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Digi-Drive
Controller for DC Motors
REM Alarm %A
S %
P CAL
rpm
DISPLAY
LOCAL HI
Digi Drive
Web: http://www.ktron.com
Important information.
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Docu-No.: 0890019601-EN K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part
of operating personnel. Further, reference is made to the purchase order, acceptance or other document that con-
Date: 2009/May/26 tains the express K-Tron disclaimer of warranties for a statement of the provisions limiting or disclaiming certain
warranties with respect to the Company's equipment. Except as otherwise expressly provided by K-Tron in any
such document, K-TRON MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
Original: 0890019601-EN PURPOSE, NOR ANY OTHER WARRANTY, EXPRESS OR IMPLIED, WITH RESPECT TO THE EQUIPMENT.
If an error or ommission is found, please contact: documentation@ktron.com.
Inhaltsverzeichnis
4 Installation .....................................................................18
4.1 Unpacking and assembly ................................................18
4.1.1 Mounting onto the K2M feeder ........................................19
4.1.2 Assembly in control cabinet ............................................20
4.2 Connecting the Digi-Drive ...............................................21
5 Operation .......................................................................23
5.1 The levels of the Digi-Drive .............................................23
5.1.1 Operating mode ..............................................................23
7 Maintenance .................................................................. 42
7.1 Cleaning .......................................................................... 42
7.2 Preventive maintenance work ......................................... 42
8 Appendix ....................................................................... 43
8.1 Connection diagrams ...................................................... 43
1 Safety notes
Do not place hands or other body parts into moving parts or machine.
Power off and disconnect air supply before working on the equipment.
V Ensure that only qualified and trained personnel work with the
equipment.
V Establish personnel responsibilities for operation and
maintenance.
V Ensure that the personnel has read and understood the operating
instructions to all installation components, particularly this chapter
"Safety notes".
V Strictly follow the operation and maintenance instructions.
V The plant owner must replace immediately damaged or missing
components.
V The plant owner is responsible for compliance with legally
prescribed accident prevention and safety regulations.
2.1 Features
The Digi-Drive is a DC motor controller.
The setpoint input can be made using:
Keyboard of the device
Analogue input
Frequency input
Local mode
The input of the speed setpoint value, hereafter called setpoint value, is
made on the keyboard of the Digi-Drive.
The input and display of the setpoint value can optionally be made in
rpm
% of maximum speed
a user-defined unit of measurement (kg/h, g/min, lb/h, etc.)
External-direct mode
The input of the setpoint value takes place as a frequency or analogue
signal. The display of the setpoint value can optionally be made in
rpm
% of maximum speed
a user-defined unit of measurement (kg/h, g/min, lb/h, etc.)
In this setting, it is not possible to change the setpoint value of the Di-
gi-Drive using the keyboard.
External-ratio mode
The setpoint is transferred to the frequency or analogue input of the
Digi-Drive as a ratio to a master setpoint value signal or to process vari-
able. The desired percentage ratio is input on the keyboard with a value
range from 0.0 to 100 %.
In the operating configurations
External-direct mode
External-ratio mode
see Technical data capter 3.
Display
The messages which appear on the display have the following mean-
ings:
Changing the
DISPLAY
Values of the process
DISPLAY or LOCAL HI
Held down at the same time as high or deep rapid increase or de-
crease of setpoint value.
Pressing DISPLAY key: display of the programmed value of a pro-
gramming variable.
STOP
HI
Shift key for the speed stage for double-reduction feeders.
LO
8 7 6
3 Technical Data
t1 = t2
4 Installation
V Ensure that the Digi-Drive is connected and put into operation only
ba authorized personnel.
V The Digi Drive includes not a disconnecting switch. Ensure that
you include this disconnecting or an emergency shut-down switch
according the EU machine guide line.
Ambient conditions
V Only use explosion-proof feeders in hazardous areas.
V Only install the feeder in an environment conforming to the technical
data (see Section 3) and the safety notes (see Section 1).
2
1
1. Mount the Digi-Drive onto the fixing support (2) using the fastening
screws (3).
2. Mount the fixing support (2) onto the feeder with the two anchor
bolts (1).
3. Fix the fixing support (2) with setting screw (4).
200 mm
295 mm
1 1. Slide the Digi-Drive (1) from the front into the recess.Tighten the
screws (2) for the front panel.
2 2. Slide the electrical duct rails (3) into the groove of the Digi-Drive
housing from the rear.
TB1
TB2
1. Open the front panel (2). Loosen the Phillips screws, but do not re-
move them.
4
2. Remove the cable to the display (1).
3 3. Remove the assembly screws on the power part (4) and pull the
power part (3) out of the housing.
4. Connect the Digi-Drive according to the connecting diagram.
2 1
Cable length from the cable grip (1) until the relevant terminal block
(2) is 23 cm.
Kabellnge: 23 cm 1
5 Operation
REM Alarm %A
S % % display
P CAL
rpm
REM Alarm %A
S % user-defined unit
P CAL
rpm
rpm S
P
%
CAL
S
P
%
CAL
S
P
%
CAL
rpm rpm rpm
REM Alarm %A
S % Example: external direct mode, setpoint value display in %.
P CAL
rpm
You can start the Digi-Drive as follows after entering a setpoint value
in local mode.
V Using the following key for HI/LO switching with a single reduction
gear can damage the gearbox. Therefore set the program variable
P3 to 2. Check the screw rotation after this programming! If rota-
tion is wrong change motor cable 5 and 6 at screw terminal TB1.
Pressing the keys at the same time until the display changes to the
first programming variable 'P0'.
REM Alarm %A
%
After approx. 2 sec., the display automatically changes to the pro-
S
P CAL
rpm
grammed value.
Press the DISPLAY key to show further program variables until the re-
quired variable is shown. 'P0' reappears after 'P24'.
Enter the numerical value for the selected variable:
Select the next programming variable, press the DISPLAY key once
again.
The changed values are stored as soon as you press the key
STOP
REM Alarm %A
S %
P CAL
rpm
Parameter Description
P1/P2 Alarm limit value in the case of interruptions of the feeding product
flow resulting from lack of product or building of bridges in the product.
Entering the limit value:
P1 for low speed gear and feeding with just a single gear speed.
P2 for high speed.
Input 0: Function off:
If the value falls below the value entered, the alarm display flashes.
Determine the start value for the limit values as follows:
Program all programming variables and specify setpoint value for
later operation.
Let the feeder run without product and note the percentage of the
nominal current.
Fill the feeder with product, allow it to run and note the percent-
age of the nominal current.
Enter the mean value of the two values obtained according to the
gear speed in P1 or P2.
Parameter Description
Input Function
Digi-Drive sets the standard value to "low speed" when switched on. The operator can
0
change this setting by pressing the "HI/LO" key on the keyboard.
Digi-Drive sets the standard value to "high speed". The operator can change this setting by
1
pressing the "HI/LO" key on the keyboard.
Start-up and operation only with "low speed".
*2
The key "HI/LO" is deactivated (for single-reduction gear).
Start-up and operation only with "high speed".
3
The key "HI/LO" is deactivated.
Parameter Description
P4 Input
of the control mode (origin of the setpoint value).
of the possibility for changing the control mode on the keyboard.
Parameter Description
P5 Input of the span factor for "external direct mode" or "external ratio
mode".
The span factor determines the factor required for the scaling of the
input frequency to 2 kHz at 2000 rpm.
Span factor = 2000 rpm / input frequency (Hz)
Example:
Input frequency: 10 kHZ /
Calculated span factor: (2000/10000)x100 = 20
Parameter Description
Input Function
0 Input and display of the setpoint value as speed of the motor in rpm.
1 Input and display of the setpoint value as percentage of the maximum motor speed (see P0).
Input and display of the setpoint value in a user-defined unit, e.g. lb/h, g/min, etc. (see section
2
"calibration").
Parameter Description
P8 For the new Digi-Drive Sw 4.7 and U3.0 and later not used and dis-
played.
Parameter Description
Parameter Description
Input Function
*0 Programming on keyboard possible.
1 Programming on keyboard not possible.
Parameter Description
P11/12 Input of the maximum admissible nominal current intensity of the mo-
tor.
When the value input is exceeded, the alarm display on the display of
the Digi-Drive lights up. At the same time, the alarm is transmitted to
the alarm relay.
Nominal current intensity, see motor nameplate.
Standard value: 2.5
Values which exceed the programmed value at P13 are not accepted.
Input of maximum current intensity
P11 for gear speed ("low") and feeder with just one gear speed,
P12 for gear speed ("high").
Parameter Description
Input Function
*6 Digi-Drive with 6-amp power supply (standard value)
12 Digi-Drive with 12-amp power supply unit.
Parameter Description
Parameter Description
Input Function
*0 Alarm
1 Motor runs
Parameter Description
Parameter Description
Input Function
*0 option board not installed.
1 option board 9191-60241 installed.
2 option board 9191-60237 installed.
Parameter Description
To activate the following function, turning off and on again the main
power.
Input Function
Volumetric operation.
*0
If programming is done from 1 to 0, the programming variable P4 must be set to the new value.
Sets the programming variable P4 to 2 (Start with "external ratio").
1
P4 is no longer displayed in programming level (gravimetric operation).
Sets the programming variable P4 to 0 (Start with "fixed local").
2
P4 is no longer displayed in programming level (manual control maintenance).
Sets the programming variable P4 to 4 (Start with "external direct").
3
P4 is no longer displayed in programming level (gravimetric operation).
Parameter Description
P19 Selecting of the motor ramp rate in seconds. How many seconds to
reach the setpoint.
Range from1-5 Sec.
Parameter Description
Input Function
*230 Current limit calculated for 230 VAC
115 Current limit calculated for 115 VAC
Parameter Description
Input Function
60 Set the right divider for the rpm display.
90
100
*120
Parameter Description
Parameter Description
Input Function
*0 Display in Watt.
1 Display in % A.
Parameter Description
Input Function
*0 All alarms active.
1 Alarm A disabled.
Step Function
Change to programming mode and program the programming variable P4 to "0" (local con-
1 troller) and P7 to "0" (setpoint value in rpm). Exit programming mode with the "Stop" key (see
Programming 5.3).
2 Select required speed with the "High/Low" key.
3 Enter setpoint value 1000 rpm.
Start feeder. If the feed flow is constant, fill a collecting hopper three times for a period of 1
4
minute in each case.
5 Weigh the samples and calculate the average feed rate in kg/h.
Calculate the calibration factor for the programming variable P9 using the average capacity
on the basis of the following formula:
( Average ) [kg/h] -
( c al factor )P9 = --------------------------------------------------------------------
6 ( Setpointvalue ) [ rpm ]
E.g.
15 [kg/h]
0, 015 = ---------------------------------
1000 [ rpm ]
7 Enter the multiplied value P9 (e.g. 0,015).
Return to programming variable P7 and change the entry to "2" (Cal). The Digi-Drive is now
8 calibrated.
If necessary, change the control mode of programming variable P4 to "External".
Press the "STOP" key to exit the programming mode. The "CAL"-symbol now appears on the
screen.
9
Note:
The setpoint value 1000 U/min should now have changed to 15 CAL = 15 kg/h at 1000 rpm.
Requirements:
Input device for setpoint value is connected according to Fig. 5.8 or
Digi-Drive Fig. 5.9;
on the option board: Jumper 1 and 2 are in position 1..2 U;
setting of the motor speed (programming variable P0): 2000 rpm.
Set programming variable P4 to 1 or 2. Then show setpoint value
on Digi-Drive.
Option board
Specify 10 V (100 %setpoint value) on terminals 3 and 4.
3 4 Set setpoint value display using potentiometer S PT3 to
2000 rpm (external direct)
or
100 % (external ratio)
Analog controller
Specify 0.1 V (1 % setpoint value) on terminal 3 and 4.
Digi-Drive
6 What to do when...?
The speed signal is a square -wave signal from 0 to 7,2 kHz/5 VDC. The
Signal can be measured at the following locations:
On the feeder: Connect frequency counter between 1 (5 VDC) and
2 (signal).
On the Digi-Drive: Connect frequency counter between TB2-8 (5
VDC) and TB2-9 (signal).
Note
The ratio of capacity level of the speed signal is influenced by the dis-
tance of the Hall effect pick-up (1) to the field spider (2). A ratio of ca-
Note
Pick-up is located in the feeder beside the drive shaft of the motor.
For all opto speed pick-up's no adjustments necessary.
2
6.2 Troubleshooting
Before you reset one of the programming variables, check whether or
not the previously selected setting was deliberately selected.
To set the programming to default values, press programming switch
on the display board during power on.
ERR 6
No measurement of
motor current Defective wiring on motor. Check and correct motor wiring.
speed impulse Have the Digi-Drive replaced by
Motor defective. K-TRON customer services.
ERR 7 Defective on the display board (data Replace display board.
Eeprom error cannot be stored).
ERR 8 Too high motor load at low speed. Check feeder.
Requested torque is
higher than the digi-
Drive can deliver.
ERR 9 Problem with power supply. Use line filter. Change power
Measured AC Voltage supply.
outside of allowed Defective power board. Change power board.
range.
ERR A Pick-up wrong adjusted. Readjust pick-up.
Speed Setpoint Disturbances on the speed signal Shield cables.
line.
7 Maintenance
7.1 Cleaning
If there is any external soiling of the housing of the Digi-Drive, wipe
down using a damp cloth and normal industrial cleaners.
8 Appendix