximum of 10
feet is allowed between the inputs and signal source. WARNING: DO NOT APPLY AC
VOLTAGE TO THIS INPUT. DOING SO MAY DAMAGE THE DIGI-DRIVE®.
5 VDC
4.7 Kž
TB2
10 Kž
6
1000 pf
Signal Common 7 Noise Filter
Maximum 10 Ft Inside Digi-Drive

701.27
Wiring, Continued
I/O electrical The following defines the recommended, maximum, and minimum
specifications electrical conditions for the Alarm Relay, Run Enable, Setpoint, and
Speed Pickup input/output circuits.
• Alarm Relay - 1 amp maximum current. Voltage range of

24 Vdc to 240 Vac.
• Run Enable - Logic low enables a run condition. See

General I/O specifications below.
• Setpoint Input - See General I/O specifications below.
• Speed Pickup - The 5 VDC nominal output pin TB2-8 can

supply up to 50 ma. See General I/O
specifications below.
I/O The following defines the input condition limits for the above signals.
specifications
• Logic low input - A logic low is defined as 1.00 volts at the terminal
block. The maximum driving impedance is 1200 ohms for the external
device. The recommended input voltage is .5 volts or less at the
terminal block. The signal must be present for more than 25
microseconds to be reliably recognized as a valid low. A signal duration
of less than 10 microseconds will be ignored.
• Logic high input - A logic high is defined as a voltage greater than or

equal to 3.50 volts at the terminal block. The maximum driving
impedance for the external device is infinite. The recommended input
voltage is 4.00 volts at the terminal block. The signal must be present for
more than 25 microseconds to be reliably recognized as a valid high. A
signal duration of less than 10 microseconds will be ignored.
• Input protection - The standard inputs can accept input voltages of

between -15.0 volts to +15.0 volts without damage or malfunction. The
inputs can accept electrostatic discharges of approximately 10,000 volts
for short duration. Typical human body discharges will not damage the
circuitry but may cause logic state transitions.

701.28
Wiring, Continued
Motor wiring The motor armature wiring from the Digi-Drive® is terminated in the
motor junction box that is attached to the drive motor. The ground wire
from the Digi-Drive® is connected to the motor junction box housing.
Refer to K-Tron interconnection drawings for exact armature wiring

details.
For a 115 Vac line a 90-100 Vdc motor is required.

For a 230 Vac line a 180-200 Vdc motor is used.
When field wound motors are used, connect a 390ufd , 400V capacitor
across the field terminal either at the Digi-Drive or the motor.
Capacitor positive (+) to terminal 7 of motor terminal block-TB-1

Capacitor negative (-) to terminal 8 of motor terminal block-TB-1

701.29
Operating Configurations, Controls, and Displays

Overview
Introduction There are three modes of control available on Digi-Drive®. They are:
• Local Control
• Remote Direct Control
• Remote Ratio Control
This section describes each of the modes of control.
To select the control mode appropriate to your application, see the

Setup Programming & Calibration Section.
In this chapter
Topic See Page
Operating Configurations 30
Touchpad Controls 31
Display 33

701.30
Operating Configurations
Local Control Setpoint is entered manually at the Digi-Drive® touchpad. Setpoint

entry/display may be in rpm, % max rpm, or in user-calibrated
engineering rate units (lb/hr, kg/min, etc.).
Remote direct Rate setpoint is provided directly via frequency input from a host
control computer or PLC. Setpoint display may be in rpm, % max rpm, or in
calibrated engineering rate units (e. g., lb/hr, g/min, etc.) per user
calibration, but can not be changed at the touchpad. Frequency input
for remote setpoint is 5 VDC square wave with 50% duty cycle, 25 KHz
max, (can be scaled).
Remote ratio In ratio applications, speed setpoint is proportioned to a master setpoint

control signal (or process variable) supplied to the Digi-Drive®’s frequency
input. Desired % proportion is entered at the touchpad using a 0.0 to
999.9% ratio entry range. Frequency input for remote setpoint is 5 VDC
square wave with 50% duty cycle, 25 KHz max, (can be scaled).

701.31
Touchpad Controls
Available Digi-Drive® provides eight front panel keys with status indicators.
functions They are:
DISPLAY KEY: Pressing the Display key scrolls the display

DISPLAY to the next display variable (or programming variable when
in Programming Mode) .
UP/DOWN SCROLLING KEYS: When keypad entry of

setpoint is permitted, pressing the Up/Down Scrolling keys
raises/lowers the setpoint value slowly. When in
Programming Mode, these keys permit the numerical entry of
set-up variables.
FAST SCROLLING KEY: When pressed simultaneously with

the Up or Down Scrolling key, this key raises or lowers the
entry value quickly by indexing the most significant digit (left
digit).
RUN and STOP KEYS: Press Run Key to start machine

operation. Green LED indicates run condition. Pressing Stop
Key stops machine operation. Green run indicator is
RUN extinguished.
STOP

701.32
Touchpad Controls, Continued
Available LOCAL/REMOTE KEY: When enabled, toggles between

LOCAL
functions local and remote setpoint entry from a PLC or host
con't computer. LED status indicator.
REMOTE
HI
HI/LO DRIVE RANGE KEY: When enabled, and when the
feeder is stopped, permits fully electronic shifting of drive
range. Toggles between Hi and Lo speed ranges. LED status
LO
indicator.
Alarm ALARM INDICATOR: The Alarm Indicator

will illuminate when either the motor
8.8.8.8. overload threshold has been exceeded or
when the no-flow detector threshold has been
passed. To distinguish between the two
alarms, the display will illuminate
continuously for a motor overload condition,
and will flash for a no-flow condition.

701.33
Display
Introduction Digi-Drive®'s display provides a 4-digit readout for numerical display.

Display labels identify each reading. To cycle to any display variable,
press the Display key repeatedly until the desired variable is displayed.
Available display variables differ slightly depending on 1) the chosen
control mode (Local, Remote Direct, or Remote Ratio Mode), and 2) the
chosen format for the entry and display of setpoint. See Set-up
Programming for control mode and setpoint format selection
procedures.
Sample displays for each combination of chosen control mode and

setpoint format are presented on the following pages.

701.34
Display, Continued
Local control Setpoint entry and display: RPM.
Motor Speed in RPM Setpoint in RPM

Indicator: rpm Indicators: SP + rpm
16 3 8 rpm
S
P 16 4 0 rpm
%A %
6 0.8 8 1.2 rpm
% of Rated Motor Amps Motor Speed in % Max RPM

Indicator: %A Indicators: % + rpm
Setpoint entry and display: % of Max RPM.
Motor Speed in % Max RPM Setpoint in % Max + RPM

Indicators: % + rpm Indicators: SP + % + rpm
% %
8 1.2 rpm
S
P 8 1.2 rpm
%A
6 0.8 16 3 8 rpm
% of Rated Motor Amps Motor Speed in RPM

Indicator: %A Indicator: rpm
Note: When in Local Control Mode the Up/Down

Scrolling keys are enabled whenever the 'SP'
indicator is illuminated.

701.35
Display, Continued
Local control Setpoint entry and display: Engineering units.

cont.
Motor Speed in Eng'g Units Setpoint in Eng'g Units
Indicators: CAL Indicators: SP + CAL
3 8 .2 CAL S
P 3 8.2 CAL
%A %
6 0 .8 16 3 8 rpm
8 1.2 rpm
% of Rated Motor Amps Motor Speed in RPM Motor Speed in % max RPM
Indicator: %A Indicator: rpm Indicator: % + rpm
Note: When in Local Control Mode the Up/Down

Scrolling keys are enabled whenever the 'SP'
indicator is illuminated.
Remote Direct Setpoint entry and display: RPM

control
Motor Speed in RPM Setpoint in RPM
Indicators: rpm Indicators: REM + SP + rpm
REM
16 3 8 rpm
S
P 16 3 8 rpm
%A %
6 0.8 8 1.2 rpm
% of Rated Motor Amps Motor Speed in % Max RPM

Indicator: %A Indicator: % + rpm
Note: When in Remote Direct Control Mode, the UP/Down keys are disabled.

701.36
Display, Continued
Remote Direct Setpoint entry and display: % of Max RPM

control,
cont. Motor Speed in % Max RPM
Indicators: % + rpm
Setpoint in % Max RPM
Indicators: REM + SP + % + rpm
REM
8 1. 2 %
rpm
S
P 8 1. 0
%
rpm
%A
6 0 .8 1 6 3 8 rpm
% of Rated Motor Amps Motor Speed in RPM
Indicator: %A Indicator: rpm
Setpoint entry and display: Engineering units

Motor Speed in Eng'g Units Setpoint in Eng'g Units
Indicators: CAL Indicators: REM + SP + CAL
REM
3 8 .2 CAL S
P 3 8.2 CAL
%A %
6 0 .8 16 3 8 rpm
8 1.2 rpm
% of Rated Motor Amps Motor Speed in RPM Motor Speed in % max RPM
Indicator: %A Indicator: rpm Indicator: % + rpm
Note: When in Remote Direct Control Mode, the UP/Down keys are disabled.

701.37
Display, Continued
Remote ratio Setpoint entry and display: RPM

control
Motor Speed in RPM Setpoint in % of input
Indicators: rpm Indicators: SP + %
16 3 8 rpm
S
P 6 3.0 0
%A % REM
6 0 .8 8 1.2 rpm
16 3 8 rpm
% of Rated Motor Amps Motor Speed in % Max RPM Setpoint in RPM
Indicator: %A Indicator: % + rpm Indicators: REM + rpm
Setpoint entry and display: % of Max RPM

Motor Speed in % Max RPMSetpoint in % of input
Indicators: % + rpm Indicators: SP + %
% %
81.2 rpm
S
P 63.82
%A REM %
60.8 1638 rpm

81.0 rpm
% of Rated Motor Amps Motor Speed in RPM Setpoint in % RPM
Indicator: %A Indicator: rpm Indicators: REM + %
NOTE: When in Remote Ratio Control, the Up/Down Scrolling keys are
enabled only when the SP and % indicators are illuminated.

701.38
Display, Continued
Remote Ratio Setpoint entry and display: Engineering units

control
cont. Motor Speed in Eng'g units Setpoint in % of input
Indicators: CAL Indicators: SP + %
Setpoint in Eng'g unit
Indicators: REM + CA
REM
%
25.03 CAL
S
P 63.80 25.00 CAL
%A %
60.8 1638 rpm

81.2 rpm
% of Rated Motor Amps Motor Speed in RPM Motor Speed in % Max
Indicator: %A Indicator: rpm Indicators: % + rpm
NOTE: When in Remote Ratio Control, the Up/Down Scrolling keys are
enabled only when the SP and % indicators are illuminated.

701.39
Display, Continued
Display mode
quick
reference
In order to quickly determine which Display /Control Mode that the

Digi-Drive® is operating in, use the chart below. Press the "Display"
key until the Setpoint display is shown (SP). Find the graphic that
shows the same text icons. The column heading indicates the Control
Mode and the row heading indicates the Display Mode. The numeric
value displayed is not important.
For example, if the SP display were to show
REM
%
S
P 0 rpm
the Control Mode would be Remote Direct and the Display Mode
would be % RPM. If the display showed
REM
S
P 3 8 .2 CAL
the Control Mode would be Remote Direct and the Display Mode
would be Engineering Units.
Control Mode
LOCAL REMOTE DIRECT REMOTE RATIO
REM
%
RPM S
P 16 4 0 rpm
S
P 16 3 8 rpm
S
P 6 3.0 0
% REM %
%
% RPM
S
P 8 1.2 rpm
S
P 8 1.0 rpm
S
P 6 3.0 0
REM REM
ENGINEERING S
P 3 8.2 CAL S
P 3 8.2 CAL
2 5.0 0 CAL
Display Mode
UNITS

701.40
Set-Up Programming and Calibration

Overview
Introduction For maximum application flexibility, feature selection, and simplicity of

operation, Digi-Drive® is fully user programmable. Fourteen
programming variables let you custom configure Digi-Drive® to your
exact performance and operating needs.
In this chapter
Topic See Page
Programming 41
Calibration 50
Remote Setpoint Calibration 53
Note on Some variables are read only on power-up and not just when they are
variable changed. To verify that a value has been changed, the unit must be
changes powered down and then back on again after the value has been
changed. These are identified by a $ symbol.

701.41
Programming
Programming To enter the programming mode, follow the steps in the table below.
procedure
Step Action
1 Simultaneously press and hold both the Display key and
Fast Scrolling key for three seconds until the display changes
to read 'P0,' the first of the fourteen programming variables.
2 To scroll to higher variables (P1–P23), press the Display key
until the desired variable is shown. Pressing Display when at
the end of the list will return the display to P0.
3 To enter a numeric value for the selected variable, press and
hold the Up or Down Scrolling key to display the desired
value. Add the Fast Scrolling key to scroll more quickly.
Press Display to enter the value. Press Display again to move
to the next programming variable.
4 After the desired entries have been made, exit the
programming mode by pressing the Stop key.
Program Use the programming procedure above to set all of the programming
variables variables to the desired value. All of the variables are listed below.
An "*" in the following tables indicates the initial factory default settings.
P0 – Maximum Motor RPM:
Variable P0 registers the feeder's maximum rpm at the output shaft. For
all standard K-Tron Volumetric feeders under Digi-Drive® control, an
entry of '2000' (default value) is correct. Refer to the motor nameplate to
confirm the value. Display is in rpm. Maximum is 2270 RPM.
P1-Low Gear/P2-High Gear – No-Flow Threshold @ Lo/Hi Drive

Ranges:
To detect a no-flow condition, whether due to material outage or

blockage, Digi-Drive® provides an alarm output when motor current
falls below a user-adjustable threshold. Two threshold values may be
entered: one each for Hi and Lo drive ranges. The factory default is 0.0
for both. A value of "0" turns off this function.

701.42
Programming, Continued
Programming To determine appropriate thresholds for your application, complete

variables initial programming and then run the feeder with and without material
cont. at a rate that is typical of your application. Display and note the motor
load in % of rated amps when the feeder is running with and without
material. Select as your initial threshold setting a value approximately
halfway between the two recorded amperage percentages. Threshold
values for the Hi drive range are entered in P2; values for the Lo drive
range are entered in P1. Entry and display is in % rated motor amps,
and an entry of '0' disables alarm output.
Note: To minimize false alarms it may be necessary to further adjust threshold

settings.
$ P3 – Hi/Lo Drive Range
Variable P3 sets how and whether drive range selection may be made.
Enter Function
0 Selects Lo range upon start-up. The operator may
toggle between ranges from the keypad using the Drive
Range key.
1 Selects Hi range upon start-up. The operator may
toggle between ranges from the keypad using the Drive
Range key.
* 2 Start-up and operate only in Lo range. Drive Range key
is disabled.
3 Start-up and operate only in Hi range. Drive Range key
is disabled.

701.43
Programming $ P4 – Control Mode:

variables
cont. Variable P4 specifies the setpoint's point of origin (local, remote direct,
or remote ratio control mode), and whether control mode changes may
be made at the keypad. Refer to the Operating Configurations Section of
this manual for control mode definitions.
Enter Control Mode Function

0 Fixed Local Setpoint entry via keypad. Local/Remote key is
disabled.
1 Fixed Remote Direct Setpoint entry. Local/Remote key is disabled.
2 Fixed Remote Ratio Setpoint entry. Local/Remote key is disabled.
* 3 Start-up in Local Enable toggling between Local and Remote
Direct Control Mode setpoint entry via the
Local/Remote key.
4 Start-up in Remote Enable toggling between Remote Direct and
Direct Local Control Model setpoint entry via the
Local/Remote key.
5 Start-up in Local Enable toggling between Local and Remote
Ratio Control Mode setpoint entry via the
Local/Remote key.
6 Start-up in Remote Enable toggling between Remote Ratio and
Ratio Local Control Mode setpoint entry via the
Local/Remote key.
7 Either Local or External Keypad disabled, external option pc bit
Direct - needs option pc determines external direct or local operation.
P17 set to "2"
8 Either Local or External Keypad disabled, external option pc bit
Ratio - needs option pc determines external ratio or local operation. P17
set to "2"
Note: use of P4-7 or P4-8 , requires the Option pc board installed and
the use of Bit Input #5, terminal #17 to be used to select either External
Ratio, External Direct or Local.

701.44
Programming P5 – Remote Input Scaling:

variables
cont. For Remote Direct and Remote Ratio Control Mode variable P5
specifies the factor required to scale input frequency to 2 KHz at 2000
rpm. Compute the scaling factor for your application according to the
following formula only when using a display in RPM. .If you are using
a remote setpoint and displayed calibrated units, refer to the calibration
section of this manual. Default is 100.
P5 = 2000 rpm / Input Frequency (Hz) * 100
Example: If you supply a 10 KHz input, P5 is 20 (=2000/10000) *100. At

25 KHz input, P5 is 8.0 (= 2000/25000) *100. Input is 5 VDC square
wave with 50% duty cycle.
P6 – Not Used:
P7 – Setpoint Entry & Feedback Display Units:
Variable P7 specifies whether setpoint is to be entered and displayed as

motor rpm, % of max motor rpm, or in engineering rate units. The table
below shows the functions.
Enter Function
* 0 Enter and display setpoint in motor rpm
1 Enter and display speed in % of max motor rpm as
specified in programming variable P0.
2 Enter and display motor speed in calibrated rate units
i.e., lb/hr, g/min, etc. See Calibration section.
P8 –Not Used

701.45
Programming P9 – Calibration Factor:

variables
cont. Variable P9 registers the four-digit conversion constant you determine
during calibration to convert measured feeder speed into the
engineering units you wish to use to express material flow rate. See
Calibration Section.
The factory default setting is 1.000. Maximum value is 4.000. Minimum

value is 0.001.
P10 – Program Mode Entry:
Variable P10 provides the option of restricting access to programming

variables.
Enter Function
* 0 Permit access to programming variables from the
keypad.
1 Disable access to programming variables from the
keypad. Requires pushbutton to access program
Note: The internal programming switch is located on the rear of the swing-out
front panel. Pressing this push-button while powering up the unit will cause
all variables to return to default values.
P11-Low Gear & P12-High Gear – Maximum Motor Current:
Variables P11 and P12 specify the rated maximum motor current for Lo
and Hi speed ranges respectively. These values are used to establish an
alarm value if the feeder should become jammed. Unless otherwise
notified by K-Tron, enter the motor's rated amperage (registered on the
motor's nameplate) for both P11 and P12 (e.g. '6' for a 6-amp motor; 12
for a 12-amp motor).
Note: P11 and P12 will not accept a value exceeding that entered for variable
P13.
The factory default setting for both is 2.50.

701.46
Programming P13 – Power Board:

variables
cont. Variable P13 specifies Digi-Drive® power board as 6 amp or 12 amp
version. All standard K-Tron K2V Volumetric Feeders employ the 6
amp power board.
Enter Function
* 6 Specify 6 amp power board (default value) This power
board provides 800 W
12 Specify 12 amp power board. This power board
provides 1600 W
P14 - External Inhibit Jumper
Variable P14 specifies whether a jumper is required between terminals 4

and 5 on the terminal block 2. Run Enable is the function.
Enter Function
* 0 No jumper needed to permit running
1 External jumper is needed to permit running per wiring
diagram.
P15 - Function of Relay
Variable P15 specifies whether the relay is used as an "Alarm" relay or

as a "Run" relay.
Enter Function
* 0 Relay used for Alarm
1 Relay is used to show motor turning

701.47
Programming P16 - Software Revision Level

variables
cont. Variable P16 specifies the version of software in the Digi-Drive®
Enter Function
$ P17 - I/O Option pc board present
Variable P17 sets the condition of whether an I/O Option pc board is

installed. This option pc board gives analog setpoint control and
selected digital inputs and outputs.
Enter Function
* 0 Option pc board not installed
1 Not a valid entry
2 Fully operational Option pc installed - 9191-602370
$ P18 - Power Up Start-Up Option
This variable determines how the unit will start. Will it start-up
applying power to the motor or not. The Digi-Drive however, will
abide by the Run Enable permissive as an interlock.
Enter Function
* 0 Normal - Stops on Power-up
1 Running on Power-Up in Ratio Mode. P4 disabled
2 Running on Power-Up in Local Mode. P4 disabled
3 Running on Power-Up in Direct Mode. P4 disabled

701.48
Programming P19 - Ramp Rate

variables
cont. This variable determines how rapidly the setpoint will ramp.
Enter a value from 1.0 to 5.0 using the up arrow key. Time is in seconds.
Default is 1.0 seconds.
P20 - Line Voltage Set
This variable determines what the applied power line voltage is to the
Digi-Drive. This is available in software rev. U3.1 and above.
Selections are 115 or 230 Vac. If entered wrong, unit will not start.
Wrong entry cannot damage unit. This entry is needed to select thermal
protection. Use Up Arrow Key to select desired entry. On new units,
this entry is 'read only' as voltage selection is by internal switch in the
module.
To access the switch in the module, open the front panel door, unplug
any connectors, use a flat blade screwdriver to remove the power
module. Locate the 115/230 Volts switch on the module. To re-install,
do the reverse.
P21 - Speed Pick-Up Type
Enter the value of the number of pulses/revolution of the motor pick-

up gear. This variable is available in software rev. U3.2 and above.
Enter Function
60 60 pulses per motor revolution
* 120 120 pulses per motor revolution

701.49
Programming P22 - Remote Speed Zero Offset

variables
cont. The entered value from 0 to 100% of nominal speed, as configured at
P0. This value is applied to bias the operating setpoint when in external
direct or external ratio mode. The prime purpose for this entry is for
prefeeder applications on a K-Tron weigh belt feeder. This variable is
available in sofware rev. U3.3 and above.
Enter Function
0-100 Operating setpoint bias offset
Ex: If P0 = 2000 rpm and P22 = 5%, the offset will be 0.05*2000 = 100
rpm. If the external operating setpoint = 1000 rpm, the actual setpoint
will be 1100 rpm, or the motor speed will be 1100 rpm rather than 1000
rpm.
P23 - Power/Current Display
There are now two versions of face plates available for the Digi-Drive.
One display is used to show percent Amps (%A) and the other is used
to display Watts (W). The actual wattage used by the motor will be
displayed. This function is available in software version 3.4 and higher.
Enter Function
0 Display in Watts
1 Display in % Amps
%A is the percent of the power board amps (12A or 6A) being

delivered. A 230 volt AC Digi-Drive develops approximately 310 volts
DC that drives the motor. A 115 volt AC Digi-Drive develops
approximately 147 volts that drive the motor.
Example: 2 HP (1500 watt), 180 Volt DC, 2000 RPM motor

230 Volt AC, 12 Amp Digi-Drive
35 %A is displayed
35% of 12 = 4.2 amps

4.2 amps * 310 volts = 1302 watts

701.50
Programming P23 - Power/Current Display, cont.,

variables
cont. A 2 HP motor only delivers 2 HP (1500 watts) at the maximum RPM
and is derated if run at less than the maximum speed. For example, a 2
HP/ 2000 rpm motor delivers 1 HP (750 watts) if run at 1/2 speed or
1000 rpm.
In the example above we see that when the 2HP/1500 watt motor is
running at 2000 rpm the motor is not overloaded. At about 40% A the
approximate wattage would be 1500. Error E8 will shut down the Digi-
Drive if there is an overload condition. You should never see 100%A.
For this reason the watts display option if available. The controls
calculates and displays the watts using the %amps value. If you know
the motor speed and the motor HP ratting, you can tell if the motor is
overloaded or not.
NOTE: If version 3.4 software is installed in a Digi-Drive with a %A face

plate, and P23 is 0, which is the default, watts will be displayed. Change P23
to 1 in order to display %A.
P24 Alarm Mask
This entry permits alarms to be masked from the alarm output.

Value 00 – No alarms masked
Value 01 – Alarm A Masked
Value 02 – Unassigned
Alarm A is “speed not equal to speed setpoint”

701.51
Calibration
Introduction To display feeder rate in desired engineering units (lb/hr, kg/min, etc.)
calibrating Digi-Drive® involves determining a scaling constant which,
when multiplied by motor rpm, yields discharge rate in the desired
units. The procedure detailed below lets you determine data entries for
programming variable P9, the calibration scaling constant for your
specific application.
NOTE: The value of P9 MUST be in the range of 0.100 to 4.000, i.e.

0.001 < P9 < 4.000.
To perform calibration you will need a watch, two adequately sized

catch sample containers with known tare (empty) weight, a calculator,
and an accurate scale.
Note: Before performing initial calibration, confirm that all Digi-Drrive feeder
mechanical and wiring installation procedures have been successfully
completed and checked out. Also, be sure that all Digi-Drive® programming
entries have been completed, and the feeder is supplied with process material
and ready to operate.
Calibration
procedure
Step Action Example
1 Run the feeder at a nominal RPM, i.e. at
the mid point of the user operating range.
2 With the unit stopped, enter Programming
Mode by simultaneously pressing the
Display and Fast Scrolling Keys for three
seconds.
3 Press the Display key four times until
programming variable P4 (Local/Remote)
is displayed. Use the Scrolling keys to
change the display to read '0' (Local
Control)
4 Press the Display key three more times to
display programming variable P7
(Setpoint Entry & Feedback Display
Units). Scroll to establish a value of '0' (this
selects rpm as setpoint display unit). Press
Stop key to select.

701.52
Calibration, Continued
Calibration
procedure
cont.
Step Action Example

5 Press Stop to escape Programming Mode.
6 Press Display as required to cycle to 1600
indicators SP + rpm. Scroll to establish a
numerical rpm entry equal to the result of
Step 1. Press Stop key to select.
7 Start the feeder by pressing Run. Allow
the flow to stabilize.
Note: If, upon start-up, Hi and Lo drive
ranges are reversed (Lo drive range
indication when in Hi range and vice
versa), simply reverse connections on #5
& #6 on Terminal Block 1 to restore
proper operation.
8 Obtain and individually weigh at least
three consecutive, accurately timed catch
samples of one minute or one pound,
whichever is greater. Catch sampling
container capacity should be sufficient to
hold a complete sample. Do not combine
the contents of multiple sampling
containers to form a single sample. When
finished press Stop.
9 Compute the average weight of the three Sample #1 Net Weight = 3.386 lb
samples. Sample #2 Net Weight = 3.319 lb
Sample #3 Net Weight = 3.164 lb
Total = 9.869 lb
Avg. = 9.869 lb/3 = 3.290 lb

10 Compute the discharge rate associated Calibration Value =
with the catch sample average value by Average Sample Weight/Sample
dividing average catch sample weight by Duration
the sample duration. Convert the result to
your desired units if needed. = 3.290 lb / 1 min = 3.290 lb/min
= 60 min/hr X 3.290 lb/min
= 197.4 lb/hr

701.53
Calibration, Continued
Calibration
procedure
cont.
Step Action Example

11 Enter the Programming Mode
again (simultaneously press
Display and Fast Up/Down
Scrolling key for 3 seconds). Press
the Display key repeatedly to
display programming variable P9
(Calibration Factor).
12 Calculate the required factor by P9 = Flow Rate /Motor Speed
dividing the calculated massflow
by the RPM 197.4/1600 = .1234 therefore
P9 = 0.1234
13 Set P9 to the correct value P9 = 0.1234

701.54
Remote Setpoint Calibration
Introduction This section will show you how to calibrate the Digi-Drive® ™ for a
specified remote setpoint from a master device.
Remote The following table defines the variable used to determine the
calibration calibration of the Digi-Drive® when using a remote setpoint.
definitions
Function Description
MFcal Calibrated massflow from the Digi-Drive® Unit in
rate units of Kg/Hr or Lb/Min as examples at a
specified Motor RPM.
Freq. Input Incoming frequency that comes the Master source.
FSS Full Scale Setpoint of the Master Device.
Fs Fs is the frequency from the Master Device when it
delivers the rate value of FSS.
P9 Calibration ratio that is equal to Motor RPM/MFcal.
Motor RPM The speed of the motor at which MFcal is taken.
P5 The remote input scaling factor.
Remote- The incoming frequency of the Master Device
Direct setpoint is unaltered by the Digi-Drive® Setpoint
control.
Remote- The incoming frequency of the Master Device
Ratio setpoint is altered by the Digi-Drive® Setpoint
control as a % of the Master.
ex: If the master setpoint is 500 Kg/Hr and the %
entry on the Digi-Drive® is 50%, the Digi-Drive®
should deliver 250 Kg/Hr.
P5 Remote Setpoint calibration value.
P9 Scaling value
SP Operating Setpoint of Master Device
% Setpoint entry in % on Digi-Drive®

701.55
Remote Setpoint Calibration, Continued
Calibration of
the remote For clarification and for those interested in algebraic issues, we present
setpoint input some equations. What we are trying to determine is the value of P5 as
an entry to the Digi-Drive® controller.
For a Remote-Direct setpoint in the Digi-Drive® Controller, the

following equation determines the motor rpm of the slave feeder.
Motor RPM = (Freq. Input)*(2000 RPM/2000 Hz)*(P5/100)
For a Remote-Ratio condition, the Motor RPM is:
Motor RPM = (Freq. Input)*

(2000 RPM/2000 Hz)*(P5/100)*(Ratio %/100)
If the % entry is desired to be as a percentage of the master device - we

can modify the value of P5 so that;
MFcal = (% Entry)*SP
Setting the ratio at 100% for ease of computation, then;
MFcal = SP
We know from earlier documentation that;
MFcal = Motor RPM*(P9)
Then substituting and where Freq. Input = (SP/FSS)*Fs
MFcal/P9 = (Fs*SP/FSS)*(2000 RPM/2000 Hz)*(P5/100) then;
SP/P9 = (Fs*SP/FSS)*(P5/100) therefore;
for Calibrated Units with a Remote Setpoint P5 = (1/P9)*(FSS/Fs)*100

where 0.100 ≤ P5 ≥ 999.9
Note: Changing gear reductions by reversing motor direction, will cause the
remote calibration procedure to be incorrect.

701.56
Remote Setpoint Calibration, Continued
Example of The following is an example of how to use the equations on the prior
remote page.
setpoint
calibration
Master Slave
K10S Digi-Drive™
WBF Controller
Full Scale Setpoint Full Scale Setpoint

= =
1750 Kg/Hr and 525 Kg/Hr at 200 RPM
10 kHz
FSS = 1750 Kg/Hr from the master feeder. And Fs = 10 kHz incoming
frequency to the Digi-Drive® at the value of FSS. The slave Digi-Drive®
Controller is the slave and to function correctly, P5 must be correctly
set. We must calculate the correct value of P5, so that the MFcal will be
correct for the specified value of master setpoint.
From the above graphic, we know the following:
1/P9 = (200 RPM)/(525 Kg/Hr )from calibration of unit
FSS = 1750 Kg/Hr and Fs = 10 kHz from master @ 1750 Kg/Hr
P5 = (1/P9)*(FSS/Fs)*(100) therefore
P5 = (200/525)*(1750/10,000)*(100) = 6.667 %
The entry value for P5 is 6.667%. You will enter a value of 6.667
With a massflow of the master of 1750 Kg/Hr, and a value of 6.667 in

P5, and a ratio setpoint of 50%, the MFcal from the Slave will be 875
Kg/Hr and the motor speed will be 333.3 rpm.

701.57
The I/O Option Pc Board

Overview
introduction This chapter deals with the I/O Option pc board that is attached to the
display pc board and permits additional I-O including analog setpoint
inputs for the Digi-Drive®. The Option pc board part number is
9191-602370.
In this chapter
Topic See Page
Description of I-O Option Pc Board 57
Installation of the I-O Option Pc Board 63
Wiring I-O Functions for the I-O Option Pc Board 65
Calibration of the I-O Option Pc Board for Analog 71
Inputs

701.58
Description of I-O Option Pc Board
Introduction This section describes the function of the I-O option pc board and
provides a basic input and output configuration diagram. It provides
additional inputs and outputs to the Digi-Drive® to what is available on
the standard terminal connections described earlier.
Outline of
I-O option pc
board X1 2 1 1 1 1 1 1 1 1 1 1 9 8 7 6 5 4 3 2 1
0 9 8 7 6 5 4 3 2 1 0
J
U
2
J
U
1
F A
I U
S 0 U .
Potentiometer Listing: "S" = Span adjustment

"0" = Zero adjustment
"U" = Reference (+10V) adjustment

701.59
Description of I-O Option Pc Board, Continued
The I-O The I-O Option pc board is designed to plug into the rear of the display
Option pc pc board. The function of the I-O pc board permits the selection of
board either 4-20 ma setpoint input for 0-10v DC input if an analog remote
setpoint either as a direct or ration value is desired. The conversion and
buffering of the analog inputs is performed by U1-IC 274CN. You may
select to have this pc board directly use a frequency signal as a setpoint.
The minimum value is 12 Hz.
The zero reference is handled by potentiometer PT2 (Zero-0- Pot) and

U1. This +10 Vdc output is for providing a source voltage for external
setpoint control applications. The output of the zero buffer is sent to the
V/F converter IC, U3 and converted into a frequency required for
injection. Span for the signal is carried out by PT3 - the Span
potentiometer -"S".
Five digital inputs are available via U7, a 74C14. Three inputs are
unused but the other two are Start/Stop and Alarm Shutdown Input.
Four digital outputs are provided from U5, a ULN2003. Two are
unused. The other two outputs are Motor Running and Alarm 1.

701.60
Schematic of The following diagram shows the circuits of the I-O Option pc board.
I-O Option pc
board Digi-Drive Op tion Board
+ I in
Fin -
1 to u P
1 Zero V/ F 2
4-20 Ma Inpu t Circuit Circuit
900ž 3
2
Vref
Span- 19,20
- I in +5
"S" Vdc
3 Zero -"0" 6
+2.5Vd c Com
2
1 12
3 JU1 Com
+ V in
18
Com
Vdc
Inp ut
4
- V in 33v
8 Feeder
F-In
5 Ru nning
from
uP Outp ut
+5Vdc
10kž
74C14
13 10kž
N ot to u P ULN 2003
Used 9
+5Vdc
10nF Alarm 1
from Outp ut
10kž uP
74C14
14 10kž
Start- to u P
Stop
Inp ut +5Vdc 10nF
10
10kž H i/ Lo
74C14 from Gear
15 10kž uP Outp ut
Alarm to u P
Shutdow n +5Vdc
Inp ut 10nF
10kž
74C14 11
16 10kž
H i/ Lo to u P N ot
Gear from Used
Inp ut +5Vdc 10nF uP
10kž
74C14
17 10kž Vref
N ot to u P
Used 7
+10V +10V
10nF Ref-"U"
Ref Ref

701.61
I-O Option pc
input state Here is the state diagram for the Input I-O
table
Input Name Low High
Start/Stop Input On a low going edge, Motor and Drive will
the unit will start if stop.
Alarm Shutdown
Input is High. Input
must be maintained
low until drive is to
stop.
Alarm Shutdown Drive Stops Drive OK to Run if
Input Setpoint and Start are
applied.
Hi/Lo Gear Low Speed - High High Speed - Low
Reduction Input Reduction Reduction
I-O Option pc Here is the state diagram for the Output I-O. These outputs sink
board output
state table
Output Name Low High
Alarm 1 Output Drive in Alarm. This Drive OK
is for Alarm types
1,2,4,5,6. Alarm type 3
is involved with this
output.
Motor Running Motor Running Motor Stopped
Output
Hi/Lo Gear Low Speed - High High Speed - Low
Reduction Output Reduction Reduction

701.62
I-O Option pc The following table gives the voltage levels for Low and High states.
board voltage
limits
I-O Type Condition Limits
Input Maximum applied 12 Vdc Max
voltage without
damage
Input Minimum voltage for 3.5 Vdc

input to be OFF
Input Maximum voltage for 1.5 Vdc
input to be ON
Output Maximum applied 24 Vdc
voltage without
damage
Output Maximum rated 100 ma per output

current line
Output Maximum saturation 1.6 Vdc
voltage for input to
be ON.

701.63
Input and The following table describes the termination connections for field
output wiring.
terminal
designations
for I-O Option
pc board
Term Function
1 + 4-20 ma current input for Remote Setpoint
2 - 4-20 ma current input for Remote Setpoint
3 + Voltage Input
4 - Voltage Input
5 Remote Frequency Input
6 Common
7 + 10 Vdc Reference
8 Feeder Running Output
9 Alarm #1 Output
10 Hi/Lo Gear Output
11 Unused Output
12 Common
13 Unused Input #1
14 Start/Stop Input
15 Alarm Shutdown Input
16 Hi/Lo Gear Input
17 Unused Input #5
18 Com
19 + 5 Vdc
20 + 5 Vdc

701.64
Installation of the I-O Option Pc Board
Introduction This module shows how to install the I-O Option pc board in the
K-Tron Digi-Drive®.
Option pc 7
board
orientation
1
6
3
4
5
1- Power Board
2- Ribbon cable
3- Option pc board
4- CPU- Display pc board
5- Front bezel
6- standoffs (4)
7- Amp multi-pin header

701.65
Installation of the I-O Option Pc Board, Continued
Procedure to This procedure tells you how to install the I-O option pc board.
install the I-O
Option pc
board
Step Action
1 Turn off all power to the Digi-Drive®
2 With a Phillips screwdriver, open the from bezel to expose
the rear of the keypad circuit pc board.
3 Remove the screws from the pc board and install 4 standoffs
that will secure the display pc board,
4 Up-plug the ribbon cable from the display pc board. Note
orientation of red conductor on the ribbon cable denotes pin
#1.
5 Mount I-O Option pc board so that its sq. pin header plugs
into the plug vacated by the ribbon cable.
Note: the 16 pin terminal block will be exposed to you for
later wiring.
Second Note: Also note the part number of the Option pc
board. It begins with 9191........ Record for later use.
6 Use the removed screws to secure the Option pc board to the
standoffs.
7 Plug the ribbon cable into the provided plug on the Option
pc board using the same orientation as before. If for some
reason the cable comes loose from both ends, remember that
pin #1 goes to pin #1. Pin 31 on power board is toward the
connector. Pin #1 on the Option board is toward the middle
of the pc board.
8 Make appropriate wiring connections to the Option pc
board. See the next section for details. Run the wiring out
through the back wire strain reliefs.
9 Check all wiring for security and re-secure front bezel
10 Re-power the unit and program as required.

701.66
Wiring I-O Functions for the I-O Option Pc Board
Introduction This section will show diagrams to enable usage of the capability of the
I-O Option pc board. Wiring will be brought in through the conduit
holes in the rear of the case and brought over the electronic module in
the case to the connections on the bezel internal face.
Wire sizes to The range of wire sizes that can be used on the option pc board are:
option pc
board Max: 22 AWG Min: 24 AWG
It is recommended that the wire be tinned before insertion.
The module terminal block has press keys, rather than screws, that
must be pushed while the wire is inserted in the terminal block.
Typical digital Here is a typical connection for a digital output signal. Inductive loads
output such as relays are also OK since the outputs are protected against
connections surges and inductive spikes. The maximum current output is 100 ma at
an applied voltage of 24 Vdc. The load can be a relay coil with proper
suppression applied, a resistive load or a opto-isolator to a PLC input
where the proper current limit is used. Examples of each are describe
here.

701.67
Wiring I-O Functions for the I-O Option Pc Board, Continued
Resistive loads
on digital The screw terminal is your connection point. The circuitry shown
outputs is your field circuitry.
Load
+
Digital Output
DC Sourc
12 Vdc
Com
Minimum resistance - ohms = Applied voltage/0.100 A
The minimum resistance of the load in this case is = 12 Vdc/0.100 A or

120 ohms. If the applied voltage is 24 Vdc, the minimum resistance is
240 ohms. For safety, it is best to de-rate the values by 25% so the
minimum loads will be greater by that value.
ex: at 12 Vdc, recommended minimum load = 150 ohms

at 24 Vdc, recommended minimum load = 300 ohms.

701.68
Inductive When driving relay loads, you have to be able to suppress the inductive
loads on spikes that occur when de-energizing the coil. This is done with a zener
digital outputs diode. The coil current must be under the maximum rating of the
digital output or 100 ma. Obviously the relay is a DC type. It is
recommend that the maximum coil current be 95 ma or less. The zener
diode will have a rating of 28 Vdc at 1 watt.
Zener
Relay
28 Vdc
+
Digital Output
DC Source
12 Vdc
Com
It is my recommendation that you use solid state, zero crossing relays

where possible to minimize noise and other electrical disturbances.

701.69
PLC opto- You can drive an opto-isolated load of a PLC digital input device in the
isolated inputs following way. Maximum current again is 100 ma at 24 Vdc as the
from digital maximum applied voltage. The output device from the Digi-Drive®
outputs
Option pc board is a sink to common when energized.
PLC I-O Input Module
RL
+
Digital Output
DC Source
12 Vdc
Com
Be sure to watch the polarity of the PLC input so that it will work
correctly. It is not possible to source current from the common signal in
the Digi-Drive system.

701.70
Typical digital Here is a typical connection for a digital input signal. Input actuation is
input signal made upon closing the switch. For most signals the switch must remain
connection closed for actuation to continue. The Start/Stop input such will cause a
Start on the falling edge but must be maintained low to continue
running.
5 Vdc
Com
The screw terminal is your connection point. The circuitry shown
is your field circuitry.
Digital Input
Com
You should know that the internal electronic circuits de-bounce the
switch closure for you. It is recommended that for low signal
applications such as this, gold flashed, sealed contacts in the switches
be used for maximum reliability.
To determine if a input is active or not, merely measure the voltage at

the appropriate screw terminal, referenced to common. If the level is
nearly 5 Vdc, the input is not active. If the voltage is within 0.5 Vdc of
common, the input is actuated and will perform the task as specified
earlier.

701.71
Driving an You can also connect to a digital input with a digital source. A NPN
I-O input from transistor with its collector connected to the input terminal and the
a digital emitter connected to signal common is one way. An active gate is
source
another way. The Vcc value to the input gate should be +5 Vdc unless
the output circuit of the gate is un-committed.

701.72
Calibration of the I-O Option Pc Board for Analog Inputs
Introduction This module provides procedures for setting the span and zero on the
I-O Option pc board.
Setting the +10 This is used when an external source is required for an external analog
Vdc reference control device such as a potentiometer. To set the reference, do the
following:
Step Action
1 Connect a digital voltmeter between terminal points #6
(com) and #7 (+10 v ref).
2 Turn the potentiometer labeled "U" until the voltage reading
is between 9.9 and 10.1 Vdc.

701.73
Calibration of the I-O Option Pc Board for Analog Inputs, Continued
Setting Option The span, zero and reference pots on the I-O Option pc board are multi-
pc span and turn trim pots.
zero for
current input
Note: Please use an insulated TV tuning adjustment screwdriver since a
metal blade might sort out circuit traces during adjustment.
Step Action
1 Configure the Digi-Drive® to use either a Remote Direct
Setpoint or a Remote Ratio setpoint. See Variable P4 and
select either entry 1 or 2 or 4 or 6 depending upon starting
conditions.
2 Set JU1 to "I" and JU2 to "A"
3 Connect a 4-20 ma analog signal.
Refer to table of input and output terminal designations .
4 Set the value to 20 ma with a stable reference source.
5 If in Ratio control, set in 100% . Be sure that Variable P7 has
an entered value of 2. Start the controller
6 Turn Span pot "S" on the I-O option board until a setpoint
reading is obtained that is 2000 rpm.
7 Set the reference current input to 4.24 ma.
8 Rotate Zero pot "0" so that the setpoint reading just becomes
30 rpm. Recheck steps to minimize interaction of span and
zero.
9 Calibration of the I-O Option pc board for a 4-20 ma input is
complete.

701.74
Calibration of the I-O Option Pc Board for Analog Inputs, Continued
Setting Option The span, zero and reference pots on the I-O Option pc board are multi-
pc span and turn trim pots.
zero for
voltage input
Note: Please use an insulated TV tuning adjustment screwdriver since a
metal blade might sort out circuit traces during adjustment.
Step Action
1 Configure the Digi-Drive® to use either a Remote Direct
Setpoint or a Remote Ratio setpoint. See Variable P4 and
select either entry 1 or 2 or 4 or 6 depending upon starting
conditions.
2 Set JU1 to "U" and JU2 to "A"
3 Connect a 0-10 Vdc analog signal.
Refer to table of input and output terminal designations .
4 Set the value to 10 Vdc with a stable reference source.
5 If in Ratio control, set in 100% . Be sure that Variable P7 has
an entered value of 2. Start the controller
6 Turn Span pot "S" on the I-O option board until a setpoint
reading is obtained that is 2000 rpm.
7 Set the reference current input to 0.15 Vdc.
8 Rotate Zero pot "0" so that the setpoint reading just becomes
30 rpm. Recheck steps to minimize interaction of span and
zero.
9 Calibration of the I-O Option pc board for a 0-10 Vdc input is
complete.

701.75
Maintenance and Troubleshooting

Overview
Introduction This chapter deals with some basic troubleshooting and maintenance
considerations for the Digi-Drive®.
In this chapter
Topic See Page
Preventative Maintenance 75
Troubleshooting 76

701.76
Preventative Maintenance
Preventative Preventative maintenance to the Digi-Drive® is simple and should be

maintenance done very 10,000 hours. This does not include any preventative
procedures maintenance to the feeder or motor.
Step Action
1 Disconnect AC Power to the Digi-Drive®.
2 Inspect the AC and Motor drive screw terminal connects do
not show signs or wear or corrosion.
3 Verify all terminal connections are tight.
4 Check condition of 2 fuses (replace after 25000 hours even if
not blown).
5 Verify any external safety switches or lockouts are still
operational.

701.77
Troubleshooting
General Listed below are some of the common failures that may be seen when
troubleshooting using a Digi-Drive® control system. Each is listed followed by some
guidelines possible reasons for the fault.
• No indicator leds on front panel. Check 15 Amp fuses (2) on power

board. Check for AC to unit.
Digi-Drive® will not start (or stop by itself)
• Verify the Digi-Drive® has a NON zero Setpoint and Press Run.
• If the RUN LED Blinks, the Run Enable is not set.

To Test, connect a wire between terminals TB2 4 & 5. The motor may
run when the connection is made. If not, press RUN again with jumper
wire installed.
• If an Error Code Appears (ERR#), See Error Code Description for

further troubleshooting.
Alarm Relay
The Alarm Relay is energized when the Digi-Drive® is NOT in alarm

and de-energizes when an alarm is present. Generally, customers use
the normally closed contacts of the relay to activate a external alarm
indication. Note that if AC power to the unit is lost, this will de-
energize the relay and appear as an alarm to the external system.
Current Underload Alarm
If the current to the motor is less than the programmed value (P1/2),
the controller will generate a error code 3 (ERR3 is displayed) and de-
energize the alarm relay.
The motor will continue to run when this alarm occurs. When the
motor load (current) is above the programmed minimum value (P1/2),
this alarm will clear.
To disable this alarm, set P1 and P2 program variables to zero (0).

701.78
Troubleshooting, Continued
General Reading the Motor Current

troubleshoot
guidelines The motor current reading is available from the Digi-Drive® Face plate.
cont.
If a external current reading is required, the current meter should be on
the AC input to the Digi-Drive®. Because this is a Pulse Width
Modulated drive, it is NOT possible to determine motor current by
putting a meter in series with the motor. During the OFF cycle of the
drive, the magnetic field of the motor collapses which generates a
voltage across the diode on the controller. This creates the appearance
of a very large current.
Keypad does not appear to function
1) Can Not Enter Setpoint

A setpoint can only be entered when the SP indication is shown.
Changing the setpoint will the RPM, %A, % RPM or CAL is displayed
will cause the display to flash.
If the Digi-Drive® is in Remote Direct Control Mode, a setpoint from

the keypad can not be entered.
2) HI/LO Range Key does not appear to function

If the HI/LO key does not switch the motor rotation, check program
variable P3. If this value is 2 or 3, switching from the keypad is not
allowed.
3) LOCAL/REMOTE Key does not appear to function

If the Local / Remote signal does not function, check the program
variable P4. If this value is 0,1, or 2, switching control modes from the
keypad is locked out.

701.79
General 4) Can not enter Program Loop

troubleshootin Open face plate and press the button and back of controller board. Be
g guidelines careful not to touch the power board or screw terminals. If program
cont.
loop is accessible, check program variable P10
Note:
See the Operating Configurations, Controls and Displays section for
more information.
Remote Setpoint Signal Does not Function
• Verify the input Frequency is present and above 20 Hz. Verify the
frequency is a 5VDC square wave.
• Verify the Digi-Drive® is in Remote Control Mode (Ratio or Direct)

If in Remote Ratio, Verify a ratio (non zero number) is
rogrammed (SP% display)
• Verify the P5 program variables is NOT zero (0).
Reading the Speed Feedback Frequency
• The speed feedback is a 0 to 7.2 kHz 5 VDC square wave frequency.

The frequency can be read at the following places:
At the feeder, place the frequency counter between terminals 1 (5 Vdc)

and 2 (Signal).
At the Digi-Drive®, place the frequency counter between Terminals

TB2-8 (5 Vdc) and TB2-9 (signal).

701.80
Error code If the Digi-Drive® detects a failure or overload condition, the Digi-
descriptions Drive® will stop the motor and generate an alarm. This protects the
Digi-Drive® and motor from damage.
An ERROR CODE will be displayed to indicate the reason for the

shutdown. The shutdown, error code, and alarm can be cleared by
pressing the run button.
The following table lists the error codes generated by the Digi-Drive®
and their meanings.
NOTE:
Speed Pickup Pulses refers to the frequency signal from the speed
pickup to the Digi-Drive®.
Error Meaning Corrective Action

Code #
ERR 1 The measured current is greater Press Run and check if the
than the limits imposed by motor is turning. Do not
program variables P11 and P12 verify by the speed display,
and no speed feedback signal is but physically check the
present. This error will stop the motor rotation.
Digi-Drive
If the motor does turn, The
speed pickup has failed
If the motor does not turn,

the motor is jammed or
failed.

701.81
Error code
descriptions
cont.
Code #
The measured current is greater Verify the maximum current
ERR 2 than the limits imposed by value on program variables
program variables P11 and P12 P11/P12 is the same as the
and speed feedback signal is motor's nameplate
present. This error will stop the maximum current.
Digi-Drive
Determine if the product or
feeder is causing excessive
load (torque) on the motor.
Verify the brushes are in

good condition and properly
seated.
ERR 3 The Digi-Drive® has detected This can indicate the feeder
the applied current is less than is out of material if the
the minimum value set in minimum values are
programming variables P1 and programmed properly.
P2.
This alarm can be disabled
If P1 and/or P2 is zero, the by programming zero (0) for
error condition will be de- program variables P1 & P2.
activated.
This alarm will not stop the

motor.

701.82
Error code
descriptions
cont.
Code #
ERR 4 The Digi-Drive detects a speed This condition is caused if
value from the motor when the the output of the Digi-
motor should not be running. Drive® have failed closed.
This is not a common alarm
but can happen. In this case
This indicates the Digi-Drive®
replace the power board.
Power board output has failed
Since it is possible the cause
in the run position.
of the FET failure may have
also caused a controller
Can also be related to electrical board failure, replacing the
noise on the speed pick-up entire Digi-Drive® may be
cable. Wire the shields in the quickest solution.
correctly. This can also be caused if the
motor armature leads are
connected to the field
voltage at the Digi-Drive®.
The Digi-Drive® has applied Verify if the speed feedback
ERR 5 the maximum allowable current is present at the screw
for 2 seconds, but no Speed terminals at the feeder (see
Feedback pulse are present. No reading speed feedback in
other overload condition exists. general troubleshooting)
This condition is caused by a If speed feedback is present
speed pickup failure. at feeder, the problem is
with the wiring or possibly a
failure of the Digi-Drive®
controller board.
If the speed feedback is not
present at feeder, replace the
speed pickup and magnet
wheel.

701.83
Error code
descriptions
cont.

Code #
ERR 6 The Digi-Drive® has applied This alarm general indicates
the maximum allowable current a motor wiring problem or a
for 2 seconds, but Speed failed motor
Feedback pulse are present. No This can also be caused if the
other overload condition exists. motor armature is wired to
The drive will shut down. the field voltage at the Digi-
Drive®.
ERR 7 This condition shows an Replace the CPU pc board
EEPROM error on the CPU pc on the display bezel.
board. A faulty checksum or
other defect is present. The
Digi-Drive cannot be started.
ERR 8 This code indicates that the Build up on feed screws may
hardware is unable to deliver be the problem. Also the
the requested load at the motor may not be of high
requested speed - thermal enough capacity.
overload- and no other overload
condition exists. This error will
stop the drive
ERR 9 Measured AC line voltage is This error can be caused by
outside of allowed range a brown condition, power
surge lasting more than 5
seconds and a Digi-Drive
hardware failure. Line
voltage permitted rnageis
115 VAC +/- 25% or 230
VAC +/- 25%.
ERR EA The actual motor speed is more It may indicate a speed pick-
than 5 rpm from the setpoint. up problem or a wiring
The drive will continue to run if problem that allows noise
able. into the Digi-Drive.

701.84
Spare parts The following is a listing of spare parts for ver 2 Digi-Drive.
Part Number Description Ratings

9191-602370 Option pc board
9191-602490 CPU pc board
9191-601100 Power Unit or 6 amp at 115/230 Vac
9191-601120 Power Unit 12 amp at 115/230
Vac
Fuse - qty 2 250 Vac at 15 Amps
#326
Service and For service and spare parts in the United States, call (609) 589-9083.
spare parts

701.85
Digi-Drive® Specifications
Specifications
Digi-Drive® Control Accuracy: + 1 rpm over 5 sec @ 70–2000 motor rpm;

specifications + 5 rpm over 5 sec @ less than 70 motor rpm
Enclosure: NEMA 4/IP65
Front Panel: Sealed membrane type with domed touchpad

keys
Display: 0.56" high, 4-digit LED display
Mounting: Surface, panel, or machine mounting
Operating 40 – 105 oF (4 – 41 oC)

Temp Range
Frequency Input 5 Vdc square wave with 50% duty cycle,

25 kHz maximum, (can be scaled)
Alarms Motor overload, no-flow detection
Line Power: 115/230 Vac +10% @ 50/60 Hz, switch

(can be selected by internal switch)
Motor Output: 0-200 Vdc (240 Vdc field)

0-100 Vdc (120 Vdc field)
Max Power: 6 Amp Power Board 0.65 kW @ 115 Vac

1.30 kW @ 230 Vac
12 Amp Power Board 1.30 kW @ 115 Vac

2.60 kW @ 230 Vac

701.86
Specifications, Continued
Digi-Drive® Wiring Terminals: Terminal Block 1 Terminal Block 2

specifications 1 = Ground 1 = Alarm Relay
cont. Center-tap
2 = AC in (L1) 2 = Alarm Relay
(N/Closed)
3 = AC in (L2) 3 = Alarm Relay
(N/Open)Note:
Alarm Relay contacts are rated at 240V, 1A capacity.
4 = Ground 4 = Run Enable

Input
5 = Motor Arm + 5 = Run Enable
Common
Note: Run enable is asserted by contact closure between pins 4 & 5.
6 = Motor Arm – 6 = Setpoint Input

(freq.)
7 = Motor Field + 7 = Setpoint Input
Common
8 = Motor Field – 8 = 5 VDC (Speed
Pickup)
9= Speed Signal
10 = Speed Pickup
Common

701.87
Index
AC line power 22
Agitator contactor wiring diagram 24
Alarm 1 Output 61
AC line power, 22
Agitator contactor wiring diagram, 24
Alarm 1 Output, 61
Alarm Relay, 77
Alarm Relay, Run Enable, and Setpoint Input
wiring, 22
Alarm Shutdown Input, 61
annunciation of an alarm, 22
Available functions
front panel keys, 31
calibrating Digi-Drive®, 51
Calibration Factor
variable, 45
Calibration of the remote setpoint input, 55
Calibration procedure, 51
Control Mode
variable, 43
Current Underload Alarm, 77
Design Features, 3
Digi-Drive® specifications, 85
Display mode quick reference, 39
Driving an, 71
ERR 1
error code, 80
ERR 2
error code, 81
ERR 3
error code, 81
ERR 4
error code, 82
ERR 5
error code, 82
ERR 6
error code, 83
ERR 7
error code, 83
ERR 8
error code, 83

701.88
ERR 9
error code, 83
ERR EA
error code, 83
Error code descriptions, 80
Example of remote setpoint calibration, 56
External Inhibit Jumper, 46, 47
fail safe operation, 24
Feeder mounted Digi-Drive®, 8
Feeder rear view, 21
Function of Relay, 46
fuse protection, 6
General troubleshooting guidelines, 77
Hi/Lo Drive Range
variable, 42
Hi/Lo Gear Reduction Input, 61
Hi/Lo Gear Reduction Output, 61
I/O electrical specifications, 27
I/O specifications, 27
I/O wiring, 22
I/O wiring - Run Enable, 24
I/O wiring - Run Enable schematic, 25
I/O wiring - Setpoint input, 26
I/O wiring - Setpoint input schematic, 26
I/O wiring cont. - Alarm Relay schematic, 23
Inductive loads on digital outputs, 68
Input actuation, 70
Input and output terminal designations for I-O Option pc board, 63
Input protection, 27
Internal view, 5
I-O Option pc board output state table, 61
I-O Option pc board voltage limits, 62
I-O Option pc input state table, 61
K2V mounting, 8
Keypad does not appear to function, 78
Line Voltage Set, 48
Local control, 34
Local Control, 30
Logic high input, 27
Logic low input, 27
low signal applications, 70
Maximum Motor Current
variable, 45
Maximum Motor RPM
variable, 41
minimum resistance of the load, 67

701.89
Motor Current, 78
Motor Running Output, 61
Motor wiring, 28
No-Flow Threshold
variable, 41
Note on variable changes, 40
Notes on hardware version, 2
numerical display
modes, 33
Operating features, 4
Option pc board orientation, 64
Outline of I-O option pc board, 58
Panel mounted Digi-Drive®, 9
Performance features, 3
PLC opto-isolated inputs from digital outputs, 69
Power Board
variable, 46
Power Up Start-Up Option, 47
Power/Current Display, 49
Power/Current Display, cont.,, 50
Preventative maintenance procedures, 76
Procedure to install the I-O Option pc board, 65
Program, 41
Program Mode Entry
variable, 45
programming mode, 41
Programming procedure, 41
Quick start steps, 11
Ramp Rate, 48
Reading the .i.Motor Current, 78
Relay wiring for agitator control, 23
Remote calibration definitions, 54
Remote Direct and Remote Ratio Control Modes., 26
Remote direct control, 30
Remote Direct control, 35
Remote Input Scaling
variable, 44
Remote ratio control, 30, 37
Remote Setpoint Signal, 79
Remote Speed Zero Offset, 49
Resistive loads on digital outputs, 67
Run Disable, 24
Run Enable, 24
RUN LED, 77
Safety precautions, 6

701.90
Schematic of, 60
Service and spare parts, 84
Setpoint Entry & Feedback Display Units
variable, 44
setpoint input, 26
Setting Option pc span and zero for current input, 73
Setting Option pc span and zero for voltage input, 74
Setting the +10 Vdc reference, 72
Software Revision Level, 47
Software version, 2
Spare parts, 84
Speed pickup replacement- K2 feeders, 19
Speed pickup schematic, 20
Speed pickup terminal block, 21
Speed Pick-Up Type, 48
Start/Stop Input, 61
The I-O Option pc board, 59
Tools, 7
Typical digital input signal connection, 70
Typical digital output connections, 66
Voltage and current selection, 7
Warning for K2 Medium, T60 and S100 feeders, 1
Wiring considerations, 15
Wiring illustration, 15
Wiring procedure, 16
wiring sizes and maximum lengths, 15
wound field motors, 17
Alarm Relay 77
Alarm Relay, Run Enable, and Setpoint Input
wiring 22
Alarm Shutdown Input 61
annunciation of an alarm 22
Available functions
front panel keys 31
calibrating Digi-Drive® 51
Calibration Factor
variable 45
Calibration of the remote setpoint input 55
Calibration procedure 51
Control Mode variable 43
Current Underload Alarm 77
Design Features 3
Digi-Drive® specifications 85
Display mode quick reference 39
Driving an 71

701.91
ERR 1 error code 80

ERR 2 error code 81
ERR 3 error code 81
ERR 4 error code 82
ERR 5 error code 82
ERR 6 error code 83
ERR 7 error code 83
ERR 8 error code 83
ERR 9 error code 83

701.92
Index, Continued
ERR EA error code 83

Error code descriptions 80
Example of remote setpoint calibration 56
External Inhibit Jumper 46, 47
fail safe operation 24
Feeder mounted Digi-Drive® 8
Feeder rear view 21
Function of Relay 46
fuse protection 6
General troubleshooting guidelines 77
Hi/Lo Drive Range variable 42
Hi/Lo Gear Reduction Input 61
Hi/Lo Gear Reduction Output 61
I-O Option pc board output state table 61
I-O Option pc board voltage limits 62
I-O Option pc input state table 61
I/O electrical specifications 27
I/O specifications 27
I/O wiring 22
I/O wiring - Run Enable 24
I/O wiring - Run Enable schematic 25
I/O wiring - Setpoint input 26
I/O wiring - Setpoint input schematic 26
I/O wiring cont. - Alarm Relay schematic 23
Inductive loads on digital outputs 68
Input actuation 70
Input and output terminal designations for I-O Option pc board 63
Input protection 27
Internal view 5
K2V mounting 8
Keypad does not appear to function 78
Line Voltage Set 48
Local Control 30, 34
Logic high input 27
Logic low input 27
low signal applications 70
Maximum Motor Current variable 45

701.93
Index, Continued
Maximum Motor RPM variable 41

minimum resistance of the load 67
Motor Running Output 61
Motor wiring 28
No-Flow Threshold variable 41
Note on variable changes 40
Notes on hardware version 2
numerical display modes 33
Operating features 4
Option pc board orientation 64
Outline of I-O option pc board 58
Panel mounted Digi-Drive® 9
Performance features 3
PLC opto-isolated inputs from digital outputs 69
Power Board variable 46
Power Up Start-Up Option 47
Power/Current Display 49
Power/Current Display, cont., 50
Preventative maintenance procedures 76
Procedure to install the I-O Option pc board 65
Program 41
Program Mode Entry variable 45
programming mode 41
Programming procedure 41
Quick start steps 11
Ramp Rate 48
Reading the .i.Motor Current 78
Relay wiring for agitator control 23
Remote calibration definitions 54
Remote Direct and Remote Ratio Control Modes. 26
Remote direct control 30, 35

701.94
Index, Continued
Remote Input Scaling

variable 44
Remote ratio control 30, 37
Remote Setpoint Signal 79
Remote Speed Zero Offset 49
Resistive loads on digital outputs 67
Run Disable 24
Run Enable 24
RUN LED 77
Safety precautions 6
Schematic of 60
Service and spare parts 84
Setpoint Entry & Feedback Display Units
variable 44
setpoint input 26
Setting Option pc span and zero for current input 73
Setting Option pc span and zero for voltage input 74
Setting the +10 Vdc reference 72
Software Revision Level 47
Software version 2
Spare parts 84
Speed Pick-Up Type 48
Speed pickup replacement- K2 feeders 19
Speed pickup schematic 20
Speed pickup terminal block 21
Start/Stop Input 61
The I-O Option pc board 59
Tools 7
Typical digital input signal connection 70
Typical digital output connections 66
Voltage and current selection 7
Warning for K2 Medium, T60 and S100 feeders 1
Wiring considerations 15
Wiring illustration 15
Wiring procedure 16
wiring sizes and maximum lengths 15
wound field motors 17

701-EN DigiDrive Ver 2 Oper

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701

Digi-Drive-ver2- Installation and Operation

No part of this publication may be reproduced or transmitted in any form or by any

Digi-Drive® Motor Control-ver 2

Introduction Digi-Drive® Direct Current Motor Control-ver 2- from K-Tron offers

Warning for WARNING!, WARNING!

Continued on next page

Rev: D Produced by the K-Tron Institute

Software The software version described by this manual is version 3.4.

Rev: D Produced by the K-Tron Institute

REMOTE RUN STOP

• Closed-loop digital control with digital speed feedback

Performance • Continuous digital speed regulation

Continued on next page

Rev: D Produced by the K-Tron Institute

Operating • Digital setpoint entry eliminates potentiometer guesswork

Rev: D Produced by the K-Tron Institute

Rev: D Produced by the K-Tron Institute

Safety It is important to remember that the Digi-Drive is a high power device.

• Never disassemble or wire the Digi-Drive while AC power is

• Never change the motor or motor brushes while AC power is

• Never install a larger fuse than recommended by K-Tron. Do

Local and National safety rules should always be observed.

Rev: D Produced by the K-Tron Institute

Introduction Digi-Drive® may be installed in a feeder mount or panel mount

• small flat blade screwdriver

Rev: D Produced by the K-Tron Institute

To mount Digi-Drive® on any K2 Modular feeder, follow the steps in

Feeder Mount ing Bracket

Mount ing Screws

Continued on next page

Rev: D Produced by the K-Tron Institute

K2V Mounting, Continued

Continued on next page

Rev: D Produced by the K-Tron Institute

K2V Mounting, Continued

E Channel Slide Rail

Rev: D Produced by the K-Tron Institute

2 Unscrew the two Mounting Screws that hold the Power

Continued on next page

Rev: D Produced by the K-Tron Institute

Quick Start, Continued

8 Re-install the Power Board Assembly.

Continued on next page

Rev: D Produced by the K-Tron Institute

Quick Start, Continued

11 Close the Front Panel Display. Tighten four corner screws.

Continued on next page

Rev: D Produced by the K-Tron Institute

Quick Start, Continued

Press the key. If the screws run at "high speed",

wires number 5 and 6 on TB1 need to be reversed. The Digi-

The Digi-Drive® is now operating in its default settings.

Rev: D Produced by the K-Tron Institute

A) Establishing motor drive and speed pick-up connection

NOTE: Strain relief for I/O connections supplied loose. Digi-Drive® is

Recommended wiring sizes and maximum lengths are provided in

Function Wire size US. Wire size DIN

Continued on next page

Rev: D Produced by the K-Tron Institute

Wiring Before establishing power connections, Digi-Drive®-to-feeder wiring

Continued on next page

Rev: D Produced by the K-Tron Institute