Weigh Feeder Manual (Keh)

WEIGH BELT FEEDER KEHKASHAN PR446
PR446 WEIGH FEEDER CONTROLLER
BELT FEEDER CONTROLLER
AUTO DEAD RANGE
SELECT RATE TOTAL CLEAR ENTER
1 2 3 4 5
6 7 8 9 0
This document applies to software versions:

PR446-1 / PR446A1 : A1.8.x
PR446M1 : A1.3.x
Issue 1.7 December 2011 1Page 1 of 54
Kehkashan Automation Pvt Ltd., weigh feeder controller
CONTENTS
1 Overview ......................................................................................... 4
1.1 Description ....................................................................................... 4
1.2 Model Versions ................................................................................ 6
1.3 Front Panel Data Entry.....................................................................6
1.4 Control Data ..................................................................................... 6
1.5 Typical Application ...........................................................................7
1.6 Digital Inputs & Outputs....................................................................8
1.7 Closed Loop Control.........................................................................9
1.8 Multiple Feeder Application - Serially Linked ..................................10
1.9 Remote PLC or Computer Serial Link.............................................11
1.10 Multiple Feeder Application - Analogue Linked............................... 12
2 Operation ...................................................................................... 13
2.1 Front Panel Operation ....................................................................13
2.2 Flow Rate Dead Range ..................................................................14
2.3 Dynamic Tare................................................................................. 14
2.4 Automatic Zero Adjustment ............................................................ 14
2.5 Tacho ............................................................................................. 14
2.6 Data Entry ...................................................................................... 15
2.7 Access to Maintenance Facilities.................................................... 15
2.8 Multidrop Serial Interface................................................................ 16
2.8.1 Basic Master/Slave Controller Mode............................................... 16
2.8.2 Full Slave PLC/Computer Mode ..................................................... 16
2.9 Serial Interface Command Set........................................................ 16
2.10 Command Definitions .....................................................................18
2.10.1 ST : Set Target Rate ....................................................................18
2.10.2 TT : Set Target Total ....................................................................19
2.10.3 FL : Flow ...................................................................................... 19
2.10.4 RT : Resettable Total .....................................................................19
2.10.5 CT : Clear Total............................................................................20
2.10.6 DT : Dynamic Tare .......................................................................20
2.10.7 DP : Decimal Places.....................................................................21
2.10.8 ER : Error ..................................................................................... 21
Page 2 of 54 December 2011 Issue 1.7

3 Dynamic Calibration and Dead Band Adjustment ..................... 21

3.1 Initial Dynamic Tare & Calibration Procedure................................. 22
3.2 Dynamic Tare & Dead Range Adjustment (Passcode 1)................ 24
4 Control Data Adjustments and Maintenance ............................. 31

4.1 Weigher Data Adjustments (Passcode 2) ...................................... 31
4.2 Feed Rate Control Adjustments (Passcode 3) ............................... 34
4.3 Maintenance (Passcode 4) ............................................................ 38
5 Specification and Installation ..................................................... 40

5.1 Mains Supply ................................................................................. 40
5.2 Load Cell Excitation ....................................................................... 40
5.3 Load Cell Input Characteristics ...................................................... 40
5.4 Tacho Supply................................................................................. 40
5.5 Tacho Input.................................................................................... 40
5.6 Digital Inputs.................................................................................. 40
5.7 Analogue Outputs.......................................................................... 41
5.8 Analogue Input (PR446A only)....................................................... 41
5.9 Serial Interface (PR446M only) ...................................................... 41
5.10 Environment .................................................................................. 41
5.11 Wiring Diagram: 4 Wire Load Cell Connection ............................... 42
5.12 Wiring Diagram: Remote Load Cell Sensing .................................. 42
5.13 Wiring Diagram: Tacho .................................................................. 43
5.14 Wiring Diagram: Digital Inputs........................................................ 44
5.15 Wiring Diagram: Digital Outputs..................................................... 44
5.16 Wiring Diagram: Analogue Outputs................................................ 45
5.17 Wiring Diagram: Analogue Input (PR446A only) ............................ 45
5.18 Wiring Diagram: Serial Interface. (PR446M Only) .......................... 46
5.19 Enclosure ...................................................................................... 47
5.20 Wiring Connections........................................................................ 48
5.21 Installation Procedure .................................................................... 49
5.22 EMC ................................................. Error! Bookmark not defined.
6 Equipment Faults......................................................................... 52
6.1 Out of Range ................................................................................. 52
6.2 Failures.......................................................................................... 53
6.3 Lost Pass Numbers : Restore Factory Settings.............................. 53

Overview
1.1 Description
The PR446Weigh Belt Feeder controls the feed rate of material from
a conveyor belt by adjustment of the belt speed or by adjustment of
material feed onto a belt running at constant speed.
It connects with one or more strain gauge load cells fitted to a belt
weigher mechanism from which it generates a calibrated weight
signal. It also connects with a digital tacho, from which it receives
pulses in proportion to belt movement. From these two inputs and
from calibration and control data held in its system memory it
continually calculates the rate of flow of material over the belt and
the total quantity of material transferred.
The quantity transfer calculation is:
Where,
The flow rate calculation is:
From the flow rate reading, it accurately controls a 4-20mA analogue

output signal, achieving a preset target feed rate whenever closed
loop control has been started.
An additional 4-20mA analogue output provides an actual feed rate

signal to PLC/Computer or remote display.
Batching Control

The PR446may be used to control the feeding of a preset quantity of
material, digital output T0can be configured to a belt run function and
together with start/stop digital inputs provide the means of running
the belt until the desired target quantity has been conveyed.
The preset material target total may be entered via the keypad or
downloaded serially in the case of the PR446M version.
This batch control mode is a configurable option available on all
models.
The following options are available:
 Analogue Remote Control
The PR446A provides an additional analogue input which

when configured will control the target feed rate and provides
remote control of the feeder from a host PLC or PC system.
In multiple feeder applications a number of PR446A
controllers may have their target feed rates controlled by a
master PR446.
 Multi drop serial communications
The PR446M provides an RS485 serial communications link

for multiple feeder applications, a simple ASCII coded
message protocol provides target flow, target total, actual
flow and total signals via a single twisted pair cable to a host
PLC or computer.

1.2 Model Versions

PR446-1 Basic unit.
PR446A1 Additional Analogue input.
PR446M1 Additional Multi drop Serial RS485 Output.
The above units are AC powered, add a suffix 'D' to specify the DC
powered versions e.g. PR446A1D is a DC powered unit with
Analogue Output.
An optional IP65 transparent front cover is available by adding suffix

'/TC' to model number, e.g. PR446A1/TC.
1.3 Front Panel Data Entry

Being a microprocessor based product the PR446 operates from
control and calibration data stored in non-volatile memory. This data
is entered and modified via the unit's front panel using the sealed
pushbutton keys provided.
1.4 Control Data

The control data determines the control functions, feeder control,
calibration, alarms, serial interface, etc and enables the unit to be
readily configured.
Closed loop feed rate control is effected by continuous monitoring of

the flow of material over the belt and adjustment of the analogue
output achieving a pre-set target feed rate.
Settings are provided to optimise stable control and account for
delays, fluctuations etc.

1.5 Typical Application
W EIGH
LENGTH
MOTOR
DRIVE
4-20mA
SPEED
SIGNAL
LOAD CELL TACHO
Practicon BELT FEEDER CONTROLLER

ACTUAL RATE
4-20mA
OPTIONAL 4-20mA
ANALOGUE INPUT AUTO DEAD RANGE
ALARM
TARGET RATE
1 2 3 4 5
W EIGHT
6 7 8 9 0 PULSE/RUN
OPTIONAL SERIAL
COMMUNICATIONS
START STOP

1.6 Digital Inputs & Outputs

The PR446 has 2 digital inputs and 2 digital outputs which are used
as defined below.
Digital Inputs
Input Function Description
D0 Start Used to start closed loop control.
It also sets the rate control analogue
output to its initial level as determined by
the target rate TR setting.
It puts the Run output T0 on whenever
parameter WO set to NO.
D1 Stop Used to stop closed loop control and turn
off the Run output whenever parameter
WO set to NO.
Digital Outputs
Output Function Description
T0 Run/Pulse Whenever parameter WO set to NO it
indicates that closed loop control is
operating.
Whenever WO set to YES it will pulse on

for 100ms whenever the totalised weight
increases by the quantity set in
parameter OP.
T1 Alarm Indicates that an out of tolerance flow
rate condition has persisted for the time
set in parameter AD ( Alarm Delay ).
Goes off when the flow rate returns within
the tolerance determined by the UN
(Under Rate) and OV (Over Rate)
settings.

1.7 Closed Loop Control

The control of feeding can be started and stopped by using the two
digital inputs either under automatic control from other equipment or
manually from external pushbuttons.
The Auto LED indicates when automatic feed rate control is in

operation.
Closed loop control of feed rate is achieved by adjustment of the 4-

20mA analogue rate control output while monitoring the error
between the target and actual rate.
Following the calibration of the rate control analogue output as

detailed in section 0 and any external adjustments to variable speed
drives etc, the Maximum Rate parameter MR setting will then
determine the working range of the controller.
At start up, the rate control output is initially set to the theoretically
correct level as determined by the target rate TR and the maximum
rate MR settings as follows.
Following the Start Delay time the closed loop control will start and
the rate control output will be adjusted every CD interval by the PA %
amount of the calculated error between the actual feed rate and the
target.

1.8 Multiple Feeder Application - Serially Linked

A PR446M may be configured as a master in which case it transmits
its actual feed rate to other slave units (PR446 or PR448) via a
single twisted pair cable.
RS485 Single Twisted Pair
PR446M
Master Slave Slave
In this multiple feeder application, one unit feeds the main material
while the others feed additional materials. The main feeder is
configured as the master and controls the feed rates of the others by
communicating its actual feed rate via the RS485 multi-drop serial
interface.

1.9 Remote PLC or Computer Serial Link

A PR446M may be configured to communicate with a host PLC or
computer, with up to 32 units connected via the RS485 multi-drop
interface.
RS485 Single Twisted Pair To host

computer
or PLC
PR446M #3
#2
#1
The protocol is simple ASCII eg:
Host sends: !02FL[CR]

PR446 address 2 replies: !02FL12345[CR]
[CR] is the carriage return character.

1.10 Multiple Feeder Application - Analogue Linked

A number of PR446A controllers may have their target rates
controlled by a master PR446 or by a host PLC or computer system.
4-20mA
ANALOGUE ANALOGUE
OUTPUT INPUT
PR446A PR446A PR446A
MASTER SLAVE SLAVE
The main feeder transmits its actual feed rate signal to the others
which have their target feed rates controlled accordingly.
If the feed rate ratio of master to slave, which is governed by the

installation characteristics, must be adjustable then the Ratio metric
Mode should be employed. This allows the target feed rate of the
slave to be further scaled by the user.
When in Ratio metric Mode a Target Percentage (TP) can be

entered on the slave unit, this is then used to scale down its target
feed rate whilst still following the analogue input signal received from
the master.
If the unit is set to ratio metric mode the slave target feed rate is
calculated as follows:

Operation
1.11 Front Panel Operation
AUTO DEAD RANGE
1 2 3 4 5
6 7 8 9 0
The PR446 display shows both parameter type and its value.
Operating the SELECT key will scroll through the working displays
as listed below:
99999K/H Flow Rate

TR Target Feed Rate
TP Target Percentage (only when AM = RAT)
TT Target Total (only when BM = YES)
T Non Re-settable Total
PASS Password Number access to internal data
Operating the RATE key shows current feed rate. Operating the
TOTAL key shows the re-settable total which may be cleared to zero
with the CLEAR key.

1.12 Flow Rate Dead Range
When the flow rate is less than the DEAD RANGE the 'DEAD
RANGE' LED is lit.
When the Flow rate is less than zero (weight input below the tare)
the display shows the amount of "negative" flow.
1.13 Dynamic Tare

To perform a dynamic tare without entering the passcode, operate
the CLEAR and SELECT (CLEAR first) for 3 seconds.
The display will flash during the dynamic tare operation as normal.
1.14 Automatic Zero Adjustment

The internal dynamic zero is adjusted every 30 seconds by 0.01% of
LC (Load Cell Capacity) during periods within the dead range with
the conveyor belt running.
1.15 Tacho
Normally the Tacho input is connected to a remote tacho device to
provide an accurate belt speed signal. However, it is possible to
operate without a tacho input by means of the internal tacho
simulator facility (refer to section1.23).
With the internal tacho selected the tacho connections may be wired
to provide a Start/Stop input (refer to section 3.13).
An * symbol is displayed in the left most position when the tacho

signal is lost i.e. belt stopped.

1.16 Data Entry

A displayed parameter is placed in the data entry mode by
operating the ENTER push-button and is seen to be in the
entry mode by one digit of the displayed value flashing on/off.
The data entry procedure is:
 Having selected a parameter operate ENTER at which point

the first digit of the parameter flashes on/off.
 Operate the numeric pushbuttons to obtain the required

setting. Note that each digit is displayed in the right hand
position upon entry and moves to the left as each successive
digit is entered so any following zeroes must be entered to
'push' the most significant digit into the correct position on the
display.
 Operate ENTER again to steady the value.

1.17 Access to Calibration and Control Data
Access to Calibration and Control Data is password number
protected. The two sections covering dynamic calibration and control
data each have their own password numbers. These are factory set
to '1' and '2' respectively but may be changed by the user for
additional security. If the password numbers are lost see section4.3.
To gain access to either data area from the working displays operate
the select key until the indicator shows PASS. Enter the password
number to show the first parameter in the area accessed. Use
SELECT to index through the parameters.
To exit a data area operate ENTER at the last parameter i.e. at

EXIT.
1.18 Access to Maintenance Facilities

Maintenance section is accessed via password number 3. See
section 2.3.

1.19 Multi-drop Serial Interface

The PR446M has an RS485 serial interface capable of supporting up
to 32 nodes via a single twisted pair cable up to 1000 metres end to
end distance.
Two serial communication modes are provided as described below.
1.19. 1 Basic Master/Slave Controller Mode

This provides for one unit to be configured as a master
communicating its actual feed rate to the others configured as
slaves.
This mode supports multiple feeder applications where the main
feeder controls a number of slaves via its serial interface.
The main unit has its Serial Mode (SM) parameter set to BM (basic
master) while the others are set to BS (basic slave).
1.19. 2 Full Slave PLC/Computer Mode

This provides for multi-drop bus communication with up to 32 units
connected to a host PLC or computer.
It supports multiple feeder applications where a number of feeders
are under the full control of a remote PLC or computer.
The Serial Mode (SM) parameter is set to FS (full slave) in each unit.
1.20 Serial Interface Command Set

Applies only when PR446M is configured to operate in Full
PLC/Computer Master Slave mode i.e. with Serial Mode (SM)
parameter set to FS.
Command Range Definition
ST 0-200.00 SET TARGET RATE, sets the target feed
rate.%
TT 0-99999 SET TARGET TOTAL, sets the target total
(scaled by DDP).
FL 0-99999 FLOW, returns the current flow rate (scaled by
DDP).
Command Range Definition
RT 0-999999 RESETTABLE TOTAL, returns the current re-
settable total value (scaled by DDP).
CT CLEAR TOTAL, clears the re-settable total.
DT DYNAMIC TARE, initiates the dynamic tare
function. Note: completion time is dependent
upon the TP setting and the belt speed.
DP 0-4 DECIMAL PLACE, returns DDP setting.
ER 0-9999 ERROR, returns the error code as defined by
the following list:
Error
Code Definition
0000 No Error
1811 Out of range Load Cell signal
positive
1810 Out of range Load Cell signal
negative
1409 Load Cell supply fault
1821 Load Cell sense voltage fault
3001 Out of range belt speed
3002 Belt Stopped
3003 Dynamic tare in progress
xxxx Internal error

1.21 Command Definitions
The general format of command strings is as follows:
! aa CC nnnnnn [CR]
Where:
! : Delimiter character
aa : 2 digits representing the station address
CC : 2 letters representing the command
n to nnnnnn : 1 to 6 digits representing the value
associated with the command.
[CR] : Carriage return
Note, the number of digits is fixed for a

given command.
All ASCII coded characters of the following format:

8 Data Bits, 1 Stop Bit, No Parity.
1.21. 1 ST : Set Target Rate

Command : Set the target feed rate %
Format : !aa ST nnn.nn [CR]
Example:
HOST SENDS PR446 RETURNS

!02ST050.00[CR] !02ST050.00[CR]
Station 02 Target Rate = 50% of MR

1.21. 2 TT : Set Target Total

Command : Set the target total
Format : ! aa TT nnnnn [CR]
Example:

!02TT05000[CR] !02TT05000[CR]
Station 02 Target Total =5000
1.21. 3 FL : Flow
Command : Return the flow rate
Format : ! aa FL nnnnn [CR]
Example:

!02FL[CR] !02FL00326[CR]
Station 02 FLOW = 326
1.21. 4 RT : Re-settable Total

Command : Return the Re-settable Total value.
Format : ! aa RT nnnnnn [CR]
Example:

!02RT[CR] !02RT014632[CR]
Station 02 Re-settable Total = 14632

1.21. 5 CT : Clear Total

Command : Clear the Re-settable Total to zero.
Format : !aa CT [CR]
Example:

!02CT[CR] !02CT[CR]
Station 02 clear total to zero
1.21. 6 DT : Dynamic Tare

Command : Initiate a dynamic tare
Format : !aa DT [CR]
Example:

!02DT !02DT[CR]
Station 02 initiates dynamic tare

1.21. 7 DP : Decimal Places

Command : Return the DDP setting which defines the Flow
and Total value decimal places.
Format : !aa DP nn [CR]
Example:

!02DP[CR] !02DP01[CR]
Station 02 returns the DDP setting which
defines Flow and Total value decimal places
1.21. 8 ER : Error
Command : Returns the error code as defined by the
following list.
Error Code Definition

0000 No error
1811 Out of range Load Cell signal-positive
1810 Out of range Load Cell signal-negative
1409 Load Cell supply fault
1821 Load Cell sense voltage fault
3001 Out of range belt speed
3002 Belt Stopped
3003 Dynamic tare in progress
Note: any other error code would be due to internal errors and
should be reported to KEHKASHAN.
Example:

!02ER[CR] !02ER0000[CR]
Station 02 returns no error code
Dynamic Calibration and Dead Band Adjustment

1.22 Initial Dynamic Tare & Calibration Procedure
Before proceeding with initial calibration or when calibration is
suspected to be very inaccurate always carry out the Tacho and
Load Cell checks outlined in the installation section 3.21 and set the
Control Data settings in section2.
 TS/TP If the internal tacho is select either set TS to 100

and TP to 1000 for convenient Dynamic Tare period
of 10 seconds.
If external tacho is used set TP to a value which will

provide a Dynamic Tare period of at least one belt
revolution.
 CF Set CF to the number of tacho pulses generated over

the weigh length.
This will provide a reasonable initial flow rate.
 DT Do Dynamic Tare with the belt running.
 FL Go back to FL and observe the flow with the belt

still running empty.
It should be moving + and - by small amounts.
Note the highest positive flow reading.
 DR Set DR just above the highest positive flow noted

above.
 DC Perform a Dynamic Calibration by passing a

known weight over the weigher.
Observe the resultant totalised weight and enter a
corrected figure as necessary.
 CF Note CF will have changed as a result of any

Dynamic Calibration adjustment.
Following any adjustment of the Dynamic Calibration

 FL Go back to FL and observe the flow with the belt
running empty (now different due to new calibration).
 DR Set DR just above the highest positive flow noted

above.
Any subsequent discrepancy between the displayed and actual total

quantity of material passed over the weigher may be corrected by
adjustment of the calibration factor parameter CF as follows:
Use the simple formula to calculate a new calibration factor.

1.23 Dynamic Tare & Dead Range Adjustment(Pass code 1)

Factory
Parameter Range Definition
Setting
RB 0-100 RUN BELT. Used to set the Run output 0
T0 on and the belt speed signal to a
specific level, when controller not in
auto.
The run output T0 will come on (unless

configured for pulse output) together with
the analogue output A1 at the set level,
whenever RB is set to a value between 1
and 100.
Procedure:
Switch off closed loop control using the
Stop input D1.
Enter the required speed, 1 to 100% to
run the belt.
Enter 0 to stop the belt.
Note: It is acceptable to leave the belt

running in manual mode for as long as
necessary. After which, the belt may be
stopped by setting RB to zero, or,
alternatively the Start input D0 may be
applied which will reset RB to zero while
simultaneously going into auto mode.
TS 0-100 TACHO SIMULATOR, Pulse/sec. 0
If zero, unit operates from external
tacho. Any other value is used to
represent a simulated fixed belt speed,
in which case a setting of 100 is
recommended.
FL - FLOW. Used to determine at what level -
DR parameter below should be set.

Factory
Setting
DR 0-99999 DEAD RANGE. Specifies the minimum 0
flow rate below which readings are
ignored. The units are tonnes or
kilograms per hour, whichever is
selected by the TONS parameter below.
To avoid spurious readings from a
weigher running empty, set to a figure
greater than the maximum flow reading
registered on parameter FL above, when
running with the belt weigher empty.
TP 1-99999 TARE PULSES. Specifies the number of 100
belt movement pulses over which the
dynamic tare facility operates.

Factory
Setting
DT - DYNAMIC TARE. The display shows a -
totalised value that is generated without
the Dead Range (DR) operating. When
the ENTER key is operated the following
occurs:
- the display is zeroed
- the system totalises, in both
positive and negative
directions, over a number of
belt movement pulses (as
determined by the TP
parameter). The totalised value
flashes on/off until the
operation is complete
- when the totalisation is
complete the weigher zero is
automatically adjusted to
compensate for the total
obtained i.e. the weigher is
dynamically tared.
The belt must be running empty for the
correct tare to be taken. Operating the
CLEAR key stops the dynamic tare
process and zeros the display.

Factory
Setting
CP 0-99999 CALIBRATION PULSES. 0
Used only for calibration method 2

described below.
Set to zero for normal calibration

method 1.
Provides for calibration over a

predetermined belt run length.
This setting specifies the number of belt

movement pulses over which the
dynamic calibration facility operates.
Useful for calibration with a static weight

attached to the load cell, i.e. in cases
where the use of a known quantity of
material is not practical
When set to 0, the calibration run period

is controlled manually.

Factory
Setting
DC - DYNAMIC CALIBRATION 0
The calibration may be checked and if

necessary automatically adjusted as
follows (the weigher should have been
dynamically tared using the DT
parameter above before this procedure
is started).
Method 1 - with material.
- operate CLEAR
- pass known weight over

weigher (or quantity of material
that can be subsequently
weighed).
- operate CLEAR to stop the

totalisation process.
- check that the totalised reading

corresponds to the test weight,
otherwise operate ENTER and
modify the readout to the test
weight value and operate
ENTER again to complete the
calibration.

Factory
Setting
DC - Method 2 - with a static weight. 0
continued
Set CP parameter above to the required
number of belt movement pulses.
Attach a calibrated weight and run the
belt.
- operate CLEAR
- the system totalises over a

number of belt movement
pulses (as determined by the
CP parameter). During this time
the display shows the pulses
counting down to zero, after
which the final totalised weight
is displayed.
- verify/record the totalised

weight or modify as necessary.
CF 1-999 CALIBRATION FACTOR 100

Determines the flow rate and the rate of
totalisation calibration. This parameter
may be automatically determined by the
dynamic calibration procedure defined
above or it may be directly adjusted
here.
Theoretically:
CC 0-99999 CALIBRATION COUNTER. This shows 0

the number of calibrations to date.

Factory
Setting
PSET 0-999 PASSWORD SET. This determines the 1
password code for access to this
section.
EXIT - EXIT. This allows the user to exit the -
calibration and return to normal display
mode upon operation of ENTER,
otherwise SELECT will cycle around to
RB again.

2 Control Data Adjustments and Maintenance
2.1 Weigher Data Adjustments (Passcode 2)
Factory
Setting
PR446 Model Version As model
number
LC 0-99999 LOAD CELL CAPACITY. Set to the full 0
capacity of the load cells Kgs.
WF 1-100 WEIGHER FILTER. Determines the 10
number of load cell input readings over
which the weight is calculated, from a
rolling average, each time a reading is
taken (every 50ms).
1 Corresponds to no
averaging
100 Corresponds to max

averaging
SF 1-100 SPEED FILTER. This parameter sets 10
the number of belt movement pulses
over which the belt speed is
calculated, from a rolling average, at
the time each pulse is received.
Setting Filter
1 Corresponds to no
averaging
100 Corresponds to max
averaging

Factory
Setting
PG 0-7 PRE-GAIN. Determines the load cell 7
input sensitivity from 0-2.5V to 0-
20mV, as follows:
Settings Full Scale Input

0 2.56V
1 1.28V
2 640mV
3 320mV
4 160mV
5 80mV
6 40mV
7 20mV (2mV/V Cells)
IN 0-99 INCREMENT (DISPLAY). 0
Determines the minimum value by
which the weight displays increment.
0corresponds to no suppression. Note
that this suppression does not apply to
calibration parameters.
UP 0-1000 UPDATE RATE (ms). 400
Determines the display update rate in
milliseconds.
DDP 0.0.0.0 DISPLAY DECIMAL PLACE No
Determines the decimal point position Decimal
for flow rate and totalised value Place
displays. Use numeric keys to set the
decimal point position required.
SDP 0.0.0.0 STATIC DECIMAL PLACE No
Determines the static weight decimal Decimal
place which applies to OP and LCS Place
parameters. Use numeric keys to set
the decimal point position required.
TONS YES/NO TONNES. Not kilograms. NO

Factory
Setting
WO YES/NO WEIGHT OUTPUT PULSE. NO
Determines the function of digital
output T0.
When set to YES, T0 is a pulse output.
When set to NO, T0 is a Run output

which will be set on whenever the Start
input D0 is applied and off whenever
the Stop input D1 is applied.
OP 0-99999 OUTPUT PULSE. Determines the 1
increase in totalised weight in either
tonnes or Kgs as selected by TONS,
for which an output pulse is produced.
BM YES/NO BATCH MODE. Determines whether NO
the Run digital output is used for batch
control.
When set to YES, the unit totalises the
quantity of material passing over the
belt until the Target Total (TT) setting
is reached, after which the Run output
is switched off.
A batch is initiated by applying the
Start digital input which clears the total
and puts the Run output on.
When set to NO, the unit continuously

totalises and the Run output remains
on until the Stop input is applied.
PSET 0-99999 PASSWORD SET. Determines the 2
password code number for entry to
these settings.
EXIT EXIT. Operate ENTER to return to the
working displays.

2.2 Feed Rate Control Adjustments (Passcode 3)

Factory
Setting
FRU /H FEED RATE UNITS. Determines the /H
/M feed rate time units ie Kg/tonnes per
hour, or minute.
MR 0-99999 MAXIMUM RATE. The feed rate at 9
100% analogue output, in Kg/Tonnes /
FRU.
Note: This determines the scaling of
the analogue input (PR446A model).
A1R 4-20MA ANALOGUE #1 RANGE. This allows
the rate control output signal range to
be set.
Display shows actual rate.
The TOTAL and CLEAR keys are used

to switch the analogue output between
100% and 0% levels respectively.
Use the 9 and 0 keys to increase and

decrease the output until the required
level at each end of the range is
achieved
(nominally 4-20mA).
Important: When setting the 100%
level, make any necessary external
adjustments to the belt speed and/or
the material depth to ensure that the
Maximum Rate (MR) setting can be
achieved before the analogue output
reaches saturation at 20.04mA.

Factory
Setting
A2R 4-20MA ANALOGUE #2 RANGE. This allows
the additional actual rate analogue
output signal range to be set.
The TOTAL and CLEAR keys are used

to switch the analogue output between
100% and 0% levels respectively.
Use the 9 and 0 keys to increase and
decrease the output until the required
level at each end of the range is
achieved (nominally 4-20mA).
Scaling determined by Maximum Rate
(MR) setting.
PA 0-100% PERCENTAGE ADJUST. 50
Determines the amount of adjustment
to the feed rate as a result of the
calculation of error between target and
actual rate.
Note: 100% setting may cause

instability.
MA 0-99999 MAX ADJUST. Determines the 10
maximum adjustment to the feed rate
as a result of any one closed loop rate
calculation, Tonnes/Kg/FRU.
SD 0-99 START DELAY. Seconds delay before 0
active control begins following
operation of the start input.
CD 1-99 CONTROL DELAY. Seconds delay 1
time between adjustments to the
control output signal.
Normally set to 1 when controlling belt
speed.
Must be set greater than any delay in
the machines response time to
achieve stability of control.

Factory
Setting
UN 0-99999 UNDER RATE. The margin below 10
which the 'LOW FEED' alarm is
displayed and the common alarm
output is set on.
Tonnes/Kg/FRU.
OV 0-99999 OVER RATE. The margin above which 10
the 'HI FEED' alarm is displayed and
the common alarm output is set on.
Tonnes/KG/FRU.
AD 0-99 ALARM DELAY. Seconds delay time 5
before alarm output is set on following
a persistent out of tolerance flow rate
condition.
Analogue Mode: shown only when PR446 parameter = A.
Factory
Setting
AM STD / ANALOGUE MODE, determines the STD
RAT analogue input mode as defined below:
STD - STANDARD, the analogue input

is used to determine the target rate ie.
4mA = 0 and 20mA = Maximum Rate
(MR).
RAT - RATIOMETRIC, this allows the

target rate, determined by the
analogue input, to be further scaled by
a user adjustable percentage. For
further information see section 1.10.

Serial Parameters: shown only when PR446 parameter = M.
Factory
Setting
SM BM SERIAL MODE, determines the serial BM
/BS communication mode as defined
/FS below:
BM - BASIC MASTER, continuously

transmits its actual feed rate to remote
slaves at 19200 baud once per
second.
BS - BASIC SLAVE, receives its target

feed rate from a Basic Master at 19200
baud.
FS - FULL SLAVE, provides

communication with a remote PLC or
computer.
BR 1200 - BAUD RATE. Serial data speed. 19200
19200 Adjustable when SM = FS otherwise
fixed at 19200.
ADDR 0-99 ADDRESS. Sets the units address 0
when using FS mode otherwise not
applicable.
Factory
Setting
PSET 0-999 PASSCODE SET. Determines the 3
password code number for entry to
these settings.
EXIT - EXIT. Operate ENTER to return to the
working displays.

2.3 Maintenance (Passcode4)
This section provides a facility for monitoring the input signals and
resetting the otherwise non-re-settable total.

T 0-9999999 NON-RESETTABLE TOTAL. which may be
reset to zero with the CLEAR key.
HZ 0-3000 TACHO SPEED. This shows the Tacho pulse
speed in pulses per second.
ADC 0-16383 Analogue to Digital Converter output0-65535
divided by 4. This is the weight input signal
before any tare or calibration adjustments have
been made i.e. the raw weight reading.
LCS 0-LC LOAD CELL SIGNAL. This is the weight input
signal displayed in Kg before any tare or
calibration adjustments have been made. It is
the gross weight applied to the Load Cell within
the range defined by the LC setting.
0-999.999 TOTAL to 3 decimal places. Only applicable
when the unit is set to display Tonnes.
Target rate analogue input: shown only when PR446 parameter = A.

AIN 0-125.0% ANALOGUE INPUT. This is the target rate input
expressed as a percentage where 0% = 4mA
input and100% = 20mA.
Scaling determined by the Maximum Rate (MR)

setting.
Note: This input can extend up to 125% before

saturation occurs.

Factory
Setting
PSET 0-999 PASSWORD SET. This determines 4
the password code for access to
calibration pass.
EXIT - EXIT. This allows the user to exit the -
maintenance and return to normal
display mode upon operation of the
ENTER, otherwise SELECT will cycle
around to T again.

3 Specification and Installation
3.1 Mains Supply
Supply : 85-264V AC or 9-36V DC
Internal mains filter fitted
Power Consumption : 10VA max
Internal Fuse : Wire ended Wickman 1A Anti-Surge type
TR5
3.2 Load Cell Excitation

10V DC @ 120mA max, up to four 350ohm load cells may be
connected in parallel, 4 or 6 wire, remote sensing for volt-drop
compensation in long cables.
3.3 Load Cell Input Characteristics

Range : 0-20mV min, 0-2.5V max
Filter : adjustable 0.2 to 20Hz
Accuracy : Up to 65,000 internal divisions with negligible drift due
to internal self calibration.
3.4 Tacho Supply

12V DC @ 120mA max, short circuit protected.
3.5 Tacho Input

Type : 3 wire NPN, or volt free contact
or Shaft Encoder - open collector or push-pull
Range : 0 - 500 Hz
3.6 Digital Inputs

Volt free contact to switch internal 12V at 3mA.

3.7 Analogue Outputs
Current Range : 3.96 to 20.04mA into 400 ohm max
Accuracy : 0.025% (1 part in 4000)
Drift : +/- 5ppm/oC maximum
3.8 Analogue Input (PR446A only)

Current Range : 0 to 24mA into 50 ohm
Accuracy : 0.025% (1 part in 4000)
Drift : ±5ppm/°C max
3.9 Serial Interface (PR446M only)

RS485 Half Duplex.
3.10 Environment
Operating : 0 to +50°C, 20 to 80% RH,non-condensing
Storage : -40 to +80°C

3.11 Wiring Diagram: 4 Wire Load Cell Connection
UP TO APPROX 25 METRES
INPUT + +VE
LOAD CELL
+SE
LOAD OUTPUT + +IN PR446
CELL OUTPUT - -IN
-SE
INPUT - -VE
SCREEN
3.12 Wiring Diagram: Remote Load Cell Sensing
OVER 25 METRES
INPUT + +VE
LOAD CELL
+SE
4 WIRE OUTPUT + +IN
LOAD PR446
CELL OUTPUT - -IN
-SE
INPUT - -VE
INPUT +
SENSE +
6 WIRE OUTPUT +
LOAD
CELL OUTPUT -
SENSE - ALTERNATIVE CONNECTION
INPUT - FOR 6 WIRE LOAD CELL

3.13 Wiring Diagram: Tacho
SHAFT ENCODER PR446
12V SUPPLY
+V
PUSH-PULL SG INPUT
- +
0V 12V
D0 INPUT
D1 INPUT
PROXIMITY SW ITCH
SUPPLY
NPN
ALTERNATIVE CONNECTION
FOR PROXIMITY SW ITCH
PR446
BELT 12V SUPPLY

+V
RUNNING
SG INPUT
- +
0V 12V
D0 INPUT
D1 INPUT

3.14 Wiring Diagram: Digital Inputs
PR446
+V
SG
- +
0V 12V
START
VOLT-FREE D0 INPUT
CONTACTS
STOP
D1 INPUT
3.15 Wiring Diagram: Digital Outputs
PR446
VOLT-FREE
CONTACTS
TO RUN OR WEIGHT PULSE OUTPUT
T1 ALARM
OUTPUT

3.16 Wiring Diagram: Analogue Outputs
PR446
+V
A2
4-20mA
A1
400R MAX
G
SCREEN
3.17 Wiring Diagram: Analogue Input (PR446A only)
PR446A
4-20mA
A+
50R
A-
SCREEN

3.18 Wiring Diagram: Serial Interface. (PR446M Only)
PR446M PLC/COMPUTER
+ +
SERIAL
- -
INTERFACE
G G
SHIELDED
TWISTED PAIR CABLE
Cable specification:
Single twisted pair screened data transmission cable, eg Belden

8760

3.19 Enclosure
144
AUTO DEAD RANGE
96
1 2 3 4 5
6 7 8 9 0
138
PANEL
92
CUT-OUT
REAR
22
CONNECTORS
REMOVABLE
SCREW
CLAMPS
110
8
The enclosure is also available with an IP65 transparent front cover.

See section 0 for model number.

3.20 Wiring Connections
SUPPLY PR446 LOADCELL

85-264 VAC MODEL NO.
+SE
+VE
-VE
-SE
+IN
-IN
N
E
L
ANALOGUE RELAY TACHO/DIGITAL

OUTPUT OUTPUTS INPUTS
SG
D0
D1
+V
A2
A1
0V
T0
T1
G
250VAC/30VDC
5A MAX
SUPPLY PR446A LOADCELL

85-264 VAC MODEL NO. +VE
+SE
-VE
-SE
+IN
-IN
N
E
L
ANALOGUE RELAY TACHO/DIGITAL ANALOGUE

OUTPUT OUTPUTS INPUTS INPUT
SG
A+
A2
A1
D0
D1
+V
0V
A-
T0
T1
G
250VAC/30VDC
5A MAX

SUPPLY PR446M LOADCELL

85-264 VAC MODEL NO.
+SE
+VE
-SE
-VE
+IN
-IN
N
E
L
ANALOGUE RELAY TACHO/DIGITAL SERIAL

OUTPUT OUTPUTS INPUTS INTERFACE
SG
A2
A1
D0
D1
+V
0V
T0
T1
G
G
+
-
250VAC/30VDC
5A MAX
3.21 Installation Procedure

Check Control Data
Configure the system by checking and if necessary modifying the
Configuration Data defined in section2.
Check Tacho and Load Cell

Using the maintenance facility via passcode4, check the tacho
operation i.e. run the conveyor and verify the Hz reading. When
internal tacho is selected HZ is the same as TS setting provided the
tacho input is linked as defined in section3.13. Also check the LCS
(load cell signal) by application of static weights and verify:
a) that the weigher is repeatable, both up and down the scale

i.e. that it operates freely.
b) that in the case of multiple load cell installations the load cells
are correctly rationalised i.e. that they each produce the same
weight reading for the same weight applied. To do this place a
weight in different positions so that each position loads a
particular load cell more than the others. Then verify that each
position produces the same reading.

Dynamically Calibrate Whole Indicator
Complete the dynamic calibration by following the procedure under
section1.22above.
Set Dead Range

Set the Dead Range (DR) to prevent the unit totalising when running
with an empty belt.
 Use the Rate Control Adjustments (Pass 3) to adjust the

analogue output zero and full scale signal levels and make
any external feeder adjustments to achieve the required
maximum and minimum feed rate.
 Set the maximum feed rate (MR) parameter (Pass 3)
Note, this will determine the accuracy of rate output during

initial start-up before closed loop control becomes effective.
 Set all control data and proceed with the first trial run

3.1Mains Filtering
While the PR446 is immune to mains born interference within the
levels specified by BS EN 50082-2, where non-compliant equipment
is close by or is sharing the same main supply, then it is
recommended that a mains filter be used. Suitable types include the
Schaffner FN610-1/06 available from FEC order code 230-546.
Shielding
Good shielding practice applies to both the enclosure as well as
cables.
Enclosure - The PR446 is best situated within a metal enclosure

which is not used to house noise generating equipment such as
unsuppressed relays, contactors, transformers and invertors motor
drives.

4 Equipment Faults
4.1 Out of Range
This condition occurs if the load cell input signal is outside the full
scale input range as defined by the amplifier pre-gain (parameter PG
under section2above), or if the tacho input is above 500 Hz.
Display Shows 'ADC SAT+'
Indicates that the load cell input is outside the range in the positive
direction.
Display Shows 'ADC SAT-'
Indicates that the load cell input is outside the range in the negative
direction.
Display Shows 'OV SPEED'
Indicates that the tacho input is outside the 500 Hz range.

4.2 Failures
Although unlikely, the following types of equipment failure are possible. In
all cases the unit may be returned to KEHKASHAN or its agents for repair.
No Response
No indication or response of any kind. Possibly a supply circuit
failure. A soldered-in PCB (Printed Circuit Board) fuse may need
replacing as a result. Alternatively the fuse failure could be the only
fault.
Display Shows 'REGFAULT'

This occurs if the Load Cell supply is overloaded due to wiring or
Load Cell faults, or if the internal 10V supply regulator has failed.
Display Shows 'SENSE ER'

This occurs if the sense voltage (between the +SE and -SE load cell
terminals) has varied by more than 3V with respect to the internal
value which was stored at the last Tare operation.
Display Shows 'ERR nnnn', is the nnnn Fault Code Number.

This indicates that a microprocessor fault has occurred. It may help
to report the Fault Code Number to KEHKASHAN when returning the
unit for repair.
4.3 Lost Pass Numbers: Restore Factory Settings

In the event of the passwords being lost the original factory default
setting of 1, 2 and 3 can be reloaded by holding down the SELECT
and ENTER keys for approximately 30 seconds (operate ENTER key
first). After this time the display changes to read RESET. The
password number will then have been restored to the value 1, 2 and
3.

Agents and Customer Support team in Globe
SWEDEN PORTUGAL POLAND BRITAIN
CHINA THAILAND SRILANKA AUSTRALIA
NEWZELAND SOUTH AFRICA UAE KSA
Dear Customer,
Thanks for choosing globally advance digital system to

measure, monitor and control your bulk material
handling. We also appreciate the engineering brain
behind this selection of most advance technology, which
going to be a part of your innovative day to day activity.
Worm wishes from technology team of Kehkashan.
Regards,
For Kehkashan Automation Pvt Ltd.
Managing Director

Weigh Feeder Manual (Keh)

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Weigh Feeder Manual (Keh)

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WEIGH BELT FEEDER KEHKASHAN PR446

PR446 WEIGH FEEDER CONTROLLER

BELT FEEDER CONTROLLER

AUTO DEAD RANGE

SELECT RATE TOTAL CLEAR ENTER

This document applies to software versions:

Page 2 of 54 December 2011 Issue 1.7

3 Dynamic Calibration and Dead Band Adjustment ..................... 21

4 Control Data Adjustments and Maintenance ............................. 31

5 Specification and Installation ..................................................... 40

Issue 1.7 December 2011 3Page 3 of 54

The quantity transfer calculation is:

The flow rate calculation is:

From the flow rate reading, it accurately controls a 4-20mA analogue

An additional 4-20mA analogue output provides an actual feed rate

Page 4 of 54 December 2011 Issue 1.7

The following options are available:

 Analogue Remote Control

The PR446A provides an additional analogue input which

 Multi drop serial communications

The PR446M provides an RS485 serial communications link

Issue 1.7 December 2011 5Page 5 of 54

1.2 Model Versions

An optional IP65 transparent front cover is available by adding suffix

1.3 Front Panel Data Entry

1.4 Control Data

Closed loop feed rate control is effected by continuous monitoring of

Page 6 of 54 December 2011 Issue 1.7

Practicon BELT FEEDER CONTROLLER

Issue 1.7 December 2011 7Page 7 of 54

1.6 Digital Inputs & Outputs

Whenever WO set to YES it will pulse on

Page 8 of 54 December 2011 Issue 1.7

1.7 Closed Loop Control

The Auto LED indicates when automatic feed rate control is in

Closed loop control of feed rate is achieved by adjustment of the 4-

Following the calibration of the rate control analogue output as

Issue 1.7 December 2011 9Page 9 of 54

1.8 Multiple Feeder Application - Serially Linked

RS485 Single Twisted Pair

Master Slave Slave

Page 10 of 54 December 2011 Issue 1.7

1.9 Remote PLC or Computer Serial Link

RS485 Single Twisted Pair To host

The protocol is simple ASCII eg:

Host sends: !02FL[CR]

Issue 1.7 December 2011 11Page 11 of 54

1.10 Multiple Feeder Application - Analogue Linked

PR446A PR446A PR446A

MASTER SLAVE SLAVE

If the feed rate ratio of master to slave, which is governed by the

When in Ratio metric Mode a Target Percentage (TP) can be

Page 12 of 54 December 2011 Issue 1.7

BELT FEEDER CONTROLLER

AUTO DEAD RANGE

SELECT RATE TOTAL CLEAR ENTER

99999K/H Flow Rate

Issue 1.7 December 2011 13Page 13 of 54

1.13 Dynamic Tare

1.14 Automatic Zero Adjustment

An * symbol is displayed in the left most position when the tacho

Page 14 of 54 December 2011 Issue 1.7

1.16 Data Entry