KingDrive

General
Warranty exclusion
The control applications and procedures described in this document represent
recommendations only.

They represent suggestions from TGW Mechanics GmbH that are based on current
measurements.
A general application validity is ruled out.

Applications for the relevant application cases may be possible and must be
checked accordingly.
Knowledge of the contents of this document as well as common controls
knowledge are required.

Only technical details of possible drive variants will be described.

Sensor fine adjustment is to be performed by the commissioning engineer responsible

for controls start-up during commissioning.

EN 619 - Continuous handling equipment and systems

You have to comply with the EN 619 standard for continuous handling
equipment and systems.

It specifies the controls design in chapter 5.7.7.

The standard provides information on key concepts.

Commissioning
Do not operate the conveyor until all sensors and mechanical components have
been tested and adjusted on the conveyor.

It is imperative to observe the activating and deactivating sequence!

1. 24 VDC on
2. 48 VDC on

Please note: 48 V alone must not be present, but may be activated immediately after
the 24 V have been switched on.

Otherwise the ConnectorModules may be damaged!!!

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General
Commissioning
Deactivation in reverse order!
The deactivation must be effected via the control system first, and afterwards the main
switch must be disconnected.

Direct deactivation via the main switch is not permitted!

In this case there will be the risk of a voltage being connected on the 48 VDC side
longer than on the 24 VDC logic supply.
This might lead to damage of the ConnectorModules!

Please note: Between switching off the 48 VDC power supply unit and switching it
back on at least 5 seconds have to pass. With 5 seconds switch-on time
and 5 seconds switch-off time, this means 360 switching cycles or 6
cycles per minute. When it comes to defining the 24 VDC power supply,
the capacitive load caused by the ConveyorController and the
ConnectorModules has to be taken into consideration.
24 VDC power supply units that cannot bear overloading when switched
on have to be protected by current limiting components.

In order to prevent overloading in the 24 V direct current supply, it is

necessary to use power supply units that are certified according to EN
61000-4-5. Additionally, a Varistor of the type VDR S14K29 29.7 V,
TGW ID No. 00527343 can be connected parallel to the
supply terminals.

All dimensions of the material to be transported must be tested during commissioning!

The conveying direction of the conveyor must be checked during commissioning!

Mains or power failure

In case of a mains or power failure, the system is switched off completely.
In this case there will be the risk of a voltage being connected on the 48 VDC side
longer than on the 24 VDC logic supply.
This might lead to damage of the ConnectorModules!

If the power is recovered, the 400 VAC voltage will be connected again, and the control,
the logic supply and the sensors will be supplied with 24 VDC first.

The 48 VDC will be connected in a controlled manner by the PLC and by the contactor.

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General
Operating modes - general
Set-up mode
Always observe the activating and deactivating sequence (see Commissioning).

No set-up mode necessary.

Manual mode
Always observe the activating and deactivating sequence (see Commissioning).

In manual mode, it would be advisable to control the accumulation lines or single zones
via the superior control by using a Human-Machine Interface set-up.

Automatic mode
Always observe the activating and deactivating sequence (see Commissioning).

In automatic mode, the superior control has to provide start and stop commands to the
KDR system by means of the interface used.
Further details are specified in the KDR Interface Description.

KingDrive Interface Description

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General
Stop criteria
In order to integrate the KDR equipment into a conveyor control system, it will be
necessary to consider the electrical shutdown in situations of danger!

TGW recommends to shut down the power (48 VDC) in case of an emergency
stop following
stop category 1 (acc. to EN 60204-1) on the primary side.

When using stop category 0 (acc. to EN 60204-1), the deactivation/activation sequence

specified in the Commissioning chapter will have to be observed.

Stop category 0 (according to EN 60204-1)

The 48 VDC power supply unit will be disconnected without particular provisions in the
control. A restart of the conveyor line may occasionally be difficult, as the loads moving
on the line will continue moving until they are braked by the friction remaining
in the system.
The resulting residual hazards will have to be evaluated separately for every installation.

Stop category 1 (according to EN 60204-1)

A bus signal to the Master ConveyorController of the KDR system allows to shut down
the entire conveyor line controlled by the MCC. The duration of the shutdown depends
on the brake ramp setting in the application. This signal is not safety related and is
therefore not be monitored. After a certain period of time (safe time) the power supply of
the 48 VDC supply unit will have to be disconnected. The control voltage (= 24 VDC)
should remain present, as it will be easier to restart the system later on.

Please note: The setting of the brake ramp for the emergency stop must be adapted
to the application. The residual hazards resulting from the implemented
emergency stop function will have to be evaluated separately for
every installation!

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General
Principal configuration
System Overview

Detail X Detail Y

W X

Y Y

Detail Z
Detail W

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Functional Description
Common structure
A system layout consists of different functions. The following functions are distinguished
in the KingDrive system:

 ACF Accumulation Function

 ACFS 1 Accumulation Function Short
 ACF2Z 2 Accumulation Function with 2 Zones
 SF Single Function

Further details on these functions are specified in the KDR Interface Description:
KingDrive Interface Description
1
Please note: .... The ACFS function is not available anymore after the KingDrive
full integration
2
The ACF2Z is only available in case of a KingDrive full integration.

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One function may include several different products. Therefore, product-internal

functions are used in the layout modules and in Budget:

Function Product-internal function

(KingDrive system) (Budget, layout module)

ACF / ACFS / ACF2Z MAC Master Accumulation Conveyor

SAC Slave Accumulation Conveyor

SF MT Master Transportation
ST Slave Transportation
SC Slippage Compensation

ACFS SF SF ACF

ACF 1 SF ACFS
Belt conveyor

SF
SF SF
SF SF
ACF SF ACF

ACF

1
Please note: .... Belt conveyor currently not integrated in the KingDrive System

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Functional Description
Functions
ACF Accumulation Function
The Accumulation Function ACF consists of more than two zones. A zone is a defined
area of the conveyor to handle a single load carrier.

The ACF Accumulation Function must consist of at least the following three zones:

 DZ 1 Discharge Zone 1
 DZ 2 Discharge Zone 2
 CZ Charge Zone

The function interface of the PLC includes the light barriers of these three zones.

Discharge Zone 1 and 2 are completely connected and disconnected by the PLC.
The Charge Zone is connected and disconnected by the Accumulation Function.
Therefore, the PLC provide the Accumulation Function with the information that a
package shall be handed over from the predecessor. The Charge Zone cannot be
disconnected selectively by the PLC.
Optional accumulation zones between the Discharge Zone 2 and the Charge Zone are
completely controlled by the ACF Accumulation Function.

The "Conveying speed" and "Acceleration / Deceleration" operating parameters are

always applicable for the whole Accumulation Function. Product-internal SAC functions
always have the same operating parameters as the corresponding product-internal MAC
function.

Further details are specified in the KDR Interface Description.

KingDrive Interface Description

If a zone is in idle mode for 3 seconds, this zone will stop. As soon as a LC is coming
from the previous zone again, it will be automatically reconnected.
This allows to save costs and reduce the noise emission.

Attention: If the light barrier of a stopped zone is interrupted manually or a LC is

placed onto the zone, this zone will reconnect automatically.

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Functional Description
Functions
ACF Accumulation Function
The Accumulation Function can be composed of the following products:

 KRC KingDrive Roller Conveyor A

 KCC KingDrive Conveyor Curve A

The following product-internal functions can be selected in the layout module and in
Budget for these products:

 MAC Master Accumulation Conveyor

 SAC Slave Accumulation Conveyor

Each Accumulation Function consists of a product-internal MAC function. Optionally, it

may be extended by one or several product-internal SAC functions. In this case the
product-internal MAC function must always be arranged at the end of the Accumulation
Function, contemplated in conveying direction.
In the realisation process, the product-internal functions (MAC and SAC) of the different
products are combined in one Accumulation Function.

The electrical components list displays the product-internal functions selected in Budget
per product.
The number of accumulation functions needed in the system layout can be derived from
the product-internal MAC functions displayed in the electrical components list.

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Functional Description
Functions
ACF Accumulation Function

Examples of use

The examples below show how the product-internal functions (MAC and SAC) can be
combined to one ACF Accumulation Function.

 1 MAC consisting of 3 zones

 1 MAC consisting of more than 3 zones

 Combination of 1 MAC and 1 SAC with a total of 3 zones

KCC A (SAC) KingDrive
Conveyor Curve
Accumulation

KRC A (MAC) KingDrive

Roller Conveyor
Accumulation

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Functional Description
Functions
ACF Accumulation Function

Examples of use

 Combination of 1 MAC and 1 SAC with a total of more than 3 zones

KRC A (SAC) KingDrive Roller

Conveyor Accumulation

KCC A (MAC) KingDrive Conveyor

Curve Accumulation

 Combination of 1 MAC and 2 SAC with a total of more than 3 zones

KRC A (SAC) KingDrive Roller

Conveyor Accumulation

KCC A (SAC) KingDrive

Conveyor Curve Accumulation

KRC A (MAC) KingDrive Roller

Conveyor Accumulation

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Functional Description
Functions
ACFS Accumulation Function Short
The ACFS accumulation function is an accumulation function reduced to Discharge
Zone 1 and Charge Zone.

The Discharge Zone 1 is completely connected and disconnected by the PLC.

The Charge Zone is connected and disconnected by the Accumulation Function.
Therefore, the PLC provide the Accumulation Function with the information that a
package shall be handed over from the predecessor. The Charge Zone cannot be
disconnected selectively by the PLC.

Further details are specified in the KDR Interface Description.

KingDrive Interface Description

Examples of use

The examples below show how the product-internal functions (MAC and SAC) can be
combined to one ACFS Accumulation Function Short.

 1 MAC with 2 zones

Please note: The ACFS function is not available anymore after the KingDrive
full integration.

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Functional Description
Functions
ACFS Accumulation Function Short

Examples of use

 Combination of 1 MAC and 1 SAC with a total of 2 zones

KCC A (SAC) KingDrive

Conveyor Curve
Accumulation

KRC A (MAC) KingDrive

Roller Conveyor
Accumulation

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Functional Description
Functions
ACF2Z Accumulation Function with 2 Zones
The ACF2Z accumulation function is an accumulation function reduced to Discharge
Zone 1 and Discharge Zone 2.

The Discharge Zone 2 is used as Charge Zone.

Other than in the ACFS function, it is possible for the PLC to separately switch on and
off both zones.
This also means that there is no difference between the operational modes
Basic/Progressive in case of ACF2Z.

Further details are specified in the KDR Interface Description.

KingDrive Interface Description Full Integration

Examples of use

The examples below show how the product-internal functions (MAC and SAC) can be
combined to one ACF2Z Accumulation Function.

 1 MAC with 2 zones

Please note: The ACFS function is not available anymore after the KingDrive
full integration.

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Functional Description
Functions
ACF2Z Accumulation Function with 2 Zones

Examples of use

 Combination of 1 MAC and 1 SAC with a total of 2 zones

KCC A (SAC) KingDrive

Conveyor Curve
Accumulation

KRC A (MAC) KingDrive

Roller Conveyor
Accumulation

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Functional Description
Functions
SF Single Function
The Single Function is a part of a system layout which is directly activated via the PLC.
The "Start / Stop", "Conveying speed" and "Acceleration / Deceleration" operating
parameters are always applicable for the whole Single Function.

Further details are specified in the KDR Interface Description.

KingDrive Interface Description

The Single Function can be composed of the following products:

 KRC KingDrive Roller Conveyor T

 KCC KingDrive Conveyor Curve T
 KCS KingDrive Conveyor Spur
 ZAS Timing Belt Transfer K
 ZUS Timing Belt Offset K
 HPT High Performance Transfer

The following product-internal functions can be selected in the layout module and in
Budget for these products:

 MT Master Transportation
 ST Slave Transportation
 SC Slippage Compensation (for KRC T only)

A Single Function can consist of the product-internal MT function or SC function.

If the Single Function consists of the product-internal MT function, it may optionally be

extended by one or several product-internal ST functions. In this case the product-
internal MT function must always be arranged at the end of the Single Function,
contemplated in conveying direction.
In the realisation process, the product-internal functions (MT and ST) of the different
products are combined in one Single Function.
If the Single Function consists of the product-internal SC function, it cannot be extended
by product-internal ST functions.
The product-internal SC function is used to correct the gap between the individual load
carriers.
From a technical point of view, the product-internal SC function does not differ from the
product-internal MT function, it only serves visualisation purposes in the system layout
and in the electrical components list.

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Functional Description
Functions
SF Single Function

The electrical components list displays the product-internal functions selected in Budget
per product.
The number of single functions needed in the system layout can be derived from the
product-internal MT and SC functions displayed in the electrical components list.

Examples of use

The examples below show how the product-internal functions (MT and ST) can be
combined to one SF Single Function.

 Combination of 1 MT with several ST

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Functional Description
Functions
SF Single Function

Examples of use

 Several individual MT

 Combination of 1 MT with 2 ST (Curve 30°, KRC T and Curve 30°)

 Combination of 1MT with 1ST (KCS AN + KRC T)

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Functional Description
ACF / ACFS operating modes
It is defined for the ACF and ACFS accumulation function with which operating mode the
load is conveyed on the optional accumulation zones and the charge zone.

The following operating modes are distinguished:

 Basic
 Progressive

General

The following functional states apply in the illustrations below:

zone conveys

zone is braked

load is moving

load is accelerated

load is braked

sensor not occupied by load

sensor occupied by load

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Functional Description
ACF / ACFS operating modes
Basic

The following internal combination of sensors is basically defined for the ACF and ACFS
accumulation functions:

The sensor and accumulation signals from two accumulation zones one following the
other are used directly for the logical combination.

Conveying direction

Negated input

Signal direction of accumulation logic

If the sensor of an accumulation zone is occupied by the load and the next accumulation
zone in conveying direction is simultaneously occupied, the respective accumulation
zone will brake.
If the sensor of the next accumulation zone becomes free, the loads on the respective
accumulation zone will be set in motion again.

The power supply of the components is effected via the ConnectorModules.

The signal of the optical sensors (occupied / not occupied) can be conducted to the
control system from the internal logic of the accumulation line.
It is not possible to lead through the accumulation signal (accumulation zone conveys /
accumulation zone stops).

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Functional Description
ACF / ACFS operating modes
Basic

Feed-in into accumulation line

Accumulation

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Functional Description
ACF / ACFS operating modes
Basic

Discharge from the accumulation line

Tote performance / weight per running metre

L Tote performance [LHM/h]

v Conveying speed [m/s]
ZL Zone length [mm]
LLHM max. Max. load carrier length [mm]
m / lfm Average weight conveyed per running metre
mLHM Average tote weight

1000  3600  v m LHM  L

L m/lfm 
ZL  L LHM max 3600  v

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Functional Description
ACF / ACFS operating modes
Progressive

The following internal combination of sensors is basically defined for the ACF and ACFS
accumulation functions:

The sensor signal of one accumulation zone and the accumulation status of the next
accumulation zone in conveying direction are used for the logic combination.

Conveying direction

Signal direction of accumulation logic

If the sensor of an accumulation zone is occupied by the load and there is a

simultaneous accumulation signal from the next accumulation zone in conveying
direction, the logic combination for the respective accumulation zone will issue an
accumulation signal (accumulation zone brakes).
If the accumulation signal of the next accumulation zone is deleted, the loads on the
respective accumulation zone will be set in motion again with a time delay of 200 ms.

The power supply of the components is effected via the ConnectorModules.

The signal of the optical sensors (occupied / not occupied) can be conducted to the
control system from the internal logic of the accumulation line.
It is not possible to lead through the accumulation signal (accumulation zone
conveys / accumulation zone stops).

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Functional Description
ACF / ACFS operating modes
Progressive

Feed-in into accumulation line

Accumulation

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Functional Description
ACF / ACFS operating modes
Progressive

Discharge from the accumulation line

Tote performance / weight per running metre

L Tote performance [LHM/h]

v Conveying speed [m/s]
ZL Zone length [mm]
LLHM max. Max. load carrier length [mm]
m / lfm Average weight conveyed per running metre
mLHM Average tote weight
tp Delay time [ms] standard = 200 ms

1000  3600  v m LHM  L

L m/lfm 
ZL  v  t p 3600  v

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System Limits
Master-Slave Controller System / full version

Please note: max. CAN bus length = 20 m

Max. load on the power supply unit

The specifications below are applicable for Single Function

KRCT (acceleration of 2 m/s²)

 Max. 150 kg with a total of 55 rollers in cyclic operating mode

 Max. 300 kg with a total of 55 rollers for one-time start (30 s pause)

KCCT (acceleration of 2 m/s²)

 Max. 100 kg in cyclic operating mode (28 rollers tested)

 Max. 200 kg for one-time start (28 rollers tested, 30 s pause)

Mixed operation of KRCT and KCCT on one power supply unit (acceleration
of 2 m/s²)

 Max. 100 kg with a total of 55 rollers in cyclic operating mode

 Max. 200 kg with a total of 55 rollers for one-time start (30 s pause)

In case the acceleration deviates from the standard value of 2 m/s², the load value
has to be adapted accordingly!

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System Limits
Master-Slave Controller System / full version
PowerTrack
Max. length from power supply unit to end of PowerTrack: max. 20 m

Attention: Also pay attention to the lengths of the installed JumperCables!

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Components
ConnectorModule Digital Input
CAN bus
DI LED
Status LED
DO LED

Power supply

Connector assignment
Pin 1 Pin 2 Pin 3 Pin 4
1
DI +24 VDC IN GND n.c.
(not
connected)
DO +24 VDC OUT GND /
CAN1 CAN_H Daisy CAN_L /
CAN2 CAN_H Daisy CAN_L /
2
Supply +48 VDC GND GND +24 VDC

1
Please note: .... 2 A fuse-protected
2
…. 4 A fuse-protected

Technical Data

Protection rating IP 20

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Components
ConnectorModule

LED display
Mode
Bootloader- Unselected 1 3 LEDs are flashing simultaneously (1 s bright, 1 s
dark, 0.5 Hz)
Bootloader- Selected 2 3 LEDs are flashing simultaneously (0.25 s bright,
0.25 s dark, 2 Hz)
Application- DI LED: LED switched on
Assembly Test 3 (maybe connect light barrier)
DO LED: LED switched on
(maybe connect pneumatic valve)
Status LED: LED switched on
ConnectorModule OK
LED is flashing
ConnectorModule roller has a problem
(depending on the problem class the
flashing frequency is 1, 2 or 3 Hz)
Application Operational DI LED: LED switched on
(ready) High level on the DI, LED is dark at low
level
DO LED: LED switched on
High level (max. 0.5 A) on the DO
LED not switched on
DO contact is not energised
Status LED: LED switched on
ConnectorModule OK
LED is flashing
ConnectorModule or roller has a
problem (depending on the problem
class the flashing frequency is 1, 2 or 3
Hz)
1
Please note: .... IDLE state, device does not communicate
2
…. ConveyorController checks firmware + CAN address and updates
it when needed
3
…. Is used to indicate where sensors or actuators are expected

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Components
ConnectorModule

Problem class Cause Measure

Class 1 (1 Hz) Software error ConnectorModule Reset the CC

If the error still occurs:

replace ConnectorModule

Class 2 (2 Hz) An error which prevents the Chech power supply

KingDrive roller from turning Check if KingDrive roller
(under- or overvoltage, excess is blocked
temperature, speed deviation)

Class 3 (3 Hz) Hardware error of KingDrive roller Replace KingDrive roller

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Components
ConnectorModule
Inputs

The digital inputs are located on the ConnectorModule (at the outside of the conveyor
profile). For a Master ConveyorController or Slave ConveyorController, the maximum
number of inputs is limited to a total of 30 inputs.

Digital Input
CAN 1
CAN 2
4. 3. 2. 1.

3.
1. 2.
2. 1.
3.
1. 1.
2. 2.
3. 3.
4. 4.

Mating connector (STOCKO)

Pin assignment

Connector assignment
Pin 1 Pin 2 Pin 3 Pin 4
DI +24 VDC 1 IN GND n.c.
(not
connected)

Please note: Mating connector type MKF 13264-6-0-404 (STOCKO)

Technical Data
24 VDC Imax = 200 mA

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Components
ConnectorModule
Outputs

The digital outputs are located on the ConnectorModule (at the inside of the conveyor
profile). For a Master ConveyorController or Slave ConveyorController, the maximum
number of outputs is limited to a total of 20 outputs.

1.
2.
3.

Digital Output

Pin assignment

Connector assignment
Pin 1 Pin 2 Pin 3
1
DO +24 VDC OUT GND

Please note: Mating connector type FMC 1.5/ 3-ST-3.5 (Phoenix Contact)

Technical Data
24 VDC Imax = 0.5 A

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Components
KingDrive roller

Connecting cable with

plug (I = 150 mm)
Optional extension cable
(Imax. = 1500 mm) B

Elevation A Elevation B

1 9 9 1
2 10 10 2

Pin assignment

Pin assignment and cable colours

Pin 1 violet V
Pin 2 brown U
Pin 3 yellow W
Pin 4 red U_Hall
Pin 5 n.c. (not connected)
Pin 6 black GND
Pin 7 blue NTC
Pin 8 green Hall A
Pin 9 grey Hall C
Pin 10 white Hall B

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Components
KingDrive roller
Technical Data

Nominal voltage [VDC] 48

Nominal current [A] 0.75
Nominal current for TGW's
specification [A] 0.5
Max. current [A] 3.5
Nominal power [W] 19.2
Nominal speed [rpm] 382
Nominal torque [Nm] 0.48
Permanent holding
torque [Nm] 0.45
IP 30
Protection rating IP 31 (connected from below in standard installation
case)

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Components
Electrical equipment
48 VDC power supply unit
The power supply unit serves to supply the 48 VDC motorised roller. It is electrically
connected to the PowerTrack via the 48/24 VDC JunctionBox.

On the primary side, shutdown measures will have to be taken in accordance with the
applicable legal standards.

Output side
Input side

LEDs

Pin assignment

 Black = +
 White = -

Technical Data

Input voltage range 380/480 +20% ÷ -10%

the special networks (star connection) are covered
by that range
Power Factor / Harmonics EN 61000-3-2
Input current active input current limitation (7 A, max. 10 A)
Efficiency >93 %
Internal input fuse 1x per phase -6.3 A time delay (6.3 x 32)
Output <-> casing insulation SELV, PELV
EN 60950-1, EN 50178; EN 60204-1, IEC 60364-4-41
Output voltage 49.2 VDC ±2.5 %
30 A
Output current 55 A peak (for 1 s every 30 s)
45 A peak (for 300 ms every 1.02 s)
Output power 1500 W
Overload protection short circuit protected
Overvoltage protection <55 V
Parallel operation possible no
Current division possible no

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Components
Electrical equipment
48 VDC power supply unit

Technical Data

residual ripple: max. 1 % Ua

Ripple and noise peak-peak spikes: max 2 % Ua
(range ~ 20 MHz)
Display 2 * LED see drawing with same number
storage: -35 °C ÷ +85 °C
Ambient temperature operation: -30 °C ÷ +70 °C
range 40 °C full performance, derating of 2.5 %/degree at 40
°C or higher
Temperature protection internal OVT protection, switch off/on for restart
Reliability / service life / MTBF > 500000 h according to IEC 61709, at 40 °C
MTBF Lifetime: min. 75000 h at 30 °C
UL 60950 recognized upgrade to UL 508 listed for
Licence
Canada/USA
Leakage current <3.5 mA
EN 61000-4-2, -3, -4, -5, -8, -11; EN 61000-6-2
EMC / ESD
installation class 3; EN 61204-1 / EN 55022 class B
4-pin cable with PG gland; 1.5 m long AWG14,
certification: cUL, free of halogens
Supply feed-in temperature range: -30 °C ÷ +80 °C
conductor colouring in black with labelling L1, L2, L3
PE in green-yellow, 8 mm ends partly stripped
4-pin cable; 1.5 m long AWG10,
certification: cUL, free of halogens
Output temperature range: -30 °C ÷ +80 °C
conductor colouring: + = black, - = white, 8 mm ends
partly stripped
Max. surface temperature
up to 40 °C environment 70 °C
Protection class I
Protection rating IP54
kg
Weight
4 ±10 %
Dimensions, identification see drawing with same number
and warnings

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Components
Electrical equipment
48 VDC power supply unit
Resetting of supply unit in case of errors
(e.g. overcurrent, excess temperature etc.)

To reset the power supply unit, the primary side will have to be disconnected from mains
for about 5 seconds (duration until the internal electrolytic capacitor is discharged). The
same applies for the use of the I/O switch.

I/O switch

No electric isolation will be effected with the switch. This switch only takes effect in the
power supply unit inside the control!

48/24 VDC Junction Box

The 48/24 VDC JunctionBox is the main supply point for the KDR system.
The 48 VDC are supplied by the KDR supply unit and are pre-wired. The 24 VDC will
have to be supplied externally and connected. Therefore, a spring-type terminal is
provided in the 48/24 VDC JunctionBox.

+48 VDC

GND

24 V input GND

+24 VDC

Please note: The system was engineered for 24 VDC ±10 %!

TGW recommends a setting to 26 VDC at the JunctionBox supply point

The 24 VDC supply units must be always be disconnected on the

primary side, in case a disconnection (e-stop) is required!

Technical Data

Protection rating IP 31

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Components
Electrical equipment
PowerTrack
It serves to transmit the 48/24 VDC energy to the ConnectorModules.

+48 VDC
GND
GND
+24 VDC

Technical Data

Copper conductor 6 mm²

Protection rating IP 20

JumperCable

The JumperCable serves to connect two PowerTracks.

Lmax = 8 m

4x6 mm²
PowerPlug

PowerPlug

Technical Data

Black +48
White GND
White GND
Blue +24

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Components
Electrical equipment
ConveyorController

The ConveyorController constitutes the control unit of the KDR system. All functions and
commands are directed from the Master ConveyorController (MCC) to the
Slave ConveyorControllers (SCC) and to the ConnectorModules (CM).

Each ConveyorController (CC) is able to control one or several functions, depending on

the system limits.
A max. number of 4 SCC may be connected to one MCC.
The SD card must be parameterised to activate the functions. This will be
done by TGW!
A MCC is a SCC into which an additional plug-in modules (e.g. Profibus module)
has been installed.

[1]

[3]
[4]
[12]
[5]
[11] [6]
[7]
[8]
Elevation A

[9]

[2] [10]

[10]

Controls
 KingDrive

Components
Electrical equipment
ConveyorController

Pos. Designation

1 1. STAT LED
2 2. STAT LED
3 3V3 LED
4 Reset button
5 7-Segment Pushbutton
6 5V LED
7 SD Card Connector
8 STAT LED
9 7-Segment Display
10 Ethernet
11 Wago mating connector type 734-164
12 Plug-in module (Profibus, Profinet)

24 VDC power supply

Pin assignment
Wago connector type 734-164 top-down

Pin 1 +24 VDC

Pin 2 GND
Pin 3 n.c. (not connected)
Pin 4 n.c. (not connected)

Controls
 KingDrive

Components
Electrical equipment
ConveyorController

LED description

Display Description

3V3 LED red light is on when 3.3 V are connected

5V LED red light is on when 5 V are connected
STAT LED green light is on after successful booting
orange light is on when booting
red light is on when CC no longer responds
red light is flashing, see 7-Segment Display
orange light is flashing, see 7-Segment Display

Note: For the CC HW version 1-8-0 and older, there is another LED between
the 3V3 LED and the 5 V LED which is switched on when 1.7 V are
connected (1V7 LED).

Controls
 KingDrive

Components
Electrical equipment
ConveyorController

7-Segment Display

Please note

i Current CC software version 2737

In case of older software versions of the ConveyorController it may be
that the status LED is illuminated/flashing differently.
The indicated error numbers are displayed on the 7-segment display
by pressing the 7-segment pushbutton for 30 s.

General errors:

Error STAT Malfunction Cause Measure

no. LED

-3 Red light CC does not boot CC software Load SD card

flashing corrupt (A.BIN) software /
replace SD card
-2 Red light CC does not boot Hardware test of Replace the CC
flashing supplier not
successful
-1 Red Error during SD Several INI files Check the INI file
card initialisation on the SD card
Plug in or replace the
SD card not SD card
plugged in or
defective
01 Red INI file could not be INI file defective Check the INI file,
read successfully replace the SD card if
necessary
02 Red Auto addressing CAN bus Check CAN bus
failed connector is connector, replace
loose, CM CM if necessary
defective
03 - - - -
04 orange Missing connection Configuration of Synchronise
light to PLC SD card or of configuration of SD
flashing PLC is incorrect card and of PLC

Controls
 KingDrive

Components
Electrical equipment
ConveyorController

7-Segment Display

Ethernet Connection Failed

Legend:

 CC A Master ConveyorController
 CC B 1st Slave ConveyorController
 CC C 2nd Slave ConveyorController
 CC D 3rd Slave ConveyorController
 CC E 4th Slave ConveyorController

Example:

 CC A MCC 015 Number of MCC can always be divided by 5

 CC B SCC 016
 CC C SCC 017
 CC D SCC 018
 CC E SCC 019

Error STAT Malfunction Cause Measure

no. LED

10 orange CC A does not

light respond
flashing
11 orange CC B does not
light respond
flashing Reset the CC
Ethernet cable not
12 orange CC C does not connected to the CC Check the
light respond or defective Ethernet cabling or
flashing CC
CC defective
13 orange CC D does not Replace the CC
light respond
flashing
14 orange CC E does not
light respond
flashing

Controls
 KingDrive

Components
Electrical equipment
ConveyorController

In-/outputs

Wago connector
No. 734-164
X

Detail X

Digital I/O e.g.

Wago mating connector
No. 2091-1426
Pin: 1
2
3
4
5
6

Please note: In-/outputs may be used as input or output depending on

their parametrisation.
Max. current of 20 mA per input or output

Controls
 KingDrive

Components
Electrical equipment
ConveyorController

In-/outputs

Pin assignment
Wago connector type 2091-1426 top-down

Pin 1 +24 VDC

Pin 2 IO 3
Pin 3 IO 2
Pin 4 IO 1
Pin 5 IO 0
Pin 6 GND

Controls
 KingDrive

Components
Electrical equipment
ConveyorController

In-/outputs

Elevation A

Board without Jumper Board with Jumper

JP1
JP2

The digital IOs on the CC are galvanically isolated from the CC power supply. Therefore,
it has to be provided for when using the IOs that the I/O unit is supplied with current.

The supply may be effected in two ways:

 Pin 1 (+ 24 VDC) and Pin 6 (GND) are supplied externally
 By plugging in the Jumpers JP1 & JP2, the supply of the I/O unit is directly
connected to the CC supply. The Pins 1 & 6 will have to remain unconnected. In
this case it will have to be ensured that no equalising currents may occur due to
different potentials.
There might be regulations in some countries that require special arrangements
or that totally forbid this.

Controls
 KingDrive

Components
Electrical equipment
ConveyorController

Technical Data

Nominal voltage [VDC] 24

Nominal current [A] 0.2
Protection rating IP 30
IP 31 (connected from below in standard installation
case)

Controls
 KingDrive

Components
Electrical equipment
ConveyorController

Profibus module
1 LED

[2]
2 LED

[3]

[1]

Connection of grounding cable

The Profibus module is integrated in the Master ConveyorController and constitutes the
interface to the superior control.

The Profibus address is set via two rotary coding switches [1].

Please note: According to the Profibus user organisation, the provided terminals [3]
have to be connected when installing the Profibus shield support [2]!

Only a straight bus connector may be used for the Profibus connection
(9-pin D-Sub).
E.g. Helmholz ref. no.: 700-972-0CA12 screwed or
700-972-0CA50 Easy Connect for rigid cables or 700-972-0CF50 for
flexible cables.
Siemens ref. no.: 6GK1500-0FC10

The Profibus address has to be set with hexadecimal numbers. The left switch is the
low-order digit and the right switch the higher order digit.

Controls
 KingDrive

Components
Electrical equipment
ConveyorController

Profibus module

Example: If you want to set the address 27 [decimal], you will have to set B at the
first wheel and 1 at the second wheel. 27 [dec] corresponds to 1B [hex]

Display Description

1st LED green light is on when 5 V are reached

2nd LED green light is on when a Profibus connection
is available

Controls
 KingDrive

Components
Electrical equipment
ConveyorController

Profinet module PN2

PN1

1st LED
[1] 2nd LED
3rd LED
4th LED

The Profinet module is integrated in the Master ConveyorController and constitutes the
interface to the superior control.

Every Master ConveyorController recevies a Profinet device name via the PLC.

The Profinet cables [1] have to be plugged in at the inputs PN1 and PN2 according to
the PLC configuration (incoming/outgoing cable)

Please note: Only a straight bus connector may be used for the Profibus connection
(RJ45 connector, IP20, 180°).
For example RJ45 connector Phoenix CO order no. VS-PN-RJ45-5-
Q/IP20 or item no. 1658435
Profinet cable as for example Siemens order no. 6XV1840-2AH10

Controls
 KingDrive

Components
Electrical equipment
ConveyorController

Profinet module

Display Description

1st LED red light is on when waiting for a Profinet connection

Bus Comm. Fail
red light is flashing during connection setup to the PLC

no light when connected successfully to the PLC

2nd LED
System Fail
red light is on when an error status occurs

3rd LED
Device Ready
green light is on when Profinet chip is initialised successfully

4th LED
Maintenance Required
yellow light is on when an error status occurs

Controls
 KingDrive

Components
Electrical equipment
CAN bus

Terminating resistor

Stocko MKF
13263-6-0-303

140 Ohm resistance

0.25 W ±1%

Connecting cable

Plug type: Stocko plug MKFL 13263-6-1-303

3.
2.
1.

1.
2.
3.

Pin assignment and cable colours

Pin 1 White CAN High (AWG 26 - 0.14 mm²)

surge impedance: 140 Ω
Pin 2 Brown Daisy Chain (AWG 26 - 0.14 mm²)
Pin 3 Green CAN Low (AWG 26 - 0.14 mm²)
surge impedance: 140 Ω

Controls
 KingDrive

Components
Electrical equipment
Ethernet

General

Ethernet Ethernet

The Ethernet sub-network is used to connect the Master ConveyorControllers to the

Slave ConveyorControllers. A 100 MBit Ethernet with RJ45 connectors and cables will
be used. A TGW protocol will be run with UDP.

Please note: The Ethernet sub-system constitutes an isolated network and must not
be connected to another Ethernet network!!

Electrical data

Rated voltage [V] 50

Rated current [A] 1.75 (at 20 °C)
Transmission rate CAT5e
Surge voltage category I
Pollution degree 1
Leakage resistance MΩ > 500 (100 V)

Controls
 KingDrive

Components
Electrical equipment
Ethernet

Ethernet connecting plug RJ-45

The assembly instructions are included in the Installation documentation of the

respective KingDrive product.

Mechanical data

Number of poles 8
Protection rating IP20
Flammability rating V0
acc. to UL 94
Contact durability >1000

Temperature

[°C]
Ambient temperature -30 ÷ +40 1

1
Please note: .... The connection plug has to be assembled at an ambient
temperature of more than -10 °C If the ambient temperature is
below -10 °C, the cables should be prepared in an appropriate
area or by means of adequate heat sources.

Controls
 KingDrive

Components
Electrical equipment
Ethernet

Ethernet connecting plug RJ-45

Diameter and connection mode

Solid conductor (1 wire) TIA568B and A: AWG 26 ÷ 24 (0.13 ÷ 0.21 mm²)

Profinet: AWG 22 (0.32 mm²)

Stranded conductor (7 TIA568B and A: AWG 26 ÷ 24 (0.14 ÷ 0.23 mm²)

wires)
Profinet: AWG 22 (0.36 mm²)

Insulation diameter ≤ 1.60

Outer cable diameter 4.5 mm ÷ 8 mm
Connection mode Insulation displacement contacts (IDC)
according to IEC 60352-4
Strain relief >50
Shielding contact large scale >180° (shield support)

Controls
 KingDrive

Components
Electrical equipment
Ethernet

Ethernet cable

Technical Data

Manufacturer Helukabel
Type Helukat
(item number 800653)

Weight 67 kg/km
Bending radius, multiple 100 mm
Operating temperature min. -40 °C to +80 °C
Fire load, reference value 0.34 MJ/m
Copper weight 32.00 kg/km

Properties

Cable 2 x 2 x 0.64 mm²

Diameter of inner conductor
Wire colours
Shielding 1
Material of inner sheath
Shielding 2
Total shielding
Material of outer sheath
External diameter of cable
Colour of outer sheath
copper, bare (AWG 22/1)
white, yellow, blue, orange
polyester film over stranded wires
PVC
polyester foil, aluminium foil
braided copper, tinned
PVC
approx. 6.5 mm ± 0.2 mm
black

Controls
 KingDrive

Components
Electrical equipment
Ethernet

Ethernet cable

Electrical data

Surge impedance 100 Ohm ± 15 Ohm at 1 to 100 MHz

Conductor resistance 62 Ohm/km
Leakage resistance 0.5 Ohm/km
Loop resistance 124 Ohm/km
Operating capacity 50 nF/km
Test voltage 2 kV

Controls
 KingDrive

Components
Electrical equipment

PTM PowerTapModule

The PTM is used to supply the electrical components with 24 V or 48 V directly via the
PowerTrack. By plugging it onto the PowerTrack it can be felibly used.
The supply of the following elements is limited by the fuses to 24 V_2 A und 48 V_7 A.

Connection 24/48 V
1. 2. 3. 4.

1.
2.

Pin assignment Opening for cable tie

Connector assignment
Pin 1 Pin 2 Pin 3 Pin 4
24 V +24 VDC n.c. GND n.c.
(not connected) (not connected)

48 V +48 VDC GND

Controls
 KingDrive

Components
Electrical equipment
PTM PowerTapModule

Technical Data

24 V 48 V
Stocko MKF 13264-6-0-404 Phoenix
Connector type
FMC 1.5/3-ST-3.5
Number of poles 4 2
Fuse 2 A time delayed 7 A time delayed
Temperature range -30 °C to +40 °C
Dimensions (L x W x H) 39.5 x 29.7 x 41.7 mm
by means of cable tie in the provided opening
Strain relief of cable
(see above)
Protection rating IP20
TGW ID number 00507398

Use cases:

Designation Voltage Nominal Other

[VDC] current [A]
Scanner 24 0.2
(Leuze) max. 0.5
Heated scanner 24 0.5
(Leuze) max. 1
Solenoid valve 24 0.2 max. 0.5
ConveyorController 24 0.16
Switch 24 0.1
Signalling column 24 0.26 4 x 0.045 A per LED
0.080 A for buzzer
MC MotorController 24 0.03
Proximity switch M12 24 0.011
48 VDC drive 48 max. 3.2

Controls
 KingDrive

Electrical Components List

The following KingDrive-relevant controls information is displayed in the Budget product
per product design option:

Description

Accumulation Function MAC Number of accumulation functions MAC

Accumulation Function SAC Number of accumulation functions SAC
Single Function MT Number of single functions MT
Single Function ST Number of single functions ST
Single Function SC Number of single functions SC
MCC Master ConveyorController Calculated number of MMC
SCC Slave ConveyorController Calculated number of SCC
Power Supply 48 V Calculated number of 48 V power supply units
Current 24 V [A] KDR Required current (24 V) in Ampere for
KingDrive integrated sensors/actuators
1
DI KDR: LOG sensor Number of sensors (reacting to load)
1
DI KDR: POS sensor Number of sensors (reacting to device)
1
DI KDR: drive Number of input signals for the electrical drive
1
DO KDR: solenoid valve Number of solenoid valves
1
DO KDR: drive Number of output signals for the
electrical drive
Engineering length for Calculated length of cable duct
electrical equipment

AC drive rev SM_KDR 0.47 kW Example for the specification of

an electrical drive
See next page for more information

The following values specified in the Controls Information are to be understood as

reference values and may slightly vary in the realisation phase:

 MCC Master Accumulation Conveyor

 SCC Slave ConveyorController
 PowerSupply 48 V

1
Please note: .... integrated in KingDrive

Controls
 KingDrive

Electrical Components List

Naming of electrical drives

Controls
 KingDrive

Scope of Supply
The table below displays the scope of supply of the required hardware components.

Component Controls partner TGW Mechanics

Control cabinet X -
Cable duct incl. cabling X -
48 VDC power supply unit - X
48/24 VDC Junction Box - X
Current requirement 24 V
- X
→Electrical Information
24 VDC supply unit incl.
X -
cabling 1
MCC Master
- X
ConveyorController
Profi-Bus/Profinet cabling
X -
incl. plug
SCC Slave
- X
ConveyorController
Ethernet cable incl.
- X
cabling
KingDrive-integrated
- X
sensor equipment
Shaft encoder for path
X -
tracking (if included)

1
Please note: .... In case of BSF K, the 24 VDC power supply unit is provided
by TGW Mechanics

Controls