OPERATION MANUAL MANUAL

Transcription

1 with AICC-SE (RCU-810-A) OPERATION MANUAL MANUAL No. GB48108G0021 YAMATO SCALE CO., LTD. GB48108G0021 (CPC 1/10) Operation SE Ver.2.XX 7,'09

2 DATAWEIGH SIGMA F1 series OPERATION MANUAL RECORD OF ISSUE DATE ISSUE NO. SOFTWARE VERSION June 1, 2000 GB48108A0068 AICC (RCU-800) Ver. 1.0X February 5, 2001 GB48108A0070 AICC (RCU-800) Ver. 1.1X December 20, 2002 GB48108A0076 AICC (RCU-800) Ver. 1.3X July 11, 2003 GB48108A0078 AICC-SE (RCU-810) Ver1.XX December 28, 2006 GB48108A0099 AICC-SE (RCU-810-A) Ver1.XX May 28, 2007 GB48108G0004 AICC-SE (RCU-810-A) Ver2.XX Nov. 25, 2008 GB48108G0013 AICC-SE (RCU-810-A) Ver2.XX July.13, 2009 GB48108G0021 AICC-SE (RCU-810-A) Ver2.XX RECORD OF REVISION DATE ISSUE NO. REVISION PART December 25, 2003 GB48108A0078 CLEAN-UP PROCEDURES GB48108G0021 (CPC 2/10) YAMATO SCALE CO., LTD. Copyright 2000 by Yamato Scale Co., Ltd. All Right Reserved. No part of this manual may be reproduced in any form without permission in writing from the publisher. Operation SE Ver.2.XX 7,'09

3 PREFACE This OPERATION MANUAL contains all the instructions for operation of the F1 series DATAWEIGH multi-head combination weigher, including the PROCEDURES for setting of preset parameters. System Installation and Calibration PROCEDURES will be described in the separate Installation Manual Part 2. INSTALLATION NOTES AND SAFETY INSTRUCTIONS Before using the DATAWEIGH, please read this Operation Manual carefully and follow all operation and safety instructions. The F1 series DATAWEIGH are precession machines. The following points should be observed to assure weighing accuracy and performance as well as prolonged trouble-free operation. ITEM TEMPERATURE* HUMIDITY INSTALLATION SURFACE ELECTRICAL POWER GROUNDING INSTRUCTION - 10 C to 40 C (or 14 F to 104 F) 35 to 85% (there should be no condensation) On rigid horizontal surface 200 to 240 V ac, 1 Phase, 50/60 Hz, Tolerance: + 10% / - 15%, Use a separate branch circuit. Make sure the grounding terminal is grounded. (*) When the ambient temperature is less than 0 C, keep on the power of machine and do not turn off or on the power. GB48108G0021 (CPC 3/10) Operation SE Ver.2.XX 7,'09

4 PREFACE DANGER, WARNING AND CAUTION NOTICES BASIC RECOMMENDATION RECOGNIZE SAFETY INFORMATION The Safety Alert Symbol brings your attention to Danger, Warning and Caution notices. When you see this symbol be alert to the potential for personal injury or damage to your machine. The safe operation of your machine depends on everyone who operates, maintains, adjusts or works near it. Please read and understand these danger, warning and caution notices. Be sure you understand the following signal words, which will be seen throughout this manual: DANGER Alerts you to an immediate hazard, which will always result in severe personal injury and possible death, if it is not avoided. WARNING Alerts you to a hazard, which will result in a serious personal injury, or possible death in some cases, if not avoided. CAUTION IMPORTANT NOTE Alerts to potential hazard, which may result in a serious personal injury if not avoided. It also alerts against an unsafe practice that will permanently damage equipment or property. Points out a proper use that will avoid damage to the machine, could result violation against the regulations of Weights and Measures or the prepackaging rules, or will extend life of machine parts. Suggestion as to how to use or adjust the machine for best product results. GB48108G0021 (CPC 4/10) Operation SE Ver.2.XX 7,'09

5 DANGER, WARNING AND CAUTION NOTCIES (continued) Installation DANGER Handling, moving and installation should be done by only machinery movers using appropriate equipment. Never install, operate, or maintain your machine unless you are qualified and trained properly. When you lift or move the machine, use adequate equipment. The bill of lading gives the machine weight. Prevent anyone from walking, crawling, or reaching under equipment while it is supported by a lifting device. Keep hands and feet clear of machine, platform or skid, and wheels of lifting equipment. Watch for overhead lines, low clearances, and other obstructions. Interlock DANGER When a packaging machine is connected with the DATAWEIGH, the packaging machine will automatically start running when the DATAWEIGH starts depending on the interlock between the two machines. Be sure no one is working on the packaging machine, when you start your DATAWEIGH either in automatic or manual operation. Electrical DANGER A qualified person must install, repair electrical equipment and verify electrical ground to avoid shock, injury or death to anyone using your machine. All electrical interlocks must work. Never use jumper wires to bypass electrical circuits. This could activate a part, which could damage the machine. Electrical modification and additions are prohibited. Any modification or additions to the electrical system or contents of this machine's electrical enclosure may impair the proper functioning of this machine and create a safety hazard. Any changes not authorized by the authorized representatives of Yamato may void your warranty. The electronic controller on your machine requires an electrically clean environment. The circuit design, placement of components, and wiring reduces malfunctions from electrical noise. Electrical noise is stray, unwanted interference like static on your radio. Noise can be generated within the system, enter through the wiring, machine frame, or through the air. Yamato has taken care to reduce electrical noise and to eliminate its potential to cause malfunctions. No modifications or additions, other than specifically described interface wiring, should be made to the electrical system. If there is any question, or unforeseen need for modifications, contact an authorized representative of Yamato before proceeding. Inspection WARNING Inspect your machine before startup. Failure to do this could result in injuries and machine damage. Always have the electrical disconnect padlocked in the OFF position before inspection of your machine. ALWAYS padlock the electrical disconnect in the OFF position before you adjust, clean, lubricate, or maintain your machine. GB48108G0021 (CPC 5/10) Operation SE Ver.2.XX 7,'09

6 DANGER, WARNING AND CAUTION NOTICES (continued) Parts Replacement DANGER Be sure the machine is turned OFF and wait more than one minute to allow the capacitors in the electrical circuit to discharge before replacing any part. High voltage can cause serious injury or death. Machine parts may be damaged if they are replaced with the power on. The machine is not operating normally when any part is removed, and this is dangerous. The solid-state relays can be damaged by stray voltage if replaced with the power on. A pin could become "welded" to the socket, which may require replacement of several parts. The removal of parts while the power is on can cause stray voltage in the system. This can stall processors or cause problems in other areas of operation. NEVER replace any board or I/O module with the power on. This could cause serious injury or death. DANGER: Never remove or replace any parts until one minute has passed after the power is turned off. BASIC CAUTION NOTICES CAUTION Do not attach or place paper, cardboard, photos, signs, string, tape, wire, tinsel, hardware, or equipment on your machine. This could cause personal injury or machine damage. If you repaint your machine cover all notices and identification plates with masking tape before painting. All warning labels must be clearly visible. All notices and plates must be in place and legible. If they are damaged, defaced or missing they must be replaced immediately. Refer to your parts manual for part numbers and descriptions. Yamato liability is limited to operation using the original program. Sales are subject to prevailing terms and conditions of sale. Specifications and illustrations may be changed without notice. All dimensions and specifications are approximate and drawings are not to scale. Machines are shown without guards for illustration purposes only. GB48108G0021 (CPC 6/10) Operation SE Ver.2.XX 7,'09

7 DANGER, WARNING AND CAUTION NOTICES (continued) SPECIFIC RECOMMENDATIONS SPECIFIC DANGER NOTES DANGER: Do not locate your machine in a combustible environment or near any combustible material or explosive substance. DANGER: GROUND the MACHINE. Failure to ground machine could result in electric shock to personnel. Use the ground lugs provided within the electrical box, on the machine from, or on other items. Run the grounding conductors directly to a permanent earth ground. DANGER: When you lift or move this machine, use equipment of adequate capacity. Prevent everyone from walking, crawling or reaching under the machine while it is supported by a hoist or other device. Keep hand feet clear of machine, platform or skid, and wheels of lifting equipment. Watch for overhead utility lines, low clearances, and other obstructions. Handling, moving and installation should be done only by competent machinery movers using appropriate equipment. Everyone must be alert and extremely careful to avoid injuries or machine damage. Be sure to follow all Danger and Caution notices. DANGER: Before you operate your machine, be sure all electrical interlocks are working. DANGER: Do not start your machine, in either automatic or manual operation, until you make sure no one working on the down stream packaging machine. DANGER: Lubricate and inspect your machine before operating. DANGER: NEVER operate your machine unless you have been instructed on its intended use. NEVER maintain or adjust the machine unless all power to it is OFF. DO NOT operate the machine without guards. DO NOT remove guards, clean, oil or repair the machine while it is in motion. DANGER: Disconnect the electrical and pneumatic power to your machine prior to adjusting the machine. DANGER: Remove or restrain loose clothing, necktie, jewelry, or long hair around any machinery. Keep hands away from moving parts and from pinch points such as rollers and gears. Failure to do so is likely to result in serious injury or death. CAUTION: Noise level around the machine must be below 80 db. If you handle a hard product such as hard candy with the machine, reduce the noise by installing lining material inside the buckets and collating chutes. If the noise level still exceeds 80 db, the operators must wear earplugs. GB48108G0021 (CPC 7/10) Operation SE Ver.2.XX 7,'09

8 TABLE OF CONTENTS PREFACE Installation Note and Safety Instruction Danger, Warning, and Caution Notice Chapter 1 INTRODUCTION DATAWEIGH SIGMA F1series Systems... p. 1 Main Components... p. 2 Advanced Interactive Command Console Second Edition p. 4 (AICC-SE)... The DATAWEIGH Concept... p. 5 THE DATAWEIGH OF SIGMA F1 FRONTIER CONCEPT... p. 6 Operation Cycle... p. 7 Model Designation... p. 8 Major Model Names... p. 10 Scale Intervals... p. 11 Operation Mode and Access Level... p. 12 How to access Higher Level Menus/Screens... p. 13 Menus and Keypads... p. 14 Data Entry... p. 15 Chapter 2 Level 1 - OPERATOR PROCEDURES Overview... p. 16 Daily Operation Cycle... p. 18 Start/Stop Procedures... p. 19 Main Menu... p. 23 Zero Adjustment (REZERO)... p. 25 Program Number Selection... p. 26 Automatic Operation... p. 29 Clean Out... p. 44 Manual Operation... p. 45 Recommended Actions at Errors... p. 51 Daily Inspection... p. 52 GB48108G0021 (CPC 8/10) Operation SE Ver.2.XX 7,'09

9 TABLE OF CONTENTS (continued) Chapter 3 CLEAN-UP PROCEDURES Clean Infeed Funnel and Main Feeder... p. 60 Removal of Parts... p. 61 Clean Removed Parts... p. 62 Install Removed Parts... p. 63 Chapter 4 Level 2 - CHIEF OPERATOR PROCEDURES How To Access Level 2... p. 65 How To Alter Preset Parameters... p. 66 Chapter 5 Level 3 - SUPERVISOR PROCEDURES Overview... p. 67 Main Menu... p. 69 How To Save Scale Setup Values... p. 70 Program Selection... p. 71 Program Setup... p. 72 Auto Setup... p. 74 Scale Setup... p. 75 Automatic Operation... p. 87 Printer Setup... p. 88 Chapter 6 TROUBLE SHOOTING Overview p. 90 Error Message Log... p. 91 Sample Test... p. 92 Software Version.. p. 96 I/O Check... p. 97 Hard Check... p. 98 Voltage Check... p. 99 Trouble Shooting for general problem... p. 100 GB48108G0021 (CPC 9/10) Operation SE Ver.2.XX 7,'09

10 TABLE OF CONTENTS (continued) Annex SUPPLEMENTARY DESCRIPTION Overview... p. 108 Related To Scale Setup... p. 109 Related To Printer Setup... p. 117 Related To DATAWEIGH Operation... p. 122 GB48108G0021 (CPC 10/10) Operation SE Ver.2.XX 7,'09

11 Chapter 1 INTRODUCTION DATAWEIGH SIGMA F1 series Systems The DATAWEIGH F1 series combination weighers are the result of over ten years of accumulated experience in design and manufacture of the multi-head weigher for the food industry. The F1 series DATAWEIGH meet the needs of today's world markets. The major features of the F1 series are: (1) Ease of Sanitation (4) Enhanced user-friendly operation (2) Reliability and durability (5) High Accuracy and Speed (3) Low maintenance cost (6) Flexibility Among these features the Advanced Interactive Command Console Second Edition (AICC-SE) offers more powerful functions with TFT color Touch-panel and 32-bit CPU using multiple color graphics for high functional display. As the result of the extensive work and tireless research, the F1 series is literally the machine to meet --- "The sum of all your needs" --- for the 21st century. The F1 series is truly the benchmark by which all others will be judged. GB48108G0021 ( 1/137) 1 Operation SE Ver.2.XX 7,'09

12 1 INTRODUCTION MAIN COMPONENTS WEIGH LEVEL SENSOR LINEAR FEEDER PAN LINEAR FEEDER MAIN FEEDER TOP CONE FEED BUCKET WEIGH/ ACTUATOR UNIT WEIGH BUCKET MEMORY BUCKET (ADW-xxxMx ONLY) MEMORY/ ACTUATOR UNIT (ADW-xxxMx ONLY) COLLATING CHUTE COLLATING FUNNEL COLLECTION GATE MAIN FEEDER (MF) A cone which vibrates to distribute product onto the linear feeders. Amplitude and duration of its vibration are controlled to assure proper product distribution. A load cell supports the unit and controls the infeed conveyor to keep the level of product consistent. The top cone is detachable with out a tool. LINEAR FEEDER (LF) Vibrators/troughs surrounding the main feeder to feed product into feed buckets. Amplitude and duration time of their vibration are controlled automatically to feed product into the feed buckets. The troughs (pans) are detachable without tools. The vibrators are totally enclosed with no exposed wiring to facilitate sanitation. GB48108G0021 ( 2/137) 2 Operation SE Ver.2.XX 7,'09

13 1 INTRODUCTION MAIN COMPONENTS FEED BUCKET (FB) Each feed bucket receives product fed from the linear feeder above it. The product is discharged when the weigh bucket below is empty or when the weigh bucket requires more products. WEIGH BUCKET (WB) Each weigh bucket holds product while the load cell reads its weight. Using weight information received from each weigh bucket, the computer calculates a combination closest to the target weight. The weigh buckets selected in the combination discharge the product into the collating chute. For three-bucket models, buckets not selected discharge their contents into memory buckets below when empty. MEMORY BUCKET (MB) The memory buckets hold product fed from the weigh buckets. As the name implies, the weight information is stored in memory. The computer calculates a combination including the memory buckets along with the weigh buckets. The memory bucket system increases the number of buckets to be included in the combination calculation. COLLECTION GATE (BUCKET) (CB) (BBHD) An optional collection gate is used to temporarily stage product discharged from weigh or memory buckets. It discharges the product into the packaging machine below upon receiving a signal. Thus, the collection gate minimizes product string out and shortens the system operation cycle. BBHD(Bottom Based Handling Device) BBHD provides sufficient sealing time for Bag Maker even with high-speed operation. For instance in case of ADW-424MV with 3 division, each groups do a job at 70 bpm, hence affording sufficient time for dose of products to settle at the BBHD, which can achieve 210 bpm without suffering from Sealing Failures. WEIGH/ACTUATOR UNIT Each weigh/actuator unit contains a load cell and two actuators. The load cell supports the weight bucket and measures product in the weigh bucket. The actuators open and close the doors of weigh and feed buckets with commands from the AICC-SE (RCU-810-A). MEMORY/ACTUATOR UNIT MEMORY/ACTUATOR unit is used for the models with a memory bucket system, signified by an "M" in the model number (ADW-xxxMx). This actuator is used to open or close the doors of memory bucket. GB48108G0021 ( 3/137) 3 Operation SE Ver.2.XX 7,'09

14 1 INTRODUCTION MAIN COMPONENTS ADVANCED INTERACTIVE COMMAND CONSOLE SECOND EDITION BLANK PANEL FOR FAN (FOR WATERPROOF MACHINE) TOUCH SCREEN / COLOR LCD PANEL FOR FAN PRINTER / ACCESS PORT COVER TOUCH SCREEN A menu-driven and operator interactive display used for set-up, operation, monitoring, and trouble shooting of the machine. PRINTER Used to print out statistical data which includes a histogram for production management. Also used to provide a hard copy of preset operational parameters for record. The printer is design for wash down along with the whole AICC-SE unit, so that no additional cover is required for wash down applications. GB48108G0021 ( 4/137) 4 Operation SE Ver.2.XX 7,'09

15 1 INTRODUCTION THE DATAWEIGH CONCEPT The DATAWEIGH system distributes product into fractional batches. These batches are weighed by weigh cells. The microcomputer instantly determines which combination of batches comes closest to the target weight without going underweight. This combination is discharged for packaging. The example below shows a partial listing of the total number of combinations possible using all of the weigh buckets on a fourteen-head DATAWEIGH model. In this example, combination No.115 would be chosen. 12g 13g 20g 36g 23g 22g 27g 25g 41g 33g 16g 35g 30g 26g *Target weight: 100 grams. Total number of combinations: Note*: Target weight is defined as the pre-determined weight of product to be discharged from the DATAWEIGH. WEIGH BUCKETS 1 4,5,14,3 4,5,14,6 4,5,14,7 4,5,14,8 4,5,14,9 4,5,14,10 4,5,14,11 TOTAL GRAMS COMPUTER DECISION NO NO NO NO BEST NO NO NO COMBI- NATION COMBI- NATION WEIGH BUCKETS 12,4,7,9 12,4,8,9 12,5,6,7 12,5,6,8 12,5,6,9 12,5,7,8 12,5,7,9 12,5,8,9 1,2,3,4,5, 6,7,8,9,10,11,12,13, 14 TOTAL GRAMS COMPUTER DECISION NO NO NO NO NO NO NO NO NO GB48108G0021 ( 5/137) 5 Operation SE Ver.2.XX 7,'09

16 1 INTRODUCTION THE DATAWEIGH OF SIGMA F1 FRONTIER CONCEPT The example below shows a partial listing of the total number of combinations possible using all of the weigh buckets on a SIGMA F1 FRONTIER DATAWEIGH model. In this example, 2 combinations No.115 and No.234 would be chosen at the same time. 12g 13g 20g 36g 23g 22g 27g 25g 41g 33g 16g 35g 30g 26g Selected by BEST1 Selected by BEST2 *Target weight: 100 grams. Total number of combinations: Note*: Target weight is defined as the pre-determined weight of product to be discharged from the DATAWEIGH. WEIGH BUCKETS 1 4,5,14,3 4,5,14,6 4,5,14,7 4,5,14,8 4,5,14,9 4,5,14,10 4,5,14,11 TOTAL GRAMS COMPUTER DECISION NO NO NO NO BEST 1 NO NO NO COMBI- NATION COMBI- NATION WEIGH BUCKETS 13,11,7,9 13,11,7,10 13,11,7,12 13,11,7,14 13,12,8,10 13,12,8,14 1,2,3,4,5,6, 7,8,9,10,11,12,13,14 TOTAL GRAMS COMPUTER DECISION BEST 2 NO NO NO NO NO NO GB48108G0021 ( 6/137) 6 Operation SE Ver.2.XX 7,'09

17 1 INTRODUCTION OPERATION CYCLE Product is fed from the infeed equipment such as the Cross Head Feeder (option) through the inlet funnel onto the main feeder. The main feeder vibrates to distribute product over linear feeders. The linear feeders vibrate to feed product into feed buckets. The feed buckets hold product and discharge it into weigh buckets upon empty signal or recharge request. The load cells supporting weigh buckets read the weight of the product in the weigh buckets and the results are sent to the AICC-SE for combination calculation. In a three-bucket system, the product in weigh buckets not selected in combination is discharged into memory buckets below if empty. The main CPU in the AICC-SE calculates possible combinations among product in weigh (and memory) buckets and select a combination closest to the target weight. The CPU also determines weighing zone (accepted, over, or under weight) the selected combination falls into based on the preset limit values. The CPU commands the actuator units to discharge the product from the selected weigh and memory buckets. The product discharged from the selected buckets dumps through the collating chutes into the packaging machine below. The cycle then repeats itself. When an optional gate is installed, the product discharged from the selected buckets is held in the collection gate temporarily and then dumps into the packaging machine upon receiving a signal from the packaging machine. GB48108G0021 ( 7/137) 7 Operation SE Ver.2.XX 7,'09

18 1 INTRODUCTION MODEL DESIGNATION ADW Model F: Sigma F1 Frontier Blank: other model Max. Pack Volume 1: Less than 0.5 liters 2: 0.5 liters and over 3: 1.0 liters and over 4: 2.0 liters and over 5: 3.0 liters and over (3L: Frontier and SN models) (5L: other model) 6: 8.0 liters and over 7: 10.0 liters and over 8: 16.0 liters and over 9: 20.0 liters and over Number of Weigh Heads (2 digits) Example - 08: 8 Heads 14: 14 Heads Bucket / Feeder Configuration S: Circular arrangement and Standard buckets method M: Circular arrangement and Memory buckets methods SN: Snack Execution Material Specification D: Dustproof (Standard) W: Waterproof(All stainless steel) V: Versatility (All stainless steel) Controller Blank: AICC-SE (RCU-810-A) Special Application Blank: Standard L: Low Capacity with High Accuracy H: High Capacity (*) SN-Model does not exactly follow this designation theory, so it is not called ADW-516MD-N. GB48108G0021 ( 8/137) 8 Operation SE Ver.2.XX 7,'09

19 MODEL NAME 1 INTRODUCTION MAJOR MODEL NAMES Number of Heads Max. Pack Volume Bucket Configuration Protection Grade F1 FRONTIER ADW F314SV 1 liters 14 Standard Waterproof ADW F318SV 1 liters 18 Standard Waterproof ADW F320SV 1 liters 20 Standard Waterproof ADW F328SV 1 liters 28 Standard Waterproof ADW F514SV 3 liters 14 Standard Waterproof ADW F518SV 3 liters 18 Standard Waterproof ADW F528SV 3 liters 28 Standard Waterproof ADW F614SV 6 liters 14 Standard Waterproof ADW F618SV 6 liters 18 Standard Waterproof ADW F714SV 10 liters 14 Standard Waterproof F1 PLUS ADW 410SV 2 liters 10 Standard Waterproof ADW 410MV 2 liters 10 Memory Waterproof ADW 414SV 2 liters 14 Standard Waterproof ADW 416SV 2 liters 16 Standard Waterproof ADW 416MV 2 liters 16 Memory Waterproof ADW 420MV 2 liters 20 Memory Waterproof ADW 424SV 2 liters 24 Standard Waterproof ADW 420MV 2 liters 24 Memory Waterproof ADW 508MV 5 liters 8 Memory Waterproof ADW 510SV 5 liters 10 Standard Waterproof ADW 514SV 5 liters 14 Standard Waterproof ADW 516SV 5 liters 16 Standard Waterproof ADW 516MV 5 liters 16 Memory Waterproof ADW 520SV 5 liters 20 Standard Waterproof ADW 520MV 5 liters 20 Memory Waterproof ADW 524MV 5 liters 24 Memory Waterproof ADW 710SV 10 liters 10 Standard Waterproof ADW 714SV 10 liters 14 Standard Waterproof ADW 714MV 10 liters 14 Memory Waterproof ADW 716MV 10 liters 16 Memory Waterproof ADW 720SV 10 liters 20 Standard Waterproof ADW 724MV 10 liters 24 Memory Standard ADW 814SV 16 liters 14 Standard Waterproof ADW 814MV 16 liters 14 Memory Waterproof GB48108G0021 ( 9/137) 9 Operation SE Ver.2.XX 7,'09

20 1 INTRODUCTION MODEL NAME MAJOR MODEL NAMES (continued) Max. Number Bucket Pack of Heads Configuration Volume F1 COMPACT Protection Grade ADW 214SD 0.5 liters 14 Standard Standard ADW 214SW 0.5 liters 14 Standard Waterproof ADW 216SD 0.5 liters 16 Standard Standard ADW 216SW 0.5 liters 16 Standard Waterproof ADW 216MD 0.5 liters 16 Memory Standard ADW 216MW 0.5 liters 16 Memory Waterproof ADW 220SD 0.5 liters 20 Standard Standard ADW 220SW 0.5 liters 20 Standard Waterproof ADW 224MD 0.5 liters 24 Memory Standard ADW 224MW 0.5 liters 24 Memory Waterproof ADW 314SD 1 liters 14 Standard Standard ADW 314SW 1 liters 14 Standard Waterproof ADW 316SD 1 liters 16 Standard Standard ADW 316SW 1 liters 16 Standard Waterproof ADW 316MD 1 liters 16 Memory Standard ADW 316MW 1 liters 16 Memory Waterproof ADW 320SD 1 liters 20 Standard Standard ADW 320SW 1 liters 20 Standard Waterproof ADW 324MD 1 liters 24 Memory Standard ADW 324MW 1 liters 24 Memory Waterproof GB48108G0021 ( 10/137) 10 Operation SE Ver.2.XX 7,'09

21 1 INTRODUCTION SCALE INTERVALS (1) Scale intervals, e 1 for manual operation and e 2 for automatic operation, are to be selected depending on model as shown in the table below. Model e 1 at manual op. (g) e 2 at auto. Op. (g) Span (g) 2 liters (4XX) liters (5XX) ,000 5 liters (5XX) L type* liters (7XX) , liters (8XX) ,500 Note 1: Note 2: (*) L type is used to applications for light density products such as potato crisps or applications with small target weight. No modification related to scale intervals is allowed after installation unless permitted from the authority of Weights & Measures. Refer to the note on DIP switch setting on Installation Manual Part 1. SCALE INTERVALS (2) When the machine is not applied to approval at W&M, Scale intervals, e 1 for manual operation and e 2 for automatic operation, are set to 0.05g for ADW-2XX, 0.1 g for other models automatically. Model e 1, e 2 (g). Span (g) 0.5 liters (2XX) liters (3XX, F3XX) liters (4XX) litters (5XXSN) liters (5XX-L, standard) litters (5XX waterproof, F5XX) 0.1 1, liters (7XX) 0.1 1, liters (7XX-H) 0.1 2, liters (8XX) 0.1 2,500 GB48108G0021 ( 11/137) 11 Operation SE Ver.2.XX 7,'09

22 1 INTRODUCTION OPERATION MODE and ACCESS LEVEL The AICC-SE operation is divided into four modes; each with its own set of menus. The AICC-SE automatically enters Operator Mode of Level 1 when the power turned on while the higher access levels require password(s) so that unauthorized personnel cannot change important preset parameters. A password allows the operator/supervisor/engineer to enter the mode of that password level as well as those of lower levels; refer to the table below for description of these operation modes. Passwords are registered in System Installation. Level 1 (OPERATOR MODE) Access to only the basic menus used to operate the machine for daily production. This mode allows the operator to perform a temporary fine-tuning for better product flow. No password is required. Level 2 (CHIEF OPERATOR MODE) Access to the basic menus of Level 1 plus additional menus for temporary fine-tuning of machine operation. A password for Level 2, or above is required. To keep the altered preset parameters permanently in memory, enter Level 3 or 4 mode, and then save. Level 3 (SUPERVISOR MODE) Access to the Level 3 menus, which allows the supervisor to set or alter preset parameters and save them. Printer set-up is possible in this level, as well as access to the trouble shooting menus. A password for Level 3 or 4 is required. Level 4 (ENGINEER MODE) Access to the Level 4 menus, which allows the engineer to perform the System Installation and calibration. Passwords are registered in this Level. A password for level 4 is required. PROCEDURES in Level 4 is described in the Installation Manual Part 2. GB48108G0021 ( 12/137) 12 Operation SE Ver.2.XX 7,'09

23 1 INTRODUCTION HOW TO ACCESS HIGHER LEVEL MENUS AND SCREENS The main menu in the Operator Mode is automatically selected when the power is turned ON. The access level will show the access level currently selected. To change the access level, touch and hold the "ACCESS LEVEL" pad for several seconds. Then, a pop up window for password entry will appear as shown in the illustration below. Enter the required password to access the menu in the desired level. When the current access level is changed, you will enter the same operation screen or menu of the new level. Touch and hold the "ACCESS LEVEL" pad for two seconds. The password entry window will be displayed as shown in the illustration right-hand: Touch characters on the alphanumeric pad to enter the password for a higher level. Then press the "ENT" pad. To exit from a higher level to Operator Mode, touch just the "ENT" pad without entering password in the password entry menu. To exit from a higher level, in the near future in AICC-SE Ver. 1.1X and later, to Operator Mode, touch just the ENT pad without entering password. GB48108G0021 ( 13/137) 13 Operation SE Ver.2.XX 7,'09

24 1 INTRODUCTION MENUS and KEYPADS The AICC-SE displays information in the form of menus, graphics and prompts to aid in operation of the machine. Each screen contains a menu bar on the top of the screen, boxed menus or graphics in the middle of the screen, and another menu bar for several keypads at the bottom of the screen. Just touch a keypad on the screen to perform the menu function. Refer to the example display shown in the illustration below: SCALE SETUP pad (1) To select a function, touch the center part of the pad or the graphic item. (2) When a function is selected, often another sub-menu is called up. To return to the previous menu or the initial menu, touch the "RETURN" pad in the menu bar at the bottom of the screen. (3) Sometime a series of menus covers multiple pages. In this case, small-boxed pads will appear at the upper right corner of the window with the number of menu pages. The Set-up menu shown in the illustration to the right is an example. Touch the desired menu page to call up that menu in the series. Another Set-up menu will be displayed. GB48108G0021 ( 14/137) 14 Operation SE Ver.2.XX 7,'09

25 1 INTRODUCTION MENUS and KEYPADS (continued) (4) Key-pads, such as "START" and "COMB", will be highlighted to show they have been selected. The "START" keypad will turn into high-lighted "STOP" during machine operation. To stop operation, just touch the pad, "STOP", which will return to "START" in normal video when the machine stops. (5) The "ON" or "OFF" pad is used to enable or to disable a function. The "ON" pad, when touched, will toggle to "OFF", which will be toggled to "ON" when touched again. (6) When pressed repeatedly, the "RETURN" key-pad allows you to return to the initial main menu from any sub-menu DATA ENTRY Data values are entered by a keypad (numeric or alpha-numeric as required), which will be displayed automatically, when a data entry area is touched, as shown in the illustration below. DATA ENTRY MENU ENTER pad SAVE pad To enter a data value, touch the desired numeric or alphabetic keypads and then touch the "ENT" pad. The value is shown right above the keypad. Make sure the value is correct before touching the "ENT" pad. The "CLR" pad clears the whole value while the "DEL" pad deletes a character, which has just been chosen. IMPORTANT All the data, either numeric or alphabetic value, should be saved before the power is turned OFF to store the data in memory, although these data will be kept with the back-up battery. Touch the "SAVE" pad after you have confirmed the selection of a function or data entry is correct. GB48108G0021 ( 15/137) 15 Operation SE Ver.2.XX 7,'09

26 Chapter 2 Level 1 OPERATOR PROCEDURES OVERVIEW This level contains all of the normal operator functions. It allows the operator to select a desired program, re-zero (zero adjustment) the scales, run production, and clean out the system when finished. The operator can view the current operation in Automatic Operation screen and take action if minor adjustment is required or an error condition has occurred. The menus or screens and items to be shown in Level 1 are as in the table below. MENUS/SCREENS PROCEDURES PAGE Daily Operation Cycle 18 Start / Stop Procedures 19 MAIN MENU Main Menu Infeed pad Customer Eye pad Machine Model Program Number Date And Time Language pad Machine (M/C) Name pad REZERO Zero Adjustment (Re-zero) 25 PROGRAM NUMBER SELECTION AUTOMATIC OPERATION PRINTER Procedures 26 Procedures 29 Scale Graphic Display 30 AFC Indication 32 Window A 33 for SIGMA F1 RONTIER model 34 Symbol Definitions 35 Window B 36 Zooming 37 Fine Adjustments Of Product Flow Window B-1 Window B-2 Key Points For Better Operation Overview How To Adjust Product Flow 40 Histogram Term Histogram Mode Function Pad Printer Production Data Printout Hourly Report Printout GB48108G0021 ( 16/137) 16 Operation SE Ver.2.XX 7,'09

27 2 Level 1 OPERATOR PROCEDURES OVERVIEW MENUS/SCREENS PROCEDURES PAGE CLEAN OUT MANUAL OPERATION RECOMMENDED ACTIONS AT ERROR DAILY INSPECTION Clean-Out 44 Procedures Manual Operation 45 Bucket Selection 46 Manual Combination Inhibit Operation Manual Actuation 47 Cycle Operation Clear Zero And Re-Zero 48 Original Point Check 49 Continuous Actuation Manual Operation Of Optional Units 50 CB3-A / CB3-B Middle Shutter Diverter Auto Infeed Ring Overweight 51 Zero Error Actuator Error Blank Out Daily Inspection 52 Pre- operation Inspection 53 Inspection During Operation 58 Inspection During Clean-up Cautionary Instruction 59 GB48108G0021 ( 17/137) 17 Operation SE Ver.2.XX 7,'09

28 2 Level 1 OPERATOR PROCEDURES DAILY OPERATION CYCLE A typical daily operation in level 1 is as follows: Push the "RESET" button, when the optional RESET/STOP BOX is installed next to AICC-SE. (See p. 19) Perform the "TARE SETTING", and then enter the main menu. (See p. 18) Turn on the Cross Head Feeder, if equipped, by touching the "INFEED" pad. Select the desired program number in the "PROGRAM NUMBER SELECTION" screen. (See p. 22) (See p. 25) Enter "AUTOMATIC OPERATION" screen. (See p. 28) Start the operation with the "START" pad. (See p. 28) View the operation status via the various displays. (See p. 29) Stop the operation with the "STOP" pad. (See p. 28) Check the machine via the "MANUAL OPERATION" menu, if necessary. (See p. 45 Clean out the machine via the "CLEAN OUT" PROCEDURES. (See p. 44 Turn off the packaging machine and the infeed equipment. To shut down the power supply, turn off the Main Switch. GB48108G0021 ( 18/137) 18 Operation SE Ver.2.XX 7,'09

29 2 Level 1 OPERATOR PROCEDURES START/STOP PROCEDURES MAIN POWER ON 1. Turn on the Main Switch, which is installed near the AICC-SE unit. The AICC-SE will change its color and scroll eight times. This demonstrates all the pixels on the touch screen of AICC-SE function. The Initial Tare Setting screen will be displayed. 2. Touch the "START" pad. All the buckets will open and close, then the Initial Tare Setting will be performed and every tare value shown in the scale graphic will be changed into zero. 3. This allows the operator to replace the weigh buckets at random after cleaning. Note that the tolerance of tare difference is ±10 % from the zero value of the Initial Zero Calibration or 1% of Span Weight. GB48108G0021 ( 19/137) 19 Operation SE Ver.2.XX 7,'09

30 2 Level 1 OPERATOR PROCEDURES START/STOP PROCEDURES continued If the optional RESET/STOP BOX is installed to AICC-SE, or if the master relay signal input from the packaging machine is allocated in I/O of Dataweigh, the Initial Tare Setting screen will be displayed with a prompt message at power on. The detailed procedures are as follows: 1. Turn on the Main Switch, which is installed near the AICC-SE unit. The AICC-SE will change its color and scroll eight times. This demonstrates all the pixels on the touch screen of AICC-SE function. The Initial Tare Setting screen will be displayed. Then the message "SYSTEM SHUTDOWN! PRESS THE RESET PUSH BUTTON!" is displayed. 2. Press the Reset Button, when the optional RESET/STOP BOX is installed. 3. Touch the "START" pad. All the buckets will open and close, then the Initial Tare Setting will be performed and every tare value shown in the scale graphic will be changed into zero. 4. This allows the operator to replace the weigh buckets at random after cleaning. Note that the tolerance of tare difference is ±10 % from the zero value of the Initial Zero Calibration or 1% of Span Weight. GB48108G0021 ( 20/137) 20 Operation SE Ver.2.XX 7,'09

31 2 Level 1 OPERATOR PROCEDURES START/STOP PROCEDURES continued 5. To carry out Tare Setting of Weigh Level Sensor, touch the "DISTRIBUTOR SELECT" pad to high-light it. Make sure that no product is on the distributor, then touch the "START" pad. PRODUCT LEVEL will show "0". 6. Touch the "RETURN" pad. The main menu in the Operator PROCEDURES will be displayed. 7. To start operation, select the desired item and touch the "START" pad on its operation screen. Then the "START" pad will be changed to the high-lighted "STOP" pad. 8 To stop the operation, touch the "STOP" pad on its operation screen. 9. EMERGENCY STOP Press the Master Stop button and to stop the machine and shut down the power supply immediately, then turn off the Main Switch. DANGER Make sure no one is working on the machine (and the connected packaging machine below) and check if all the buckets of the machine are properly installed before starting it up. GB48108G0021 ( 21/137) 21 Operation SE Ver.2.XX 7,'09

32 2 Level 1 OPERATOR PROCEDURES START/STOP PROCEDURES continued If W&M regulation (Option bit 8-6) is SET for European, the Initial zero setting screen will be displayed at power on. This procedure is arranged to meet the requirements from NMI. The detailed procedures are as follows: (1) Turn on the main switch. After scrolling eight times, the initial zero setting screen will be displayed along with the messages: "SYSTEM SHUT DOWN! PRESS THE RESET PUSH BUTTON" and "ATTENTION, THE SCALE WILL OPEN ALL BUCKETS TO MAKE THE INITIAL ZERO ADJUSTMENT". (2) Press the reset button. All the bucket doors of the weigh buckets will automatically open and close and then the zero setting will be performed. (3) To carryout Zero Setting of weigh Level Sensor, touch the "DISTRIBUTOR SELECT" pad to high-light. Then, touch the "START" pad. PRODUCT LEVEL will show "0". (4) After finishing the zero setting, every segment of the scale graphic will show its weight value (0.0) and the "RETURN" pad will appear in the menu bar at the bottom of the screen. (5) Press the "RETURN" pad. The main menu of the operator procedure will be displayed. Note: The above initial zero setting act as "Tare Setting" and allows adjusting tare difference ±10 % from the zero value of the Initial Zero Calibration or 1% of Span Weight. GB48108G0021 ( 22/137) 22 Operation SE Ver.2.XX 7,'09

33 2 Level 1 OPERATOR PROCEDURES MAIN MENU When the power is turned on, the Operator Mode is automatically selected and the main menu in the Operator Mode will be displayed. The main menu contains the five boxed items, "PROGRAM NUMBER SELECTION", AUTOMATIC OPERATION", MANUAL OPERATION", CLEAN OUT" and "REZERO" (zero adjustment). Each of these item pad can call up the corresponding menu. The menu bar on the top of the screen contains three pads labeled "CROSS HEAD FEEDER", "ACCESS LEVEL", "MACHINE (M/C) NAME and the indication of machine model number. INFEED pad CUSTOMER EYE pad MACHINE MODEL ACCESS LEVEL pad MACHINE NAME PROGRAM No. LANGUAGE pad DATE &TIME INFEED pad CUSTOMER EYE pad This pad is displayed when a Cross Head Feeder or Auto Infeed Ring is installed. (Refer to I/O Allocation in Installation Manual Part 2.) To enable the Cross Head Feeder or Auto Infeed Ring, touch this pad. A pop-up window opens to make ON or OFF the Cross Head Feeder or Auto Infeed Ring. This pad is displayed when a customer eye (photo-electric sensor) is installed on the Cross Head Feeder. (Refer to I/O Allocation in Installation Manual Part 2.) To enable the customer eye, touch this pad. Then, a pop-up window opens to make ON or OFF the CUSTOMER EYE. GB48108G0021 ( 23/137) 23 Operation SE Ver.2.XX 7,'09

34 2 Level 1 OPERATOR PROCEDURES MACHINE MODEL The model name of the machine is indicated. MACHINE (M/C) NAME pad PROGRAM NUMBER The program number currently selected along with its product name is indicated. DATE AND TIME The current date and time are shown at the right below screen. The format for date & time are set in the System Installation. This pad indicates which side of the machine is currently under control of twin machine. Touch this pad to switch control from one side to the other. For single machine there is no border around the machine name. LANGUAGE pad The language currently used is in this pad. To change the language, touch this pad. The language can be selected among those installed the System Installation procedures. (Refer to System Installation 3 in the Installation Manual Part 2.) GB48108G0021 ( 24/137) 24 Operation SE Ver.2.XX 7,'09

35 2 Level 1 OPERATOR PROCEDURES ZERO ADJUSTMENT (REZERO) To perform zero adjustment manually, follow the procedures below. Please note that this zero adjustment is not always necessary during automatic operation because Zero adjustment will be carried out automatically. Refer to "AUTO ZERO" in SCALE SETUP 1. (1) Touch the boxed item, "REZERO". The zero adjustment "REZERO" screen will be displayed. (2) Touch the "START" pad. The bucket doors automatically open to discharge product remaining in buckets. Then the zero adjustment is performed. The "START" pad will highlight "STOP". (3) When the zero adjustment is finished, the highlighted "STOP" pad will return to normal video "START". (4) Confirm zero indication of each scale. Each segment of the machine graphic circle represents one of the scales and displays the weight reading of that scale. (5) To carry out Zero Adjustment of Weigh Level Sensor, touch the "DISTRIBUTOR SELECT" pad to high-light it. Then, touch the "START" pad. PRODUCT LEVEL will show "0". (6) To return to the main menu, touch the "RETURN" pad. (7) If zero deviation from the initial zero exceeds the range of ± 2 % scale capacity, an error mark " " will be shown in that segment of the scale. An alarm (beep) will sound if an alarm is selected in the output allocation table at the system installation. To stop the alarm, touch any area in the screen. This ± 2 % range is applied when European W&M application is selected, if not, 16 % range will be applied. (8) If the zero error mark " " is indicated, check (a) if any product or foreign item remains in or on the weigh bucket, or (b) if that weigh bucket is properly placed on the bucket hanger. Then perform REZERO again. GB48108G0021 ( 25/137) 25 Operation SE Ver.2.XX 7,'09

36 2 Level 1 OPERATOR PROCEDURES PROGRAM NUMBER SELECTION Touch the boxed item, "PROGRAM NUMBER SELECTION", in the main menu. The "PROGRAM NUMBER SELECTION" screen will be displayed. The Program Number Selection screen is used to select a program number for operation. When the screen is initially entered, the currently selected program is always high-lighted. PROCEDURES (1) To select a menu program number, scroll the program list and move the highlighted bar using the arrows in the scroll bar by touching the product name to the desired program number. Then touch the "ENTER" pad. A message asking whether a save is required will be displayed if any changes have been found in the original program. (2) Touch the "RETURN" pad. (3) The next operation becomes 3 different operation by the current system no. and the selected system number. ENTER pad Current System No. Selected System No. 1. selected system no. is same as the current system no. 2. selected system no. is different from the current system no. 3. the selected system no. is "0" (4) Case 1. Touch the "RETURN" pad, then it return to main menu. RETURN pad GB48108G0021 ( 26/137) 26 Operation SE Ver.2.XX 7,'09

37 2 Level 1 OPERATOR PROCEDURES Case 2. Reboot is necessary since selected program has different system no. from current system no.. (5) case 3. The selected system no. is "0" mean that this program is not created and the system is not selected for this program. Therefore the system no. must be selected before select or create the program. To cancel reboot, press CANSEL pad and to accept reboot, press OK pad. If you select same system no. as current system no., press OK pad to return main menu. If you select different system no., it needs to reboot. Press OK pad again, then reboot will be started.. To cancel select system no., press CANCEL pad. Then it returns to program selection. GB48108G0021 ( 27/137) 27 Operation SE Ver.2.XX 7,'09

38 2 Level 1 OPERATOR PROCEDURES CAUTION: If following display appears after reboot, the system no. is mismatch between selected no. and current no. Please re-select system no. or program no. Press OK pad to confirm system no. and program no. GB48108G0021 ( 28/137) 28 Operation SE Ver.2.XX 7,'09

39 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION Touch the boxed Item, "AUTOMATIC OPERATION", in the main menu. The zoomed pack weight display of the AUTOMATIC OPERATION screen shown below will be displayed. This screen allows you to start or stop the machine and view the operation status. This pack weight display is a zoomed window, a part of the Automatic Operation screen, and will return to the Automatic Operation menu when you touch the zoomed pack weight screen. PROCEDURES (1) Touch the "START" pad. The machine will start running and the "START" pad will change into the highlighted "STOP" pad. (2) To stop the operation, touch the "STOP" pad. The machine will stop and the highlighted "STOP" pad will return to the normal "START" pad. (3) Touch the zoomed pack weight pad. The multi-function-graphic menu for Automatic Operation will be displayed. GB48108G0021 ( 29/137) 29 Operation SE Ver.2.XX 7,'09

40 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION The AUTOMATIC OPERATION screen is a semi-graphic and multi-function menu which displays system run time data for the operator to review the current system operation. SCALE GRAPHIC Window A Window B The left-half of the screen is the scale graphic menu and the right-half contains two windows which show the operation status. The upper window, "WINDOW A", displays three screens: Pack Weight, Statistics Summary, and Symbol Definition. The lower window, "WINDOW B", displays the operation status of the linear and main feeders, or product level on the main feeder. When the automatic feeder control (AFC) is selected, a pad "AFC-T", "AFC-I", or "AFC-R" is displayed upper right corner of the screen according to the kind of AFC selected. The window, when touched, enlarges these window screens. The window will switch over when the " " or " " is touched. SCALE GRAPHIC DISPLAY PRODUCT LEVEL OF WEIGH SENSOR SCALE HEAD NUMBE The circle represents the whole weigher and each segment represents a scale head with its number. The outer ring corresponds to weigh bucket while the inner ring to the memory bucket if the machine is memory bucket system. The center circle represents the product level on weight sensor. Several function pads surround the scale circle. Several operation statuses can be shown in the scale graphic so that the operator can view the current operation in detail. These operation statuses are described in this section item by item along with guidelines for proper operation. Further description on key points for better operation will be described in the section for FINE ADJUSTMENTS OF PRODUCT FLOW. MEMORY BUCKET WEIGH BUCKET GB48108G0021 ( 30/137) 30 Operation SE Ver.2.XX 7,'09

41 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION (a) The combination (COMB.) pad, when touched and highlighted, indicates, at each weigh (or memory) bucket, which buckets are selected in the current combination by the " "(green) symbol. (c) The number of combinations (NO. OF COMB) pad indicates, by highlighting each weigh (and memory) bucket, the ratio of the number of times that bucket was selected as part of a combination over the last 50 cycles. (b) Available combination (AVAILABLE) pad, when touched and highlighted, indicates "Available buckets" by the " " mark along with the selected buckets with " "(green) symbol. (d) Average weight (AVERAGE WT.) pad indicates, by highlighting in each section, the ratio of the average weight of product fed in each bucket over the last 50 operation cycles to the maximum average weight among all the buckets. If the machine is running properly, total number of the symbols of " "(green) and " " should be more than 8. If not, you should check the operation conditions in detail. Note: "Available Bucket" means weigh (or memory) bucket that contains product above NO LOAD DETECT and under High limit. "NO LOAD DETECT" is the weight of product in a weigh bucket less than this value, when the bucket is regarded as empty. A lower setting value for NO LOAD DETECT is limited to 20 e 1. Refer to p. 73 for details. In these two graphics the bar graph in the circle should look even. If not, you should check product distribution into weigh buckets. GB48108G0021 ( 31/137) 31 Operation SE Ver.2.XX 7,'09

42 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION (e) The feed time (TIME) pad indicates, by highlighting each scale section, the ratio of the linear feeders' feed time to one operation cycle. (Operation time value of each linear feeder is displayed in its section at access level 3.) AFC INDICATION This indication is displayed with dim gray when the automatic feeder control (AFC) is enabled in Scale Setup. (Refer to "SCALE SETUP 3" 74 for AFC setting.) "AFC-T", "AFC-I", or "AFC-R" will be indicated according to the selected type of the automatic feeder control. (Refer to Supplementary Description on page 121 for details.) When the AFC is activated, this pad will high-light with blue back as shown below. (f) The feeder amplitude (AMP) pad displays, by highlighting each scale section, the ratio of its vibration amplitude to the maximum amplitude. (Amplitude value of each linear feeder is displayed in its section at access level 3.) In these graphics the bar graph in the scale circle should look even. If not, you should check if wrong parameter setting for linear feeders might cause this. GB48108G0021 ( 32/137) 32 Operation SE Ver.2.XX 7,'09

43 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION WINDOW A Window A, to the upper right of the screen, displays one of three screens: (b) pack (combination) weight (c) statistics summary (d) symbol definitions which are toggled by touching or key. MULTI DUMP COUNT: number of dumps in count-up mode if the multi-dump mode is selected. (a) The pack (combination) weight screen displays the pack weight of each cycle, operation speed in packs per minute (running average for last 10 cycles), and the combination results each cycle during production. Those combination results are shown by highlighted pads of accepted, over, or under weight determined based on the preset limit values. NOTE Average number of buckets should be 4 with the standard bucket models and 3 to 4 with the memory bucket models. As described, further description and recommendation mainly concerning product flow for better operation will be made in the section for Fine Adjustments of Product Flow on page 36. Any changes of parameters are allowed only in Level 1 or 2 for temporarily fine-tuning while in Level 3 or 4 for permanent change. (b) The statistics summary screen contains; TARGET WT.: the target weight preset in the program number currently selected, AVERAGE WT.: average weight of the packs for the last 10 cycles (running average of combination calculation), AVE WEIGH HEAD: average number of weigh (and memory) buckets selected in combination for the last 10 cycles, PACK NO.: count of the packs discharged since the current sampling cycle for histogram has been started, and (c) The symbol definition screen displays the definitions of the status symbols of the weigh and memory bucket as shown in the table on the next page: GB48108G0021 ( 33/137) 33 Operation SE Ver.2.XX 7,'09

44 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION AUTOMATIC OPERATION screen for SIGMA F1 FRONTIER model Two combinations are selected in the same time of each cycle when the SIGMA F1 FRONTIER model is selected and SIMULTANEOUS mode is set in SYSTEM INSTALLATION screen. SCALE GRAPHIC The combination (COMB.) pad, when touched and highlighted, indicates, at each weigh bucket, which buckets are selected in the current combination by the " "(green) and " "(blue) symbols in the same combination timing. WINDOW A The pack (combination) weight screen displays the pack weight of two combinations of each cycle, operation speed in packs per minute (running average for last 10 cycles), and the combination results each cycle during production. Those combination results are shown by highlighted pads of accepted, over, or under weight determined based on the preset limit values. The display of A is one of the selected combination and the head which selected and displayed " "(green) symbol is discharged from inside door of WB to CB2. The display of B is another selected combination and the head which selected and displayed " "(blue) symbol is discharged from outside door of WB to CB1. GB48108G0021 ( 34/137) 34 Operation SE Ver.2.XX 7,'09

45 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION SYMBOL DEFINITIONS SYMBOL INDICATION DESCRIPTION (Green) (Blue) SELECTED COMBINATION IN SELECTED IN COMBINATION (Only F1 FRONTIER MODEL selected) UNDER ZERO ADJUSTMENT Indicates the weigh or memory bucket selected at that cycle in the combination during automatic operation. The head discharges from inside door of WB to CB when SIGMA F1 FRONTIER model is selected. Indicates the weigh bucket selected at that cycle in the combination during automatic operation. The head discharges from outside door of WB to CB1 when SIGMA F1 FRONTIER model is selected. Indicates the scale under zero adjustment during automatic operation. (Red) E RECHARGE AVAILABLE COMBINATION CALCULATION INHIBITED OVERWEIGHT IN Indicates the weigh bucket being recharged during automatic operation. Indicates the weigh or memory bucket, which is able to be selected as part of combination calculation during automatic operation. Indicates the weigh bucket which is disabled to join combination when disabled by the "INHIBIT" in manual operation, or the bucket has been removed in automatic operation. Indicates the weigh bucket filled with product over the target weight plus high limit during automatic or manual operation. ZERO ERROR Indicates the scale of which zero deviation from the initial zero exceeds the range of ±2% scale capacity during automatic or manual operation. This figure (±2%) is applied when European W&M application is selected, if not 16% range is applied. ACTUATOR ERROR Indicates the scale head whose actuator has not returned to its home position during automatic or manual operation. SPAN ERROR COMMUNICATION ERROR Indicates the scale whose span value deviation exceeds the range of 1% scale capacity from the span value at initial calibration during calibration. If span error occurs with a scale, the weigh bucket of the scale will be inhibited. Indicates a trouble in communication between the actuator or weighing unit and AICC-SE. Note: (1) If the CPU could not find a combination within the acceptable zone or product in a weigh bucket is less than NO LOAD DETECT, the CPU demand a feed bucket to recharge product into the bucket with least product. (2) Recommended actions against these errors will be described on page 49. (3) Besides the error symbols listed above, weight display in the scale segment of the graphic display will be blanked out if weight signal exceeds (MAX + 9 e 1 ). (This range is applied when European W&M application is selected.) GB48108G0021 ( 35/137) 35 Operation SE Ver.2.XX 7,'09

46 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION WINDOW B Window B displays two kinds of operation data; one is a) operation status of the linear and main feeders, and the other is b) the current system speed (operation speed) and product level of the main feeder. Each setting can be changed temporarily for fine-tuning when the window is zoomed. Refer to the description from next page for details. a) The figures represent amplitude or time of the Linear Feeders and the Main feeder(s). To select AMP or TIME, zoom the window and the AMP/TIME pad. Refer to the procedures on page 36. b) The figure of System Speed shows the current operation speed in packs per minute. The figure(s) of Weigh Sensor shows product level on the Main Feeder(s) in the range of 0 to "CURRENT", "HIGH", and "LOW" represent the current level, the upper limit, and the lower limit respectively. When multiple main feeders are installed for a mixing application, each product level will be indicated by Weigh Sensor 1, 2, 3, etc. To alter these values, zoom the window and follow the procedures shown on page 36. GB48108G0021 ( 36/137) 36 Operation SE Ver.2.XX 7,'09

47 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION ZOOMING The screen of Window A (of the pack weight, statistics summery, or symbol definitions) is enlarged to the size of full screen while Window B (of operation status or current system speed and product level) to the half size of screen. Each of them will be zoomed when touched or return to the normal size when touched again. GB48108G0021 ( 37/137) 37 Operation SE Ver.2.XX 7,'09

48 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION FINE ADJUSTMENTS OF PRODUCT FLOW Performance of the machine mainly depends on how product flow is adjusted. Preset parameters related to product flow such as amplitude and time of the Linear Feeders, Main Feeder as well as Product Level on the Main Feeder can be altered temporarily for fine tuning using zoomed Window B. These adjustments of parameters are performed in this Level 1 Operator PROCEDURES. Refer to the next section of "Key Points for Better Operation". Note that these changes are temporary, although these values will be kept with the battery-backup. It is recommended to save the values by following the parameter setting PROCEDURES in Level 3 Supervisor PROCEDURES. WINDOW B-1 WINDOW B-2 Touch the Window B-1. The Window B-1 will be enlarged as follows: Touch the Window B-2. The Window B-2 will be enlarged as follows: (1) Touch AMP/TIME pad. The figures for both Linear Feeders and Main Feeder will be changed into amplitude or time alternately and AMP or TIME will be displayed to the right of the AMP/TIME pad. (2) Touch the row of Linear Feeders or Main feeder; the selected row will be high-lighted. (3) Touch or to increase or decrease the amplitude. (1) Touch a figure of System Speed, or Lower or Upper Limit for Product Level to be changed. A numeric keypad window will be displayed. (2) Alter the figure of the desired parameter using the keypad. Note: Recommended Product Level is 4 or 5 times the Target Weight. GB48108G0021 ( 38/137) 38 Operation SE Ver.2.XX 7,'09

49 2 Level 1 OPERATOR PROCEDURES FINE ADJUSTMENTS 1. OVERVIEW PRODUCT FLOW It is important to ensure an even flow of product so that the combination result is always within an acceptable range with few under or over weights. About 3 to 5 buckets on average should be selected in each cycle. Excessive product flow makes less number of buckets selected in combination. If less than 3 buckets on average are selected each cycle, combination results will be poor with many under or over weights. Too many buckets will be selected with inadequate product flow. If more than 5 buckets on average are selected in each cycle, combination results will be poor as well. Also eccentric product flow may cause similar results. PROPER AVERAGE NUMBER OF BUCKETS IN COMBINATION The average number of buckets to be selected in combination varies depending on machine model and required speed. The proper number of Weigh (and Memory) buckets for a combination is shown in the table below. If the average number of weigh (and memory) buckets in combination is out of that range, system speed is also affected. During Automatic Operation, be sure to check the average number of weigh buckets selected in a combination. The average number of weigh (and memory) buckets is shown as AVE WEIGH HEAD in the window A in the Automatic Operation screen. Proper Average Number of Buckets for Combination SPEED Less than 70 (packs per minute) STANDARD BUCKET MODEL MEMORY BUCKET MODEL More than 70 (packs per minute) 4 to 5 3 to 4 3 to 4 3 to 3.5 Note: Proper number of buckets for a combination varies depending on combination (pack) volume in specific application. For example, a greater average number of buckets for a combination is recommended if packages of close to or a little more than the rated volume of that model are required, even in lower speed, because of low bulk density. GB48108G0021 ( 39/137) 39 Operation SE Ver.2.XX 7,'09

50 2 Level 1 OPERATOR PROCEDURES FINE ADJUSTMENT 2. HOW TO ADJUST PRODUCT FLOW Adjust the infeed funnel, main feeder(s), linear feeders, and Cross Head Feeder to keep correct product flow. ECCENTRIC PRODUCT FLOW Product flow onto the top cone (main feeder) can be eccentric depending on product volume and speed. If eccentric product flow occurs, some buckets will receive too much product while the other buckets inadequate product. Adjust centering of the infeed funnel so as to distribute product evenly on the top cone. Adjust the position of the Cross Head Feeder trough as well if necessary. EXCESSIVE PRODUCT FLOW If product amount on the main feeder looks excessive, decrease the product level on the main feeder by adjusting the weight range of the weight sensor for the main feeder using the Scale Setup 3 screen or Window B2 screen. If product flow from the Cross Head Feeder is excessive, decrease its amplitude using the Scale Setup 3 screen. If product amount on the main feeder looks proper but amount of product on linear feeders look excessive, decrease the main feeder amplitude and time using the Scale Setup 2 screen or Window B1 screen. If amount of product on linear feeders looks proper, decrease linear feeder time and/or amplitude. INADEQUATE PRODUCT FLOW If product amount on the main feeder looks inadequate, increase the product level on the main feeder weight. If product flow from the Cross Head Feeder is inadequate, increase its amplitude and time. If product amount on the main feeder looks adequate but amount of product on the linear feeders looks inadequate, increase main feeder amplitude. If amount of product on the linear feeders looks adequate, increase linear feeder time and/or amplitude. Note 1: Note 2: These adjustment values will vary depending on characteristics of product to be handled as well as machine models. If the product is sticky and causing uneven product flow, try increasing the feeder amplitude higher instead of time values. If the product is fragile, try decreasing the amplitude lower instead of the time to minimize product breakage. These changes are temporary and will return to the preset values when the program number is changed. To alter the preset values permanently, follow the PROCEDURES in Scale Setup in Level 3 (Supervisor PROCEDURES). GB48108G0021 ( 40/137) 40 Operation SE Ver.2.XX 7,'09

51 2 Level 1 OPERATOR PROCEDURES HISTOGRAM HISTOGRAM Touch the "HISTOGRAM" pad in the menu bar in the Automatic Operation menu. The Histogram screen will be displayed. The Histogram screen shows the statistical data of the current operation. The screen is divided into two parts. The left half shows the histogram and the right half shows the summarized statistical data and function pads. Note that the statistical data shown on this Histogram are calculated based on the Target Weight if the application is used in European W&M countries, Nominal Weight data are calculated. This data is commonly used for printout and printed along with the Histogram. Parameters of histogram for each program are set on the "DATE/TIME & PRINT" screen. Refer to the description for PRINTER SETUP. 1. TERMS The definitions of the terms used in the histogram screen are as follows: TARGET WEIGHT (g) Represents the target weight set in the current program. SAMPLE NO. Represents the total number of sampled packs since it was cleared last time. TOTAL (g) Represents the total weight, in grams, of the total packs sampled for the Histogram. AVERAGE (g) Represents the average weight, in grams, of packs sampled for the Histogram. STD. DEV. (g) Abbreviation for the Standard Deviation, in grams, of the sampled packs. This standard deviation is calculated using the equation given in the footnote. RANGE (g) Represents the difference between maximum and minimum weight among sampled packs. Note: Standard Deviation is calculated using the following equation: = x 2 - x 2 /n / n-1 GB48108G0021 ( 41/137) 41 Operation SE Ver.2.XX 7,'09

52 2 Level 1 OPERATOR PROCEDURES HISTOGRAM 1. TERMS (continued) MAX Represents the maximum weight of a pack among the sampled packs. MIN Represents the minimum weight of a pack among the sampled packs. SPEED The running average (for 10 cycles) speed of operation in packs per minute. 2. HISTOGRAM MODES The following two modes can be selected for the histogram: E. O. S. E. O. S. stands for "End of Shift." This mode is selected in the "DATE/TIME & PRINT" screen in page 86. The end of shift times is set in that screen. SAMPLE This pad stands for SAMPLE mode and will be displayed when the SAMPLE mode is selected in the "DATE/TIME & PRINT" screen. In the "SAMPLE" mode, statistical data will be accumulated since the last sample data has been cleared at the end of last sample time (interval) or sample count, which is set in the "DATE/TIME & PRINT" screen. Refer to the description of PRINTER SETUP screen. To review the histogram of the sample data, touch this pad. The pad will highlight and the histogram of the data accumulated in the sample mode is displayed. 3. FUNCTION PADS PRINT DATA Used to printout accumulated the statistical data in the mode currently selected. To print the data, touch this pad. GB48108G0021 ( 42/137) 42 Operation SE Ver.2.XX 7,'09

53 2 Level 1 OPERATOR PROCEDURES PRINTER PRINTER The AICC-SE equips a printer as a standard. PRODUCTION DATA PRINTOUT (3) SHIFT DATA When "END OF SHIFT PRINT" is set to "ON" on the "DATE/TIME & PRINT" screen, the production data during each shift will be printed out at each shift end. Refer to the description on the "DATA/TIME & PRINT" screen in Printer Setup of Chapter 5. (2) PRODUCTION DATA will be printed out at the time when the current program has been changed and a new program is starts. Note: Detailed PROCEDURES for PRINTER SETUP is described in Printer Setup of Chapter 5. The memory for production data is protected by a backup battery to avoid accidental loss. HOURLY REPORT PRINTOUT When an option for NMI requirements is selected in Option Selection of Installation Manual Part 2. Hourly Report will be automatically printed out every hour. Where; a) The printout interval is fixed to one hour. b) The function of SAMPLE PRINTOUT is fixed to "ON". Note: Further description for HOURLY REPORT will be given on in Supplementary Description of Printer Setup in Annex. GB48108G0021 ( 43/137) 43 Operation SE Ver.2.XX 7,'09

54 2 Level 1 OPERATOR PROCEDURES CLEAN OUT CLEAN OUT The "CLEAN OUT" PROCEDURES is used to discharge all the product left on the Cross Head Feeder and the machine before changing product or at the end of production. Touch the boxed item, "CLEAN OUT", on the main menu. The "CLEAN OUT" screen will be displayed. PROCEDURES (1) Before starting the CLEAN OUT operation, be sure the infeed equipment has been turned off. (2) Touch the "START" pad. The machine begins its automatic operation disregarding whether the pack weight is underweight. (3) The clean out operation will automatically stop when 20 consecutive under weight combinations have been made. To stop the operation during the clean out operation, touch the "STOP" pad. (4) Make sure no product remains in any buckets or on feeders. If some product is found, touch the "ALL BUCKETS OPEN" or "ALL BUCKETS OPEN / CLOSE" pad so that no product may remain in every bucket. (5) The functions of "ALL BUCKETS OPEN" or "ALL BUCKETS OPEN / CLOSE" are useful for clean out of wash down type machines. IMPORTANT The pack weight discharged during the clean out operation will be random. Do not mix these packages with the regular production packages. GB48108G0021 ( 44/137) 44 Operation SE Ver.2.XX 7,'09

55 2 Level 1 OPERATOR PROCEDURES MANUAL OPERATION MANUAL OPERATION Touch the boxed item, "MANUAL OPERATION", on the main menu. The MANUAL OPERATION graphic screen, as shown below, will be displayed. This function allows you to check operation of each part of the machine as well as to inhibit a malfunctioning bucket until it can be serviced. The " WT. " display upper right corner in the screen shows the product weight in the selected bucket or of the selected combination. DANGER Be sure no one is working on the connected packaging machine below. The connected packaging machine may start running automatically when you perform manual operation. GB48108G0021 ( 45/137) 45 Operation SE Ver.2.XX 7,'09

56 2 Level 1 OPERATOR PROCEDURES MANUAL OPERATION BUCKET SELECTION To select an individual weigh (or memory) bucket, touch the desired segment of the outer ring (or inner ring) of the left-hand scale graphic menu. To select all of the weigh (or memory) buckets, touch the respective pad in those surrounding the scale graphic. The desired section, when touched, will be highlighted to indicate the selection. The "COMB. & DISCHARGE" pad allows manual combination, which is discharged automatically. This PROCEDURE is used to verify weight of an individual pack. (1) Touch the "COMB. & DISCHARGE" pad, which will highlight. (2) Touch the "START" pad. MANUAL COMBINATION The "COMB." pad allows manual combination calculation and selection of the combination equal to or closest to the target weight. The selected weigh buckets or memory buckets will be highlighted. This PROCEDURE can be used to check performance of combination calculation in a static mode. INHIBIT OPERATION If you have trouble with a bucket, either weigh or memory bucket, such as "ZERO ERROR", "ACTUATOR ERROR" or "SPAN ERROR" and want to check it in detail or to exclude it from combination to continue operation using rest of the buckets, you can inhibit the bucket in this PROCEDURES. (1) Touch the "COMB." pad, which will highlight, (2) Touch the "START" pad. The selected buckets will be highlighted and weight reading of product in each bucket and symbol indicating status of that bucket will be shown alternately. (1) Touch the weigh (or memory) bucket to be disabled, which will highlight, and (2) Touch the "INHIBIT OPERATION" pad, which will be highlighted, then GB48108G0021 ( 46/137) 46 Operation SE Ver.2.XX 7,'09

57 2 Level 1 OPERATOR PROCEDURES MANUAL OPERATION (3) Touch the "START" pad. The disabled bucket will be indicated with the symbol "". (1) Select the desired scale head segment, either weigh or memory bucket, in the left-hand scale graphic, which will be highlighted. (2) Touch the desired bucket (for example, feed bucket, FB) pad to the right (only one pad can be selected), which will be highlighted. When returning to Automatic Operation, the highlighted pad will be in dark gray while the " " symbol will stay on the inhibited bucket. To restore the inhibited bucket to operation, (1) Touch the "INHIBIT OPERATION" pad, which will be highlighted, (2) Touch the "START" pad. Then the inhibited bucket will return in operation and the symbol " " will disappear. Note: This PROCEDURE Should be performed while the inhibited bucket is indicated by the " " mark in normal video, not highlighted. MANUAL ACTUATION A pad in the individual scale graphic to the right is used to select an individual actuator as follows: (3) Then, touch the "START" pad. The selected feed bucket door will open and close. The door of the feed bucket will open and close one time. (4) To select the collection gate, the PROCEDURES (1) above can be skipped. Note: No more than one graphic pad can be selected at one time except a selection of a outer weigh bucket and a memory bucket. These outer weigh and memory bucket can be selected together in combination. CYCLE OPERATION The "CYCLE" pad is used to perform one cycle of operation of a scale head; the collection gate, if available, discharges product first, the memory bucket above discharges product into the empty collection gate, the weigh bucket above discharges product into the empty memory bucket, the feed bucket above discharges product into the empty weigh bucket, then the linear feeder above feeds product into the empty feed bucket. With this PROCEDURE you can check a series of operation discharging product in an individual group of the scale head. GB48108G0021 ( 47/137) 47 Operation SE Ver.2.XX 7,'09

58 2 Level 1 OPERATOR PROCEDURES MANUAL OPERATION (1) Select the desired scale head segment, by touching weigh bucket, in the left-hand scale graphic, which will be highlighted. (2) Select the desired scale head segment or touch the "SELECT ALL WEIGH BUCKETS" pad. Or touch the main feeder in the graphic. (3) Touch the function pad, "CLEAR ZERO" or "REZERO", which will highlight, (4) Touch the "START" pad. (Note that the "REZERO" will be carried out after opening and closing of weigh buckets.) CLEAR ZERO (2) Touch the "CYCLE" pad, which will be highlighted. The zero deviation will be indicated in each weigh bucket segment. REZERO (3) Then, touch the "START" pad. The scale head will perform one cycle of operation. CLEAR ZERO and REZERO The "CLEAR ZERO" is used to view zero deviation of an individual scale, including the main feeder weigh sensor, from the zero at the initial calibration. The "REZERO" pad is used to reset the weight display to zero. (1) Before performing either "CLEAR ZERO" or "REZERO", make sure nothing is in the weigh bucket. The weigh bucket(s) segment(s) will indicate(s) 0.0. If you have "ZERO ERROR" ( ) of a scale, check first to make certain no product is in the weigh bucket or the bucket is properly placed on the bucket hanger and then perform "REZERO". Please refer to the page, "RECOMMENDED ACTIONS AGAINST ERRORS". GB48108G0021 ( 48/137) 48 Operation SE Ver.2.XX 7,'09

59 2 Level 1 OPERATOR PROCEDURES MANUAL OPERATION ORIGINAL POINT The "ORIGINAL POINT" pad is used to return the stepper motor for a actuator to its original point in case of "ACTUATOR ERROR" ( ). Or an actuator's original point can be checked with this PROCEDURE. (1) Select the desired scale head segment. (This Procedure is not necessary for the actuator of the collection gate.) CONTINUOUS ACTUATION The "CONTINUOUS" function allows for continuous actuation of a vibrator feeder or a bucket door(s). With this PROCEDURE you can check an individual feeder vibration, a door movement, or an actuator operation. This PROCEDURE is used to check an individual bucket door motion for a certain period. (1) Select the desired scale head segment. (This Procedure is not necessary for the actuator of the collection gate.) (2) Touch the desired graphic pad in the right-hand scale graphic, (3) Touch the "ORIGINAL POINT" pad, which will highlight, (2) Touch the desired graphic pad in the right-hand scale graphic (for example, outer weigh bucket), (3) Touch the "CONTINUOUS" pad, which will highlight, then (4) Touch the "START" pad. The outer weigh bucket door will open and close continuously. (4) Touch the "START" pad. (5) To stop the actuation, touch the highlighted "STOP" pad. Note: Make sure no product is on the vibrator feeder or in the bucket. GB48108G0021 ( 49/137) 49 Operation SE Ver.2.XX 7,'09

60 2 Level 1 OPERATOR PROCEDURES MANUAL OPERATION MANUAL OPERATION OF OPTIONAL UNITS The optional units, CB3-A, CB3-B, Middle Shutter, Diverter and Auto Infeed Ring are operated in the manual operation mode, where; CB3-A / CB3-B CB3 represents an optional collection bucket in the 2 point 3 bucket system. CB3-A and CB3-B are installed under the collection bucket of the DATAWEIGH and receive product from the collection bucket. Each CB3 distributes the received product to the underneath packaging unit respectively. MIDDLE SHUTTER Middle Shutter is an optional unit to be installed between weigh bucket (or memory bucket) and collection bucket. The product that is discharged from weigh bucket is stopped for a while by middle shutter before going into collection bucket. This function is for fragile product. DIVERTER Diverter is an optional unit to be installed above the separated main feeders of a twin system. It diverts product to the separated main feeders as required. AUTO INFFFG RING Auto infeed ring is an optional unit to be installed instead of the fixed infeed ring. The position of auto infeed ring will be moved by the product level. If the product level is lower than low-low limit of weigh sensor setting, auto infeed ring move down to original position and if the product level higher than low-low limit, the ring move up. Touch the "OPTION" pad on the MANUAL OPERATION screen. The pads of these optional units will be displayed as shown in the illustration below. To perform operation of an optional unit, touch its pad. The pad will highlight. Then touch the pad of the desired operation right-hand of the screen as the PROCEDURES described in the preceding section for the standard units. GB48108G0021 ( 50/137) 50 Operation SE Ver.2.XX 7,'09

61 2 Level 1 OPERATOR PROCEDURES MANUAL OPERATION RECOMMENDED ACTIONS AGAINST ERRORS If the scale graphic in the Automatic Operation screen indicates an error symbol (along with beep) described in the Symbol Definition table, the following actions or measures are recommended: " "(Red) OVERWEIGHT Possible cause is too much product fed into the weigh bucket by improper product flow. (1) Open the weigh bucket using "MANUAL ACTUATION" in Manual Operation to discharge the product in it. (2) Confirm if the product has been discharged. Return to the "AUTOMATIC OPERATION" via the main menu. (3) If you have a question in product flow, take action referring to the instructions described in Chapter 4, Level 2. " " ZERO ERROR If zero deviation from the initial zero exceeds ± 2 % the scale capacity, the zero error symbol " " will be indicated in the weigh bucket of the left-hand scale graphic in the Automatic or Manual Operation screen. This figure (± 2 %) is applied when European W&M application is selected. If not, ± 16 % range is applied. Possible causes for zero error are product buildup, product bridge, or a foreign item in the weigh bucket. Or the weigh bucket might not be placed in the bucket hanger properly or damage of the load cell due to excessive load could be considered. (1) Open the bucket in Manual Operation to discharge product. (2) Perform "REZERO" to reset weight display in zero. (3) If you still have the "ZERO ERROR", remove the bucket to check buildup or other possible abnormality. (4) Clean the bucket or remove other problem if any. (5) If it looks OK, replace the bucket in the bucket hanger properly. Then perform "REZERO" again. (6) If you still have this same problem, perform "CLEAR ZERO" to read its zero deviation and consult your scale supplier with these information. (7) If necessary, inhibit the bucket and continue operation. Refer to Paragraph "INHIBIT OPERATION. " " ACTUATOR ERROR If an actuator has not returned its original (home) position, the error symbol " " will be indicated. Follow the PROCEDURES below to have the actuator returned to its original position. (1) Stop the machine and enter Manual Operation. (2) Touch the scale segment with the error symbol in the left-hand scale graphic circle. (3) If product or its fragments have found bitten by an actuator, remove the product. (4) Touch the "RETURN" pad to return to the Automatic Operation screen. BLANK OUT Weight display in the scale segment of the graphic display will be blanked out if weight signal exceeds (MAX + 9 e1). Possible cause is too much product in the weigh bucket. Take actions as described in "OVERWEIGHT". Note: The above action is applied when the system is applied to European W&M regulation. GB48108G0021 ( 51/137) 51 Operation SE Ver.2.XX 7,'09

62 2 Level 1 OPERATOR PROCEDURES DAILY INSPECTION DAILY INSPECTION To ensure the proper operation and maximum performance, perform the preventive maintenance periodically. Maintenance is divided into daily, monthly and annual inspection PROCEDURES, and cautionary instruction. This chapter contains the PROCEDURES and instruction for daily inspection as follows: 1 Daily Inspection 1.1 Pre-operation Inspection (1) Top Cone (2) Linear Feeder Pans (3) Feed Bucket (4) Weigh Bucket (5) Memory Bucket (6) Zero Adjustment (7) Weigh Level Sensor Zero Adjustment 1.2 Inspection during Operation (1) Main Feeder and Linear Feeders (2) Bucket Door Noise 1.3 Inspection during Clean-up (1) Common Bed Doors (2) Actuator Unit 2 Cautionary Instruction (1) Weigh Level Sensor (2) Load Cell on Weigh/Actuator Unit (3) Weigh Bucket Doors GB48108G0021 ( 52/137) 52 Operation SE Ver.2.XX 7,'09

63 2 Level 1 OPERATOR PROCEDURES DAILY INSPECTION 1. DAILY INSPECTION 1.1 PRE-OPERATION INSPECTION (1) Top Cone Check that the top cone is installed at its proper position on the Main Feeder. See if the top cone is fastened firmly with the catch-clip on the vibrator and that the clip arm of the catch-clip is pulled up to the bottom of the top cone. TOP CONE CATCH CLIP 2 1 MAIN FEEDER For ADW-2XX/3XX, Place the top cone at its proper position on the center vibrator and fasten tightly with the fixing bolts. FIXING BOLT SPRING WASHER TOP CONE MAIN FEEDER GB48108G0021 ( 53/137) 53 Operation SE Ver.2.XX 7,'09

64 2 Level 1 OPERATOR PROCEDURES DAILY INSPECTION (2) Linear Feeder Pans Check that each linear feeder pan is installed at its proper position on the vibrator. See if the pan is fastened firmly with the catch-clip on the vibrator and that the clip arm of the catch-clip is pulled up to the bottom of pan. Each pan should be overlaying the pan to its right without making any contact. LINEAR FEEDER PAN LINEAR FEEDER CATCH CLIP 2 1 For ADW-2XX/3XX Place the pan on the vibrator and then the catch clip hooks the pan downward to clamp the pan as shown in the illustration below LINER FEEDER PAN CATCH CLIP 2 1 LINER FEEDER 3 GB48108G0021 ( 54/137) 54 Operation SE Ver.2.XX 7,'09

65 2 Level 1 OPERATOR PROCEDURES DAILY INSPECTION PRE-OPERATION INSPECTION continued (2) Feed Buckets Check that each feed bucket is installed at its proper position and mounted properly on its support hanger. See if the FB door toggle arm pin roller is placed properly between the fingers of the FB drive lever and if the bucket doors close firmly. Perform "ORIGINAL POINT" in Manual Operation and check that open and close motion of bucket doors is smooth. GB48108G0021 ( 55/137) 55 Operation SE Ver.2.XX 7,'09

66 2 Level 1 OPERATOR PROCEDURES DAILY INSPECTION PRE-OPERATION INSPECTION continued (3) Weigh Buckets Check that each weigh bucket is installed at its proper position and mounted properly on its support hanger. See if the pin roller of the WB drive lever is placed properly between the fingers of WB toggle arm and if the bucket doors close firmly. Perform "ORIGINAL POINT" in Manual Operation and check that open and close motion of bucket doors is smooth. GB48108G0021 ( 56/137) 56 Operation SE Ver.2.XX 7,'09

67 2 Level 1 OPERATOR PROCEDURES DAILY INSPECTION PRE-OPERATION INSPECTION continued (4) Memory Buckets Check that each bucket is installed at its proper position and mounted properly on its support hanger. See if the pin roller of the MB drive lever is placed properly between the fingers of MB toggle arm and if the bucket doors close firmly. Perform "ORIGINAL POINT" in Manual Operation and check that open and close motion of bucket doors is smooth. (5) Zero Adjustment Perform Zero Adjustment (REZERO) of all weigh heads in Manual Operation after confirming that no product in any weigh bucket. See display of scale graphic on the AICC-SE screen and confirm that weight value of each scale is 0.0 g. (6) Weigh Level Sensor Zero Adjustment Perform Zero Adjustment of the Main Feeder Weigh Level Sensor in Manual Operation after confirming of no product on the main feeder. See display of scale graphic on the AICC-SE screen and confirm that product level is approximately 0. GB48108G0021 ( 57/137) 57 Operation SE Ver.2.XX 7,'09

68 2 Level 1 OPERATOR PROCEDURES DAILY INSPECTION 1.2 INSPECTION DURING OPERATION (1) Main Feeder and Linear Feeders Check that there is no unusually loud sound coming from a linear feeder or the main feeder during operation. If a leaf spring of a linear feeder or the main feeder breaks or a leaf spring fastener bolt loosens, an abnormal loud vibration will result. (2) Bucket Door Noise Check that there is no unusual loud noise coming from bucket doors of a bucket. If bucket doors of a bucket are found producing abnormal noise, take out that bucket after performing "INHIBIT OPERATION" of that head in Manual Operation and see a probable cause of such noise. 1.3 INSPECTION DURING CLEAN-UP (1) Common Bed Doors Confirm that the common bed doors are closed securely before beginning the clean-up. Since electrical and/or electronic units are installed in the common bed, water for clean-up may damage these units if the doors are not securely closed. (2) Actuator Unit Check that there are no pieces of product caught between Weigh Bucket Hanger and the front plate. Pay attention to this especially when you use air to clean the machine. Weighing accuracy can be affected seriously if a piece of product is caught there. Be careful not to give excess force on Weigh Bucket Hanger, which is connected with the load cell. (For ADW-2XX/3XX) (For ADW-514SN) GB48108G0021 ( 58/137) 58 Operation SE Ver.2.XX 7,'09

69 2 Level 1 OPERATOR PROCEDURES DAILY INSPECTION 2. CAUTIONARY INSTRUCTION (1) Weigh Level Sensor The main Feeder is supported with a load cell to measure and control product level on the top cone. Although the load cell is designed to support enough load, be sure not to apply too much load by stepping foot, for example, on the top cone. (2) Load Cell on Weigh/Actuator Unit The load cell installed on each Weigh/Actuator unit supports the WB hanger. Since the load cell is a sensitive component, be sure not to apply excess load on the load cell by pushing down or pulling up, for example, the weigh bucket. Such a careless action could damage the load cell. (3) Weigh Bucket Doors Be sure not to open by hand doors of a bucket while the bucket is installed on the bucket hanger. This could damage the inside mechanism, and pulling down the weigh bucket door with excess force could damage the load cell as well. GB48108G0021 ( 59/137) 59 Operation SE Ver.2.XX 7,'09

70 Chapter 3 CLEAN-UP PROCEDURES Clean-up procedure should be performed at least once a day, and depending on product, more often if necessarily. To perform the clean up of the machine, detach the detachable parts such as linear feeder pans, feed buckets, weigh buckets, memory buckets, chutes, and collating funnels from the main body first, then clean them individually. Parts removal should be performed in the order of the following procedures: 1. CLEAN INFEED FUNNEL Use a damp cloth to wipe off the inner surfaces of the infeed funnel. 2. CLEAN MAIN FEEDER Use a damp cloth to wipe off the top cone surface of the main feeder directing waste product onto the linear feeders. 3. REMOVAL OF LINEAR FEEDER PANS Press each catch clip downwards to release and pull the linear feeder pan out horizontally and then slightly upwards as shown in the illustration below. Be careful to pull out far enough to clear rear part of the pan from the edge of main feeder top cone. LINEAR FEEDER PAN CATCH CLIP 1 2 LINEAR FEEDER For ADW-2XX/3XX, Pull the catch clip upwards to release and pull the liner feeder pan out horizontally and then slightly upwards as shown in the illustration below. LINER FEEDER PAN CATCH CLIP 2 LINER FEEDER 1 GB48108G0021 ( 60/137) 60 Operation SE Ver.2.XX 7,'09

71 3 CLEAN-UP PROCEDURES 4. REMOVABLE OF TOP CONE Press each catch clip downwards to release and pull the top cone out horizontally and then slightly upwards as shown in the illustration below. TOP CONE CATCH CLIP 1 2 MAIN FEEDER For ADW-2XX/3XX Loosen the fixing bolt and pull the top cone out upwards as shown in the illustration below. FIXING BOLT SPRING WASHER TOP CONE MAIN FEEDER GB48108G0021 ( 61/137) 61 Operation SE Ver.2.XX 7,'09

72 3 CLEAN-UP PROCEDURES 5. REMOVAL OF CHUTES Remove each of the section of the collating chutes by pulling upwards. When the insert flap has cleared its holder, pull it out horizontally. 6. REMOVAL OF COLLATING FUNNEL Lift the funnel to clear each pin at the three arms of the funnel and turn the funnel to remove downwards as shown in the right-hand illustration. COLLATING CHUTE COLLATING FUNNEL 7. REMOVAL OF BUCKETS To remove buckets, lift each bucket upwards first and then take it horizontally as shown in the illustration below. FEED BUCKET WEIGH BUCKET MEMORY BUCKET (ADW-xxxMx ONLY) GB48108G0021 ( 62/137) 62 Operation SE Ver.2.XX 7,'09

73 3 CLEAN-UP PROCEDURES 8. CLEAN TOP COVER AND MAIN BODY Use a damp cloth to wipe off the top surface of the top cover of the main body. To perform clean up of the machine of normal models, do not use a hose to clean the machine portions except removed parts. To perform clean up of the machine of wash-down models, it is allowed to use a hose under the conditions described below. a) Confirm that the all the doors and actuator units are installed properly and there are no loose bolts on them. b) Water pressure should be less than 4.3 PSI or 30 kpa. c) Wipe off the water drops on the machine thoroughly after washing. 9. CLEAN REMOVED PARTS Use a cloth to wipe off the inner surfaces of top cone, all pans, buckets, and chutes. Pay special attention to that no waste product or its residual remains on inner surface if flavor product is handled. Each entire part may be washed with water if necessary. Be sure all the parts dry thoroughly before reinstalling. When you clean up the removed parts, you use if necessary only neutral detergent (ph6-ph8). Rinse the detergent out of the parts and wipe off the water on the parts. 10. INSTALL REMOVED PARTS After all parts have dried thoroughly, install them in the reverse order. Make sure of the following points: (1) These chute sections are installed in the same position from which they were removed. (2) The collating funnel is installed on their mounts inserting each pin of the three arms securely in the hole of each supporting brackets. (3) Install the top cone of main feeder on the vibrator and pull the catch clip upwards to fasten the pan securely on the vibrator. (4) Install the pan of each linear feeder on the vibrator and pull the catch clip upwards to fasten the pan securely on the vibrator (5) Install each bucket in its proper position holding bucket doors by hand upwards, closing the doors. Make sure of the following points referring to the illustration on the next page: (a) Be sure two bars in the rear bucket stay securely on the hangers. (b) Be sure the pin of bucket door link arm is securely stay in the notch at the end of the actuator arm. (c) Be sure the bucket door firmly closed when reinstalled. IMPORTANT: If you use a detergent to clean up the removed parts, use only neutral detergent (ph6 to ph8) and wash it out off the parts. Otherwise the parts will be caused damages including serious rust. CAUTION: Buckets with ball bearing connections are not submersible. Submersing bearings will result in water infiltration of inner bearings. Water infiltration will result in breakdown of the bearing lubrication. As inner bearings cannot be re-lubricated or properly dried, internal bearing corrosion will occur. The resulting internal bearing corrosion will significantly reduce bearing life cycle, and potentially cause catastrophic bearing failure. GB48108G0021 ( 63/137) 63 Operation SE Ver.2.XX 7,'09

74 3 CLEAN-UP PROCEDURES The illustration below shows installation of a feed bucket as an example. GB48108G0021 ( 64/137) 64 Operation SE Ver.2.XX 7,'09

75 Chapter 4 Level 2 CHIEF OPERATOR PROCEDURES This level requires a password to access and allows the operator to alter any preset parameters on the Automatic (or Manual) Operation screen temporarily. (These parameters will be described in the next chapter.) This will help to determine proper parameter settings through tuning or adjustment during Automatic or Manual operation. To save the altered parameters, perform the same settings at Level 3. Refer to the section, "HOW TO SAVE SCALE SETUP VALUES" in the next chapter. HOW TO ACCESS LEVEL 2 Touch the "ACCESS LEVEL" pad in the menu bar in any kind of menu screen, either the main menu, the automatic operation, or others, in Level 1. The pop-up menu for password entry will be displayed. Enter the password for Level 2. For example, when you enter the Level 2 password on the Automatic Operation screen, the Automatic Operation screen in Level 2 (Chief Operator mode) will be displayed. GB48108G0021 ( 65/137) 65 Operation SE Ver.2.XX 7,'09

76 4 Level 2 CHIEF OPERATOR PROCEDURES HOW TO ALTER PRESET PARAMETERS Automatic and Manual operation screens in Level 2 contain the "SCALE SETUP" pad in the menu bar at the bottom of the screen while the rest of the display is the same as in Level 1 (Operator mode). Touch this "SCALE SETUP" pad. The Scale Setup screens will be displayed. These screens allow you to temporarily alter preset parameters for tuning the performance during Automatic and Manual operation. Such PROCEDURES are important for proper operation assuring weighing accuracy and performance especially with a new product. The detailed PROCEDURES will be described in the next chapter. Note: These changes are temporary and will return to the preset values when the program number is changed. To alter the preset values permanently, follow the PROCEDURES in Scale Setup in Level 3 (Supervisor PROCEDURES). GB48108G0021 ( 66/137) 66 Operation SE Ver.2.XX 7,'09

77 Chapter 5 Level 3 SUPERVISOR PROCEDURES OVERVIEW This chapter contains the instructions required for preset of parameters and selection of functions using the Scale Setup screens. The following table shows the screens along with the preset parameters to be set and functions to be selected: MENUS/SCREENS PROCEDURES PAGE MAIN MENU Main Menu 69 How To Save Scale Setup Values 70 PROGRAM SELECTION 71 PROGRAM SETUP Product Name 72 Target Weight 73 Speed Auto Setup 74 Op. Pattern No. 75 Nominal Weight (g) High Limit WT. (g) Auto Zero SCALE SETUP 1 T.N.E. Over Discharge Auto Zero Time (min) 76 SCALE SETUP 2 Multi-Dump Count 77 Stagger Dump Time (ms) Collection Gate Histogram degree WT. (g) Menu Screen 78 Combination Mode 79 Target Weight (g) Bias Weight (g) No Load Detect (%) No Select Detect CF AMP MF AMP MF TIME LF AMP LF TIME Settle Time FB Motor Pat. FB Open Time WB Motor Pat. In WB Motor Pat. Out WB Open Time 80 GB48108G0021 ( 67/137) 67 Operation SE Ver.2.XX 7,'09

78 5 Level 3 SUPERVISOR PROCEDURES MENUS/SCREENS PROCEDURES PAGE SCALE SETUP 2 MB Motor Pat. 80 MB Open Time CB Motor Pat. CB Open Time Setup Procedures 81 AFC 82 Reset Interval Target WB No. (AFC-T) Limit WB No. (AFC-T) AFC-Target Weight (AFC-I) SCALE SETUP 3 SCALE SETUP 4 AFC Limit WT. (AGFC-I) LF Time (AFC-R) Product Sensor FB Delay 2 (WBFB) Transfer Limit Weight (%) WB Discharge Delay Weigh Sensor Low Low Limit Dump Signal (ms) Dump Signal Delay (ms) CB Discharge Delay (ms) Middle Shutter Middle Shutter Open Time Middle Shutter Delay Time Middle Shutter Motor Pattern Insert Signal (ms) Insert Signal Delay (ms) CB3 open Time (ms) CB3 Motor Pattern Diverter Motor Pattern Infeed Ring Movement (mm) Infeed Ring Speed (pps) Infeed Diverter For Twin System AUTOMATIC OPERATION 2-Point 3-Bucket System Auto Infeed Ring System PRINTER SETUP GB48108G0021 ( 68/137) 68 Operation SE Ver.2.XX 7,'09

79 5 Level 3 SUPERVISOR PROCEDURES MAIN MENU To access the Level 3 (Supervisor PROCEDURES) menus or screens, one of the passwords for Level 3 or 4 is required. When the password is entered, the main menu of Level 3 will be displayed. The main menu of Level 3 contains three additional pads, "PROGRAM SETUP", "DATE/TIME & PRINTER", and "TROUBLE SHOOTING", in addition to those items in the Operator PROCEDURES (Level 1). PROGRAM SETUP Used to call up the Scale Setup screens to perform preset of parameters for operation and selection of functions. DATE/TIME & PRINTER Used to call up the DATE/TIME & PRINTER screen to perform printer setup and to set date and time. TROUBLE SHOOTING Used to call up the TROUBLE SHOOTING menu to view causes and actions against trouble. TROUBLE SHOOTING is shown in the next chapter. In addition to these features, the following items can be performed in the Level 3 PROCEDURES: (1) Fine tuning during Automatic and Manual Operation as those in the Chief Operator PROCEDURES. (2) To alter printer setting using the "DATE/TIME & PRINTER" screen during Automatic or Manual Operation. (3) Copy or clear programs using the "PROGRAM SELECTION" screen. GB48108G0021 ( 69/137) 69 Operation SE Ver.2.XX 7,'09

80 5 Level 3 SUPERVISOR PROCEDURES HOW TO SAVE SCALE SETUP VALUES The scale setup values described in this chapter are temporary and will be kept with the back-up battery. It is recommended, however, to save these set or altered values permanently. The PROCEDURES for saving are as follows: (1) Touch the "SAVE" pad in the menu bar at the bottom of the screen. A pop-up window indicating the message, "CURRENT PROGRAM IS MODIFIED! DO YOU WANT TO SAVE?" will appear. (2) Confirm if the values set or altered are correct. Then touch the "YES" pad. The values entered using these SCALE SETUP screens are permanently stored in permanent memory. (3) To cancel, touch the "NO" pad. The message will disappear. GB48108G0021 ( 70/137) 70 Operation SE Ver.2.XX 7,'09

81 5 Level 3 SUPERVISOR PROCEDURES PROGRAM SELECTION Touch the "PROGRAM NUMBER SELECTION" boxed item in the main menu. The Program Number Selection screen in Level 3 will be displayed. The Program Number Selection screen in Level 3 contains three additional function pads "CLEAR", "COPY", and "COPY NEXT" other than those on the Program Number Selection screen in Level 1 (Operator Mode). CLEAR Used to delete the highlighted program. COPY Used to copy the currently selected program (shown at the top of the screen) to the highlighted area. All the preset parameters in the current program will be pasted together. This allows the current preset parameters to be used for other program numbers. COPY NEXT Used to copy the program currently selected in the first available program list. PROCEDURES To select a program number, scroll the program list and move the high-lighted bar to the desired program number using the arrows in the scroll bar. Then, touch any pad. A message asking where save is required will be displayed if any changes have been found in the original program. To return to the main menu, touch the "RETURN" pad. Note: A message asking whether a save is required will be displayed at any of the above steps if any changes have been found in the original program. GB48108G0021 ( 71/137) 71 Operation SE Ver.2.XX 7,'09

82 5 Level 3 SUPERVISOR PROCEDURES PROGRAM SETUP Touch the boxed item, "PROGRAM SETUP", in the main menu. The "PROGRAM SETUP" screen is displayed. The PROGRAM SETUP screen contains Program Name pad, Target Weight pad, and Operation Speed pad. PRODUCT NAME Used to register or change the product name for the program number currently selected. (1) Touch the "PRODUCT NAME" pad. The pop-up menu for alphanumeric value entry will be displayed as shown in the illustration below. (2) Touch characters on the alphanumeric pad to enter the desired product name. This product name will be displayed above the pop-up menu. (3) The "CLR" pad can clear the whole the name in the pop-up menu and the "DEL" pad can delete one character, which has just been chosen. (4) Confirm if it is correct, then touch the "ENT" pad. The pop-up menu will disappear and the chosen product name will be displayed in the product name pad on the PROGRAM SETUP screen. GB48108G0021 ( 72/137) 72 Operation SE Ver.2.XX 7,'09

83 5 Level 3 SUPERVISOR PROCEDURES PROGRAM SETUP TARGET WEIGHT Used to set or alter the target weight for the currently selected program number. (1) Touch the "TARGET WT." pad. The pop-up menu for numeric value entry (10-key pad) will be displayed. SPEED Used to set operation speed. (1) Touch the "SPEED" pad. The pop-up menu for numerical value entry (10-key pad) will be displayed. (2) Enter the target weight using 10-key pad. The target weight value will be displayed above the 10-key pad. (3) Touch the "ENT" pad. The pop-up menu will disappear and the entered value will be displayed in the "TARGET WT" pad on the Program Setup screen. Note: (1) No value smaller than the Nominal Weight can be set to for the Target Weight. If such value is tried to set to, just the value of the Nominal Weight will be displayed. This is applied when European W&M requirements is applied. (2) This target weight cannot be changed in Mix application and indicates the target weight for total groups of scales. (2) Enter the value of the desired speed in packs per minute using the 10-key pad. (3) Touch the "ENT" pad. The chosen value will be displayed in the "SPEED" pad on the Program Setup screen. GB48108G0021 ( 73/137) 73 Operation SE Ver.2.XX 7,'09

84 5 Level 3 SUPERVISOR PROCEDURES AUTO SETUP The "AUTO SETUP" PROCEDURES allows the operator to perform a setup of a program by touching the "AUTO SETUP" pad in the menu bar at the bottom of the PROGRAM SETUP screen. This "AUTO SETUP" PROCEDURES will automatically set related parameters based on the target weight and speed previously entered. PROCEDURES (1) Touch the "AUTO SETUP" pad on the PROGRAM SETUP screen after setting a desired target weight and speed. Then a prompt of "DO YOU WANT TO AUTO SETUP?" will be displayed as shown in the illustration below. (2) Touch the "YES" pad to perform the AUTO SETUP. Then, the CPU in the DATAWEIGH will calculate all the necessary parameters according to the "Typical Parameter Settings" based on the two parameters, Target Weight and Speed, which have been selected. These parameters will be entered into the currently selected program number and can be reviewed on Scale Setup screens. (3) To save the parameters set with this AUTO SETUP, follow the instructions given in the section "HOW TO SAVE SCALE SETUP VALUES" on page 68. (4) To cancel touch the "NO" pad. (5) The "Typical Parameter Settings" are given in Annex - Supplementary Description. These settings will be helpful for Scale Setup. GB48108G0021 ( 74/137) 74 Operation SE Ver.2.XX 7,'09

85 5 Level 3 SUPERVISOR PROCEDURES SCALE SETUP 1 Touch the "SCALE SETUP" pad in the menu bar of the "PROGRAM SETUP" screen. The "SCALE SETUP 1" screen will be displayed. The following preset parameters will be set in this screen in the manner similar to setting the target weight using pop-up menu (10-key pad), which will be displayed when each pad is touched. OP. PATTERN NO. OP. PATTERN NO. represents the operation pattern number to be used in the blending application. Details will be described in MIX PATTERN SETTING of Installation Manual Part 2. Set "1"in this pad in the normal (not blending) application. NOMINAL WT. (g) NOMINAL WT. represents the nominal weight of the product in the package. The preset target weight for the machine operation is determined by the nominal weight plus allowances such as outage, tare variability, process variability, etc. Note: The nominal weight will be the base of statistical data calculation such as standard deviation, etc. and indicated on printout. This is used when European W&M requirement is applied. HIGH LIMIT WT. (g) Used to set upper limit of combination or pack weight. No value greater than 25 % above the Nominal Weight can be set to. (When Option to meet Austria W&M requirements, no value greater than 9 % above the Target Weight is allowed. This is used when European W&M requirement is applied.) A combination exceeding this High Limit will be judged as OVERWEIGHT while a combination between the target weight and the high limit is judged as ACCEPTED. AUTO ZERO When European W&M requirements are not applied, this pad is always selected "ON" and cannot be selected "OFF". This means Automatic Zero Adjustment of each scale will be always performed during Automatic Operation. The interval of the Automatic Zero Adjustment is set in the "AUTO ZERO TIME" PROCEDURES, which cannot be set to greater than 30 minutes. While Automatic Zero Adjustment of a scale is carried out, the symbol of " " is indicated in the scale (weigh bucket) in the scale graphic of Automatic Operation screen. If zero deviation from the initial zero exceeds the range of ±2 % (Note when European W&M requirements are not applied, ±16 % is used instead of ±2 %.) the scale capacity at Automatic Zero Adjustment, the zero error symbol " " will be indicated in the graphic display and an alarm (beep) will sound. When an alarm is equipped to the I/O, In the event of "ZERO ERROR", check possible causes in Manual Operation. GB48108G0021 ( 75/137) 75 Operation SE Ver.2.XX 7,'09

86 5 Level 3 SUPERVISOR PROCEDURE SCALE SETUP 1 T. N. E. When European W&M requirements are applied, T. N. E. stands for "Tolerable Negative Error" based on Nominal Weight in the prepackaging rules in the Average System in European countries. This value is automatically calculated in accordance with the table shown in the footnote. No value greater than this TNE can be set here. Combination search and statistical data printout is performed according to those rules, details of which are described in Average System in Annex. OVER DISCHARGE When this item is set "ON", a combination exceeding the High Limit can be discharged if no other combination closest to the target weight has been found in the acceptable zone. If only a combination exceeding the High Limit is available when the "OVER DISCHARGE" is set "OFF", the machine will stop operation and a message "NO COMBINATION" will be displayed. Then the operator must change the operation mode to manual and discharge the product from the bucket before restarting operation "ON" and "OFF" will toggle when touched. AUTO ZERO TIME (min) Used to set the interval of Automatic Zero Adjustment. The interval time should be determined depending on the product buildup in Weigh buckets. Typical values for the interval are Heavy buildup: 1 min. Medium buildup: 2-5 min. Light buildup: 5-10 min. But no value greater than 30 min. can be set to. (If "0" is set for the interval, zero adjustment will be carried out every weighing cycle.) Selection of the next AUTO ZERO head waits until the preceding AUTO ZERO head will return to available condition in order to keep count of available heads. Note: T.N.E. values are calculated according to the following table: 0 g Nominal WT < 50 g TNE = 9.0 % of Nominal WT 50 g Nominal WT < 100 g TNE = 4.5 g 100 g Nominal WT < 200 g TNE = 4.5 % of Nominal WT 200 g Nominal WT < 300 g TNE = 9.0 g 300 g Nominal WT < 500 g TNE = 3.0 % of Nominal WT 500 g Nominal WT < 1000 g TNE = 15.0 g 1000 g Nominal WT < g TNE = 1.5 % of Nominal WT g Nominal WT < g TNE = g g Nominal WT TNE = 1.0 % of Nominal WT GB48108G0021 ( 76/137) 76 Operation SE Ver.2.XX 7,'09

87 5 Level 3 SUPERVISOR PROCEDURES SCALE SETUP 1 MULTI-DUMP COUNT This function sets the number of discharge to achieve the final target weight. When the target weight exceeds the maximum single discharge weight or more than five buckets are required, this function should be used. This function can be used to prevent product choking at the funnel of the packaging machine as well. When "1" is set in this pad, no multi-dump mode is selected. Detailed operation will be given in Supplementary Description of Annex. STAGGER DUMP TIME (ms) This function is used to sequentially discharge the buckets selected in combination. The value set is the total delay time for all the buckets to open and added to the cycle time. If product has a potential to makes bridge in the funnel of the packaging machine, this function should be used. Detailed description will be given in Supplementary Description of Annex. When "0" is set in this pad, no staggered dump will be performed. COLLECTION GATE Two selection pads will be displayed when a collection gate is installed and its function is selected in System Installation (Interface and I/O Allocation). The first pad will be toggled, when touched, between "ON" and "OFF". Select "ON" to use this collection gate. To keep it open so as to pass product without interruption, select "OFF". When "ON" is selected as above, two additional operation modes can be selected with the second pad. This second pad will be toggled, when touched, between "PASS" and "STOCK". Select "STOCK" to use the collection gate with its normal function. To cut product string-out only without stocking product, select "PASS". Timing of the collection gate operation will be described in Supplementary Description of Annex. HISTOGRAM DEGREE WT. (g) Used to set the increment of histogram in weight. Note: Parameter settings in SCALE SETUP PROCEDURES are limited so that the relationship among these parameters may be suitable for operation. Such limitations are described in Annex - Supplementary Description. GB48108G0021 ( 77/137) 77 Operation SE Ver.2.XX 7,'09

88 5 Level 3 SUPERVISOR PROCEDURES SCALE SETUP 2 SCALE SETUP 2 Touch the "2" pad in the upper right corner on the SCALE SETUP 1 screen. The SCALE SETUP 2 screen will be displayed. The SCALE SETUP 2 screen contains two groups of menus; one consists of 5 function pads left-hand, and the other a graphic menu of one scale head with the parameter setting pads for each unit. The functions of the graphic menus are labeled in the illustration below. Note: This screen is used to set parameters and select functions for each group of scales if the blending application is selected. In normal (not blending) application, the same values are to be set in the pad with the same label on the PROGRAM SETUP and SCALE SETUP 1 screens. The value set later, on either screen, supersedes if a different value is set in the same labeled pad in the other setup screen in normal application, when the pervious value will be automatically replaced with the new value. CHF AMP MVF AMP LVF AMP FB MOTOR PATTERN WB (IN) MOTOR PATTERN WB (OUT) MOTOR PATTERN MB MOTOR PATTERN CB MOTOR PATTERN MVF TIME LVF TIME FB OPEN TIME SETTLE TIME WB OPEN TIME MB OPEN TIME CB OPEN TIME GB48108G0021 ( 78/137) 78 Operation SE Ver.2.XX 7,'09

89 5 Level 3 SUPERVISOR PROCEDURES SCALE SETUP 2 COMBINATION MODE Used to select the combination mode, weight, count, or extra mode. This pad, when touched, toggles among "WEIGHT", "COUNT" (Number of pieces or count), and "ETC". "WEIGHT" mode is the standard operation mode, in which a combination is selected in weight. "COUNT" mode is the counting mode, in which a combination is selected in count and weight. "ETC" (extra mode) is provided for a special application called as "Priority Head". The "Priority Head" is one of mixing applications, in which a weigh head selected as "Priority Head" will discharge one of ingredients for mixing, not joining the normal combination calculation for a pack weight. Refer to "How to set a priority weigh head" in Instruction Manual for Mixing. TARGET WEIGHT (g) Used to set the target weight of each group in the blending application. The same target weight is to be set as in the PROGRAM SETUP screen in normal (not blending) application. BIAS WEIGHT (g) Bias weight is used compensate for insufficient settle time or external vibration. The actual target weight used for combination will be (TARGET WEIGHT + BIAS WEIGHT). NO LOAD DETECT (%) If weight reading of a weigh bucket is less than this value, the bucket is regarded as empty. Upon NO LOAD DETECT occurs at an operation cycle, the bucket will be fed with product again (RECHARGE). No value smaller than 20e 1 can be set to. Thus, the allowable range is as follows: NO LOAD DETECT (%) (20e 1 / TW) 100 The above does not applied when European requirements are not used. NO SELECT DETECT If a weigh or memory bucket has not been selected in combination over cycles of the number set in this pad, the bucket will be forced into combination even if overweight. This value is usually used with frozen food application to prevent product from staying in a bucket for a long time so as to prevent product from deterioration. A typical value for frozen food is 20 while 80 for all other product. To disable this function, set "0" in this pad. CF AMP Used to set the amplitude of the Cross Head Feeder. The amplitude is to be set between 0 (stop) and 99 (maximum amplitude). Set this value to 50 initially and adjust it to feed product in proper level onto the Main Feeder. MF AMP Used to set the amplitude of the main feeder. The amplitude is to be set between 0 (stop) and 99 (maximum amplitude). Initially set this value to 50 and adjust along with MF TIME to feed proper volume of Product into Linear Feeders. MF TIME Used to set time of main feeder vibration. Initially set this time to feed product approximately 150 ms. LF AMP Used to set the amplitude of linear feeders in total. The amplitude is to be set between 0 (stop) and 99 (maximum amplitude). Initially set this value to 50 and adjust along with LF TIME to achieve the proper number of buckets selected in combination. LF TIME Used to set duration time of linear feeder vibration. Initially set this time to feed product approximately 200 ms. This time should not be set greater than one cycle time minus feed bucket open time. GB48108G0021 ( 79/137) 79 Operation SE Ver.2.XX 7,'09

90 5 Level 3 SUPERVISOR PROCEDURES SCALE SETUP 2 SETTLE TIME Used to set a time, which allows a weigh bucket to settle before it is selected in combination. The settle time should be set according to the Scale Capacity for each machine model, but no value smaller than the settle time shown in the table in Limitation of Parameter Setting of Annex. FB MOTOR PAT Used to select the actuator motor operation pattern number for the doors of feed bucket, which can be selected between five patterns set in System Installation. FB OPEN TIME* Used to set the time the feed bucket is held in the full open position. Set an appropriate time in milli-seconds to discharge product of one third of the target weight. WB MOTOR PAT IN Used to select the actuator motor operation pattern for the inner door of the weigh buckets, which can be selected between five patterns set in System Installation. WB MOTOR PAT OUT Used to select the actuator motor operation pattern number for the outer door of the weigh buckets, which can be selected between five patterns set in System Installation. WB OPEN TIME* Used to set the time the weigh bucket is held in the full open position. Set an appropriate time in milli-seconds to discharge product of one third of the target weight. MB MOTOR PAT Used to select the actuator motor operation pattern number for memory bucket doors, which can be selected in five patterns set in System Installation. MB OPEN TIME* Used to set the time the memory bucket is held in the full open position. Set an appropriate time in milli-seconds to discharge product of one third of the target weight. CB MOTOR PAT Used to select the actuator motor operation pattern for the doors of collection gate if installed, which can be selected in five patterns set in System Installation. CB OPEN TIME* Used to set the time the collection gate is held in the full open position. Set an appropriate time to discharge product at the target weight. Note (*): Besides the above FB open time, WB open time, MB open time, and CB open time, the bucket door stationary open time for each bucket is set in the motor pattern settings in the System Installation, which is set to minimum "0" ms. Thus the actual bucket door stationary open time is the total time of the stationary open time set in the motor pattern setting plus the bucket open time set in the above section. Pattern No. 5 of each motor pattern can be used for high-speed application. Its open time, if selected, will be fixed to "0". GB48108G0021 ( 80/137) 80 Operation SE Ver.2.XX 7,'09

91 5 Level 3 SUPERVISOR PROCEDURES SCALE SETUP 2 SETUP PROCEDURES To enter new value for a parameter or change a parameter currently set, follow the PROCEDURES that have been given in the Paragraph "DATA ENTRY" of Chapter 1 - INTRODUCTION. When there is multiple units such as weigh buckets, memory buckets, etc., a parameter newly set is applied for all the same units. However, it is often required to set a different parameter for individual linear feeder or main feeders (if multiple main feeders are used). To set or change a parameter for individual unit, follow the PROCEDURES given below. Linear Feeders Touch the TIME pad of linear feeders in the graphic display. A parameter-setting window will be displayed on the SCALE SETUP 2 screen as follows: PROCEDURES 1. Touch the time pad of the linear feeder 1 in the window. The ten-key pads will be displayed as shown in the illustration for DATA ENTRY. 2. Enter or change the parameter using the ten-key pads. 3. Touch the next pad and enter or change the parameter. 4. Repeat the same PROCEDURES for other linear feeders. 5. To return to SCALE SETUP 2 screen, touch the RETURN pad. 6. To enter a same parameter for all the linear feeders, touch the AVERAGE pad and then enter a new value. To enter or change parameters for multiple Main Feeders or Cross Head Feeders, follow similar PROCEDURES. Note: (1) Least significant digit of each value of Target Weight, Nominal Weight, High Limit, TNE, Histogram Degree, and Bias Weight will be rounded to multiple of e2, which is shown in the table "SCALE INTERVALS". The above is applied to European W&M requirements. (2) The value shown in a pad for multiple units such as linear feeders on the SCALE SETUP 2 screen represents an average value of the different values set for individual units. GB48108G0021 ( 81/137) 81 Operation SE Ver.2.XX 7,'09

92 5 Level 3 SUPERVISOR PROCEDURES SCALE SETUP 3 SCALE SETUP 3 Touch the "3" pad on the SCALE SETUP 2 screen. The SCALE SETUP 3 screen will be displayed. AFC Used to select "T" (AFC-T), "I" (AFC-I), "R" (AFC-R), or "OFF" (disable) of the automatic feeder control for product feed of the linear feeders. The automatic feeder control function adjusts automatically amplitude of the linear feeders so that average number of buckets selected in combination may be within the range preset below. Refer to Supplementary Description AUTOMATIC FEEDER CONTROL for detailed operation. RESET INTERVAL Used to set the interval cycle count for reset of accumulated deviation in AFC-T or AFC-I. Set an appropriate interval cycle count for accumulation. Set 10 as a typical value for reset interval cycles. TARGET WB NO. (AFC-T) Used to set the AFC-T target number of Weigh buckets to be selected in combination. Enter 4.0 for the normal operation to adjust linear feeders to select 4 weigh buckets, on average, in combination. LIMIT WB NO. (AFC-T) Used to determine a range of dead zone for accumulated deviation from target number of weigh buckets. Control action of AFC will not take place until accumulated deviation has exceeded this range. Set to 2.0 as a typical limit number. AFC-TARGET WEIGHT (AFC-I) Used to preset a desired product weight for AFC-I in an individual weigh bucket. Set the value of one fourth of the target weight as standard. GB48108G0021 ( 82/137) 82 Operation SE Ver.2.XX 7,'09

93 5 Level 3 SUPERVISOR PROCEDURES SCALE SETUP 3 AFC LIMIT WT. (AFC-I) Used to determine a range of dead zone for accumulated deviation from target product weight in a weigh bucket. Control action of AFC will not take place until accumulated deviation has exceeded this range. LF TIME (AFC-R) Used to determine a difference time between individual linear feeders for AFC-R. Set 200 msec as standard. PRODUCT SENSOR (OPTIONAL FUNCTION) Used to enable or disable an optional sensor installed at the edge of each linear feeder. This pad will be displayed when this option is selected in System Installation. (Option Selection 3) FB DELAY 2 (WB FB) Used to set a delay time from WB to FB. This delay time can be set to a minus value. TRANSFER LIMIT WEIGHT. (%) (OPTIONAL FUNCTION) Used to set a limit weight for gummy application. If product in a weigh bucket exceeds this limit, it is not allowed to be discharged into the memory bucket below. This pad will be displayed when the Gummy Product option is selected in System Installation. (Option Selection 2) WB DISCHARGE DELAY Used to set a delay time for staggered dump for mixing application. Set this value to 0 for normal application. WEIGH SENSOR Used to set a upper limit and lower limit for each weight sensor of the Main Feeder. It is recommended to set a value of 4 or 5 times of Target Weight. LOW LOW LIMIT (OPTIONAL FUNCTION) Use to set a low-low limit for operating point of STOP BY LOW LOW LIMIT or AUTO INFEED RING. (Option Selection 14) GB48108G0021 ( 83/137) 83 Operation SE Ver.2.XX 7,'09

94 5 Level 3 SUPERVISOR PROCEDURES SCALE SETUP 4 SCALE SETUP 4 Touch the "4" pad on any SCALE SETUP screen. The SCALE SETUP 4 screen will be displayed. DUMP SIGNAL (ms) Used to set the duration time of the dump signal to be sent to the packaging machine. DUMP SIGNAL DELAY (ms) Used to set a delay time of product discharge signal to be sent to the packaging machine after the "READY" signal has been sent from that packaging machine. CB DISCHARGE DELAY (ms) Used to set the delay time the collection gate discharges product after the "READY" signal has been sent from the packaging machine below. MIDDLE SHUTTER (OPTIONAL FUNCTION) Used to select "enable" or "disable" of an optional middle shutter if installed. Select "ON" to enable the middle shutter. To disable it, select "OFF". MIDDLE SHUTTER OPEN TIME (OPTIONAL FUNCTION) Used to set the open (duration) time of the middle shutter. MIDDLE SHUTTER DELAY TIME (OPTIONAL FUNCTION) Used to set a delay time to initiate the middle shutter open after the "READY" signal has been sent from the packaging machine below. MIDDLE SHUTTER MOTOR PATTERN (OPTIONAL FUNCTION) Used to set a motor pattern for motor driven middle shutter. INSERT SIGNAL (ms) (OPTIONAL FUNCTION) INSERT SIGNAL means the duration time of signal sent to the inserting machine. INSERT SIGNAL DELAY (ms) (OPTIONAL FUNCTION) An "insert" (coupon, desiccant or other premium) is inserted in a package in some application. This delay is used to determine the timing to send the signal to the inserting machine. Set an appropriate delay time after the "READY" signal has been sent from the packaging machine below. GB48108G0021 ( 84/137) 84 Operation SE Ver.2.XX 7,'09

95 5 Level 3 SUPERVISOR PROCEDURES SCALE SETUP 4 SCALE SETUP 4 continued CB3 OPEN TIME (ms) (OPTIONAL FUNCTION) Used to set the OPEN TIME the optional CB3 buckets open in ms. CB3 is a pair of optional collection buckets installed in the optional 2 point 3 bucket system. CB3 MOTOR PATTERN (OPTIONAL FUNCTION) Used to set the MOTOR PATTERN of the optional CB3 buckets. INFEED RING MOVEMENT (mm) (OPTIONAL FUNCTION) Used to set the movement distance of auto infeed ring from original point. Maximum distance is approximately 100mm. INFEED RING SPEED (pps) (OPTIONAL FUNCTION) Used to set the ascent/descent SPEED of the auto infeed ring. DIVERTER MOTOR PATTERN (OPTIONAL FUNCTION) Used to set the MOTOR PATTERN of the optional diverter. DIVERTER is an optional unit installed for the twin discharge system using separated main feeders. The diverter provides product separately to each segment of the main feeder as required. INFEED DIVERTER for TWIN SYSTEM DIVERTING INFEED FUNNEL MAIN FEEDER (TOP CONE) LINEAR FEEDER GB48108G0021 ( 85/137) 85 Operation SE Ver.2.XX 7,'09

96 5 Level 3 SUPERVISOR PROCEDURES SCALE SETUP 4 SCALE SETUP 4 continued 2-POINT 3-BUCKET SYSTEM COLLATING FUNNEL COLLECTION GATE CB3-A CB3-B AUTO INFEED RING SYSTEM ACTUATOR INFEED FUNNEL INFEED RING GB48108G0021 ( 86/137) 86 Operation SE Ver.2.XX 7,'09

97 5 Level 3 SUPERVISOR PROCEDURES AUTOMATIC OPERATION Touch the boxed item, "AUTOMATIC OPERATION" in the main menu of Level 3 Supervisor PROCEDURES. The "AUTOMATIC OPERATION" screen will be displayed. The "AUTOMATIC OPERATION" screen in Level 3 contains one additional pad "Scale Setup" in the menu bar at the bottom of the screen other than those in Level 1. DATE/TIME & PRINT Note: This pad is also displayed at the access level 1 and 2. Parameters to be set or altered at these levels are limited. The pads of items that cannot be altered are displayed without frames on the screen. Used to call up the "DATE/TIME & PRINT" screen so that the statistical data can be printed or printer preset values can be altered during the Automatic Operation. (Printer: Option) Refer to the description for "DATE/TIME & PRINT" on the next page. GB48108G0021 ( 87/137) 87 Operation SE Ver.2.XX 7,'09

98 5 Level 3 SUPERVISOR PROCEDURES PRINTER SETUP Touch the boxed item "DATE/TIME & PRINT" in the main menu or the same pad in the menu bar at the bottom of the AUTOMATIC OPERATION screen. The DATE/TIME & PRINT (PRINTER SETUP) screen will be displayed. Although the printer is an optional unit, some of these items are set on this screen. The Date & Time of the internal clock and preset parameters of statistical data for printout as well as for Histogram are set on this screen. DATE The calendar date is set in one of three formats: dd/mm/yy, mm/dd/yy, or yy/mm/dd, which is selected in the System Installation. TIME The real time is to be set in the format of hh:mm in the 24-hour system. HISTOGRAM DEGREE (g) The histogram degree means the interval or increment of the histogram. SAMPLE COUNT When the desired sample size is set in this pad and "SAMPLE PRINT" below is selected "ON", statistical data including histogram will be automatically printed when the Sample Count has been reached. SAMPLE TIME The SAMPLE TIME means sampling interval to be set in the format of hh:mm. Every SAMPLE TIME data for the SAMPLE COUNT will be accumulated and printed after the sample count is over. The relationship between "SAMPLE COUNT" and "SAMPLE TIME" will be shown in Supplementary Description on page 115. Note (1) The printout mode will be viewed in Supplementary Description as well. (2) When an option for NMI requirements is selected in Option Selection of Installation Manual Part 2. (1) Hourly Report will be printed out every hour. (2) The printout interval will be fixed. (3) SAMPLE PRINT will be fixed to "ON". GB48108G0021 ( 88/137) 88 Operation SE Ver.2.XX 7,'09

99 5 Level 3 SUPERVISOR PROCEDURES PRINTER SETUP INDIVIDUAL WEIGHT Every pack weight will be printed when both the "INDIVIDUAL WEIGHT" and the "SAMPLE PRINT" are selected "ON". To disable, select this function "OFF". END OF SHIFT PRINT Select "ON" in the "END OF SHIFT PRINT" pad to print statistical data every end of shift set in the "END OF SHIFT TIME" pads. If two or more products have been packed during the current shift, statistical data will be printed out by program. The accumulated data is cleared after the printout and new data will start accumulating. SAMPLE PRINT Select "ON" in this "SAMPLE PRINT" pad to print statistical data automatically at timing set in the preceding pads. END OF SHIFT TIME Up to three shift times can be set in these pads. Set each time of the end of shift in its pad in the format hh/mm in 24-hour system. You can skip a pad not used. When the "END OF SHIFT" pad selected "ON", statistical data will be printed every end of shift at the times set here. END CURRENT SHIFT Touch this pad to print statistical data before the time of end of shift. The accumulated data during that shift will be cleared. PRINT PROGRAM LISTING Touch this pad to print out the preset parameters of the currently selected program for record. ADVANCE PRINTER PAPER Touch this pad to advance printer paper. Note that the description of PRINTOUT Mode and PRINTOUT samples are given in Supplementary Description of Annex. GB48108G0021 ( 89/137) 89 Operation SE Ver.2.XX 7,'09

100 Chapter 6 TROUBLE SHOOTING OVERVIEW This chapter contains the instructions for using TROUBLE SHOOTING screens. The Level 3 or higher password is required to see these screens. Also, the troubleshooting methods for general problems are shown in this chapter. MENUS/SCREENS PROCEDURES PAGE ERROR MESSAGE LOG 91 Sample Test Screen 92 SAMPLE TEST Vibration Waveform 1 94 Vibration Waveform 2 95 SOFTWARE VERSION 96 I/O CHECK 97 HARD CHECK 98 VOLTAGE CHECK 99 TROUBLE SHOOTING FOR GENERAL PROBLEMS 100 GB48108G0021 ( 90/137) 90 Operation SE Ver.2.XX 7,'09

101 Chapter 6 TROUBLE SHOOTING ERROR MESSAGE LOG ERROR MESSAGE LOG The AICC-SE, Weigh/Actuator unit, and I/O unit are connected with LAN, where errors can occur in communication. Most probable errors in communication are "TIME OUT" and "RE-CONFIGURATION", and the error symbol mark "E" will be displayed in the scale graphic on AICC-SE screen if an error has not been cured by themselves. The "ERROR MESSAGE LOG" allows the engineer to see the current record of these communication errors. (1) Touch the TROUBLE SHOOTING pad on the main menu of Level 3 (Supervisor Procedure) or higher. The following TROUBLE- SHOOTING menu will be displayed. (2) Touch the ERROR MESSAGE LOG pad on the TROUBLESHOOTING menu. The Error Message Log (ERROR LOG) will be displayed as shown in the illustration below. ID No. in the table is that of the unit (Weigh/Actuator, AICC-SE, or I/O unit) where that error occurred. If no ID No. is identified, "0" will be displayed. Date/Time shows when that error occurred. The table consists of 16 rows and the oldest record will be erased if all the 16 rows are filled up. (This table shows the record at the time when this table was displayed.) (3) Most probable errors in communication are, as described above, "TIME OUT" and "RE-CONFIGURATION". If frequent errors have occurred at a specific unit (ID No.), consult your supplier for corrective action. (4) The data on display can be printed with an optional printer by touching PRINT pad. (5) All log data on display can be erased by CLEAR pad, at Access Level 4. (6) To return to the TROUBLESHOOTING menu, touch the RETURN pad. GB48108G0021 ( 91/137) 91 Operation SE Ver.2.XX 7,'09

102 Chapter 6 TROUBLE SHOOTING SAMPLE TEST SAMPLE TEST SAMPLE TEST MODE allows the engineer to perform vibration analysis of scales along with filter constants. It is useful as well to find appropriate filter constants and settle time. You can see the vibration waveform of A/D output from the load cell. Procedures in the SAMPLE TEST MODE are as follows: SAMPLE TEST SCREEN (1) Touch the SAMPLE TEST pad on the TROUBLESHOOTING menu. The SAMPLE TEST MODE screen will be displayed. These screens are as shown in the illustrations below. GB48108G0021 ( 92/137) 92 Operation SE Ver.2.XX 7,'09

103 Chapter 6 TROUBLE SHOOTING SAMPLE TEST (2) Select the SAMPLE HEAD number by touching " "or " " right-hand to check and analyze the vibration of a specific head. If the vibration by a specific unit and head is required to see, touch the unit graphic pad and the segment(s) of the scale graphic. Especially to find a settle time, select FB and the segment corresponding to the SAMPLE HEAD number. (3) Touch the START pad. The FILTER SETTING screen will be displayed in a few seconds as shown in the illustration below. If each of the four filter constants shown in the FILTER pads from FIRST to FOURTH is set to 1, a waveform without any filter effect will be displayed. The default values for filter constants on this screen are the ones set in FILTER & DELAY screen in System Installation. The changes made in this screen for the filter constants are used only in this test mode, will not have any effect on the filter constants set in System Installation. Any value changed in this screen can not be saved, and will be cleared and returned to the default values once you return to the main menu. (4) Touch the GRAPH pad on the screen. The waveform will be displayed on the FILTER CHART screen as shown next page. To return to the SAMPLE TEST MODE screen, touch the RETURN pad. GB48108G0021 ( 93/137) 93 Operation SE Ver.2.XX 7,'09

104 Chapter 6 TROUBLE SHOOTING SAMPLE TEST VIBRATION WAVEFORM 1 (1) Touch the GRAPH pad in the FILTER SETTING screen. A vibration wave will be displayed in the FILTER CHART screen. (2) In the FILTER CHART, the horizontal axis represents TIME (msec), and the vertical axis represents A/D counts. These graduations can be changed in the FILTER SETTING screen (X-DIV, Y-DIV). START TIME can shift the original point of the horizontal axis. With this test, it is possible to see vibration waves while a feed bucket door is opened and product is dropped into the weigh bucket below until the vibration has settled. It is also possible to check the influence on a single weigh head by the other bucket(s) in operation. A/D counts per 0.1 g are as follows: DW model A/D Counts DW model A/D Counts ADW-2XX (0.5liters) 36.5 ADW-5XX (5liters) 9.1 ADW-3XX (1liter) 36.5 ADW-7XX (10liters) 4.9 ADW-4XX (2liters) 18.2 ADW-8XX (16liters) 4.9 ADW-514SN (3liters) 18.2 ADW-7XX-H (10liters) 2.4 ADW-5XX-L (5liters) 18.2 GB48108G0021 ( 94/137) 94 Operation SE Ver.2.XX 7,'09

105 Chapter 6 TROUBLE SHOOTING SAMPLE TEST VIBRATION WAVEFORM 2 (1) The next graph shows an example waveform with the following parameters: In this example, the waveform shows that the weight settles by around 670 msec with the filter constants above. (2) Waveform data can be printed with an optional printer by touching PRINT pad. (3) To return the FILTER SETTING screen, touch the RETURN pad. It is possible to change the setting parameters and return to the FILTER CHART screen. GB48108G0021 ( 95/137) 95 Operation SE Ver.2.XX 7,'09

106 Chapter 6 TROUBLE SHOOTING SOFT VERSION SOFT VERSION (1) Touch the SOFT VERSION pad on the TROUBLESHOOTONG menu. The each software version number in the board of Weigh/Actuator unit, I/O unit, and AICC-SE will be displayed as the illustration below. (2) These data can be printed with an optional printer by touching PRINT pad. (3) To return to the TROUBLESHOOTONG menu, touch the RETURN pad. GB48108G0021 ( 96/137) 96 Operation SE Ver.2.XX 7,'09

107 Chapter 6 TROUBLE SHOOTING I/O CHECK I/O CHECK (1) Touch the I/O CHECK pad on the TROUBLESHOOTONG menu. The I/O check screen will be displayed. The I/O CHECK screen is used to check the status of the input / output signals from the terminals TB2 / TB3 on I/O board. (2) You can check the current Input signals to the scale. Each INPUT pad for a pair of terminals will be highlighted when it is ON. (3) You can check the current Output signals from the scale, and also change the status manually only when you are at this screen. Touch a OUTPUT pad of a pair of terminals, this pad will be highlighted and its output signal will be sent. (4) When there are two I/O boards, you can check the status from each I/O board by changing the NODE NO. with " "or " " pad. (5) To check I/O status of the other side in TWIN system scale, touch the RETURN pad to return to the TROUBLESHOOTING menu and touch the MACHINE NUMBER pad in the menu bar to change the machine side. Then touch the I/O CHECK pad again on the TEST MODE menu. GB48108G0021 ( 97/137) 97 Operation SE Ver.2.XX 7,'09

108 Chapter 6 TROUBLE SHOOTING HARD CHECK HARD CHECK This mode allows the engineer to check the output from the load cell of each weigh head. In this mode, a certain voltage is applied to the pre-amplifier and the A/D converter will convert the output from the pre-amplifier. Then the output from the A/D converter will be displayed on this HARD CHECK MODE screen. (1) Touch the HARD CHECK pad on the TROUBLESHOOTING menu screen. The HARD CHECK MODE screen will be displayed as shown in the illustration below. (2) Each NO. represents that of the weigh head. The output from the A/D converter of each head is displayed at the corresponding number. These data are used for diagnosis of the load cell, pre-amplifier and A/D converter. (3) These data can be printed with an optional printer by touching PRINT pad. GB48108G0021 ( 98/137) 98 Operation SE Ver.2.XX 7,'09

109 Chapter 6 TROUBLE SHOOTING VOLTAGE CHECK VOLTAGE CHECK This mode allows the engineer to check the exciting voltage supplied to load cell and digital circuit of each weigh head. These voltages are converted into digital values with the A/D converter and then displayed this VOLTAGE CHECK MODE screen. Those values on the screen are not actual voltages, but converted values. (1) Touch the VOLTAGE CHECK pad on the TROUBLESHOOTING menu screen. The VOLTAGE CHECK MODE screen will be displayed as shown in the illustration below. (2) A/U No. represents the Weigh Head number. And others represent as follows: P24 (5 or 3V): Voltage for the optional product sensor Vcc (2.5V): Voltage exciting digital circuit +VA (2.5V) and -VA (2.5V): Voltage exciting load cell Note1: These values do not show actual voltages. Note2: In Model ADW-2xx, 3xx and 514SN, the values on P24 line should be 0.0, because they are not supplied in those models. (3) These data can be printed with an optional printer by touching PRINT pad. GB48108G0021 ( 99/137) 99 Operation SE Ver.2.XX 7,'09

110 Chapter 6 TROUBLE SHOOTING GENERAL PROBLEMS TROUBLE SHOOTING FOR GENERAL PROBLEMS (1) DATAWEIGH DOES NOT WORK AT ALL PROBABLE CAUSE No power a) Main circuit breaker ELB1 is not turned on. b) No power supply to the machine. Improper setting at System Installation or Program setup Communication error Reset button on AICC-SE does not work against "SYSTEM SHUT DOWN". CORRECTIVE ACTION Turn on the circuit breaker. Supply power to the machine. Check improper setting and change it. Check that terminator is properly set** See DIP SW settings on Sub CPU Board in Weigh/Actuator unit (see Installation Manual Part 2) See DIP SW settings on I/O Board (see Installation Manual Part 2). Or replace the board with new one. Check I/O box or AICC-SE. Note: * lf communication error has occurred between AICC-SE and Weigh/Actuator unit, an error symbol mark "E" will be displayed at the segment in problem in scale graphic on the Automatic Operation screen. ** The terminator resistor must be selected at the end of the I/O Board on LAN bus line. (The other terminator resistor must be set to W/A Unit (Weigh Head) No. 1 as the end of the LAN bus line.) T HEAD HEAD No. 1 No. 2 HEAD No. 3 HEAD No. N I/O I/O T AICC-SE EVA-0029F For ADW-2XX, 3XX and 514SN, LAN bus line is as shown below. Do not mind terminator in EVA0009F. EV0009F Board PR1 EV0009F Board PR2 I/O I/O T AICC-SE EVA-0029F GB48108G0021 ( 100/137) 100 Operation SE Ver.2.XX 7,'09

111 Chapter 6 TROUBLE SHOOTING GENERAL PROBLEMS (2) THE MACHINE HAS STOPPED RUNNING SUDDENLY PROBABLE CAUSE No combination has found in acceptable range and "OVER DISCHARGE" is set OFF. With message of "WAIT FOR DUMP". (Problem in the interface with packaging machine) With message of "WAIT PRODUCT FEED". With message of "EXTERNAL INTERLOCK OFF". Trip of the Earth Leakage Breaker (ELB1) CORRECTIVE ACTION b) Check product flow and improve it. c) Check that parameters for operation are set properly and change them if necessary. d) Set "OVER DISCHARGE ON in Scale Setup 1, if necessary. a) Check that the machine transmits "DW READY" (or DUMP ) signal to the packaging machine or receives "READY" signal from the packaging machine. If not; Check I/O signal allocation at System Installation. Check LED on I/O Board and replace the board if the LED does not light. Check cable connection and interface with the packaging machine. Check any other problem with the packaging machine. a) Supply product. b) Check the product distribution on the machine. Then adjust the position of Infeed Funnel, if necessary. c) Perform proper settings for LVF and/or MVF Amplitude and/or Time. Check that the photo sensor for Customer's Eye is set at proper level. If no problem, supply product to that level. Check leakage and fix it. GB48108G0021 ( 101/137) 101 Operation SE Ver.2.XX 7,'09

112 Chapter 6 TROUBLE SHOOTING (3) NO VIBRATION OF MAIN FEEDER VIBRATOR (MVF) PROBABLE CAUSE GENERAL PROBLEMS CORRECTIVE ACTION Coil wire is broken. Replace the coil. Problem with I/O Board or Feeder Control Board in I/O unit. Blown fuse of Feeder Power Supply Board in I/O unit. Improper or no settings for MVF at System Installation. Replace the board. Replace the fuse. Perform proper setting for MVF at System Installation. Improper (zero) settings for amplitude and/or driving time of MVF at SCALE SETUP. Perform proper setting for MVF at SCALE SETUP 2. (4) NO VIBRATION OF LINEAR FEEDER VIBRATOR (LVF) PROBABLE CAUSE Coil wire is broken. Problem with Feeder Control Board or Sub CPU Board in Weigh / Actuator unit. Blown fuse of Feeder Power Supply Board in Weigh / Actuator unit. CORRECTIVE ACTION Replace the coil. Replace the board. Replace the fuse. Improper (zero) settings for amplitude and/or operation time of LVF at SCALE SETUP. Perform proper setting for MVF at SCALE SETUP 2. (5) PRODUCT FLOW TO THE MACHINE DOES NOT STOP PROBABLE CAUSE CORRECTIVE ACTION Too high value in High Limit setting for weight sensor. Too much drift of weight sensor zero point in minus direction. Failure of weight sensor Failure of I/O Board. Reduce High Limit at SCALE SETUP 3. Check weight sensor sensitivity and perform its zero setting again at Initial Calibration. Replace the weight sensor. Replace the board. Improper setting of interface between the infeed equipment and the machine. Perform proper setting for the interface. GB48108G0021 ( 102/137) 102 Operation SE Ver.2.XX 7,'09

113 Chapter 6 TROUBLE SHOOTING (6) INFEED EQUIPMENT DOES NOT WORK PROBABLE CAUSE Too high value in Low Limit setting for weight sensor. Too much drift of weight sensor zero point in positive direction. Failure of weight sensor Failure of I/O Board. GENERAL PROBLEMS CORRECTIVE ACTION Increase Low Limit at SCALE SETUP 3. Check weight sensor sensitivity and perform its zero setting again at Initial Calibration. Replace the weight sensor. Replace the board. Improper setting of interface between the infeed equipment and the machine. Improper or no setting of FEED signal at I/O allocation in System Installation. Product build-up on the top cone. Perform proper setting and wiring for the interface. Perform proper setting in Allocation of Output Signal. (See Installation Manual.) Clean up the top cone. (7) FEED BUCKET DOORS DO NOT OPEN PROBABLE CAUSE Blown fuse of Motor Power Supply Board in Weigh/Actuator unit. Failure of Sub CPU Board or Motor Drive Board in Weigh / Actuator unit. Failure of actuator motor Improper motion of bucket door even at manual operation of individual bucket. Improper setting in motor pattern. Replace the fuse. Replace the board. Replace the motor. CORRECTIVE ACTION Perform proper adjustment of the bucket. Perform proper Motor Pattern setting. (See Installation Manual.) (8) WEIGH BUCKET DOORS DO NOT OPEN PROBABLE CAUSE Blown fuse of Motor Power Supply Board in Weigh/Actuator unit. Failure of Sub CPU Board or Motor Drive Board in Weigh / Actuator unit. Failure of actuator motor Improper setting in motor pattern. Cam follower comes out of fork (off the home position). Improper motion of bucket door even at manual operation of individual bucket. Weigh bucket is not installed properly. Replace the fuse. Replace the board. Replace the motor. CORRECTIVE ACTION Perform proper Motor Pattern setting. (See Installation Manual.) Perform "ORIGINAL POINT" in Manual Operation to return the cam follower to its home position. Perform proper adjustment of the bucket. Install the bucket again properly. GB48108G0021 ( 103/137) 103 Operation SE Ver.2.XX 7,'09

114 Chapter 6 TROUBLE SHOOTING (9) MEMORY BUCKET DOORS DO NOT OPEN PROBABLE CAUSE Blown fuse of Motor Power Supply Board in Weigh/Actuator unit. Failure of Sub CPU Board in Weigh / Actuator unit or Motor Drive Board in Memory unit. Failure of actuator motor. Improper setting in motor pattern. Improper motion of bucket door even at manual operation of individual bucket. Incomplete connection between Weigh / Actuator unit and Memory unit. GENERAL PROBLEMS CORRECTIVE ACTION Replace the fuse. Replace the board. Replace the motor. Perform proper pattern setting. Perform proper adjustment of the bucket. Connect both units with the machine properly. (10) COLLECTION BUCKET DOORS DO NOT OPEN PROBABLE CAUSE CORRECTIVE ACTION Blown fuse of Motor Power Supply Board in I/O unit. Replace the fuse. Failure of I/O Board or Motor Drive Board. No I/O allocation for Collection Bucket in System Installation. Replace the board. Perform proper setting in System Installation. (See Installation Manual 2.) Improper setting at SCALE SETUP. Perform proper setting at SCALE SETUP 1 / 2. Connector CON02A(B) is not plugged in firmly. A bolt fastening the drive shaft in CB Actuator unit is loosened or broken. Failure of actuator motor. The connecting rod is loosened between the bucket and Actuator unit. Plug in the connector firmly. Fasten the bolt firmly using LOCTITE or replace the bolt. Replace the motor. Fasten the screws for connecting rod. (11) ZERO ERROR MARK " " IS DISPLAYED DURING AUTOMATIC OPERATION PROBABLE CAUSE CORRECTIVE ACTION Product caught between WB holder and front plate. Remove the product. Actuator motor has not returned to its home position. (Cam follower is touching the fork.). WB doors do not open. The bolts fixing WB holder are loosened and the holder is touching with front plate. Too much product buildup on WB. Check that proper motor drive pattern is set and that WB has assembled properly. Then perform "ORIGINAL POINT" at Manual Operation. Refer to Item (8) above. Fasten the bolts. Remove the product buildup and take action to prevent the product buildup. GB48108G0021 ( 104/137) 104 Operation SE Ver.2.XX 7,'09

115 Chapter 6 TROUBLE SHOOTING GENERAL PROBLEMS (12) ACTUATOR ERROR MARK " " IS DISPLAYED DURING AUTOMATIC OPERATION PROBABLE CAUSE CORRECTIVE ACTION Product buildup on bucket doors. Too short time setting for bucket door open time. Failure of Sensor Board in Weigh / Actuator unit. Disk for motor sensor detection has loosened. Improper motion of bucket door because of improper motor drive pattern setting. Product from FB comes down into WB before WB doors close. Remove the product and take action to prevent the product buildup. Perform proper time setting for bucket door open time to discharge whole product. Replace the board. Tighten the screws for disk or replace the actuator unit. Perform proper pattern setting. (See Installation Manual 2.) Perform proper FB Delay 2 setting at Scale Setup 3. (13) OVERWEIGHT ERROR MARK " " IS DISPLAYED DURING AUTOMATIC OPERATION PROBABLE CAUSE CORRECTIVE ACTION Too high value setting for LVF amplitude and/or time. Product sliding into FB directly from top cone when it is fed from cross-head feeder. Too much product pushed from top cone into FB through Linear Feeder. Product distribution on top cone and linear feeders is uneven. Reduce these setting value. Adjust height of the cross-head feeder and/or infeed funnel properly. a) Reduce MVF amplitude. b) Adjust the infeed funnel. a) Adjust height and position of infeed funnel. b) Adjust height and position of cross-head feeder. (14) TOO OFTEN RE-CALCULATION DUE TO UNDERWEIGHT PROBABLE CAUSE CORRECTIVE ACTION Too low value setting for MVF / LVF amplitude and/or time. Shortage in product supply from the line. Perform proper value setting at Scale Setup 2. a) Increase product supply. b) Check if EXTERNAL INTERLOCK is properly set. C) Check that weight sensor setting is proper. GB48108G0021 ( 105/137) 105 Operation SE Ver.2.XX 7,'09

116 Chapter 6 TROUBLE SHOOTING GENERAL PROBLEMS (15) TOO MUCH DIFFERENCE BETWEEN WEIGHT VALUES IN DISPLAY AND ACTUAL WEIGHT PROBABLE CAUSE CORRECTIVE ACTION WB cam follower is touching the fork at its home position. Product remained in bucket due to short time setting for WB, MB, or CB open time. Adjust the fork position. Perform proper time setting at Scale Setup 2. Product caught in bucket doors due to improper timing of opening. Low scale accuracy due to the floor or gantry vibration. Zero drift of a scale. Span change of a scale. Product caught between WB Holder and front plate. a) Set FB Delay 2 properly in Scale Setup 3 if product is caught in WB doors. b) Set WB Discharge Delay properly in Scale Setup 3 if product is caught in CB doors. a) Confirm that the machine is installed firmly. b) Adjust filter constants in System Installation. a) Check if no product buildup on WB. b) Set short interval for AUTO ZERO adjustment at Scale Setup 1. c) Check the output from the load cell, then replace the load cell and/or Sub CPU Board if necessary. a) Perform span calibration again. b) Check the output from the load cell, then replace the load cell and/or Sub CPU Board if necessary. Remove the product and clean up. Improper motion of WB or MB doors. Check WB and or MB setting. Refer to Item (8) and 1.9 above. Product leakage due to the improper toggle arm setting. Buckets are kept open because of improper installation. Adjust the toggle arm of each bucket properly. Install all buckets properly. (16) CAN NOT PERFORM ZERO ADJUSTMENT AT INITIAL CALIBRATION PROBABLE CAUSE CORRECTIVE ACTION Failure of load cell. Failure of Sub CPU Board. Replace the load cell. Replace the board. (17) CAN NOT PERFORM SPAN CALIBRATION AT INITIAL CALIBRATION PROBABLE CAUSE CORRECTIVE ACTION Failure of load cell. Failure of Sub CPU Board. Replace the load cell. Replace the board. GB48108G0021 ( 106/137) 106 Operation SE Ver.2.XX 7,'09

117 Chapter 6 TROUBLE SHOOTING (18) PROBLEM WITH DISPLAY ON AICC-SE SCREEN PROBABLE CAUSE GENERAL PROBLEMS CORRECTIVE ACTION Failure of LCD display. (Flickering of display or no partial display). Failure of EL display and/or CPU board EVA0029F (No display on SCC screen). Replace the LCD display. Replace the LCD display and/or the board. (*) The names for electrical circuit boards are as follows (in standard application): I/O Board : EV211F for all models SUB CPU Board : EVA0009F for ADW-2XX, 3XX, 514SN (in Common Bed) EV206F for other models (in Weigh/Actuator unit) Motor Drive Board for FB : EVA0010F for ADW-2XX, 3XX, 514SN (in Common Bed) EV209 for ADW-4XX, 5XX (in Weigh/Actuator unit) EV161 for ADW-7XX, 8XX (in Weigh/Actuator unit) Motor Drive Board for WB : EVA0010F for ADW-2XX, 3XX, 514SN (in Common Bed) EV171 for ADW-4XX, 5XX (in Weigh/Actuator unit) EV161 for ADW-7XX, 8XX (in Weigh/Actuator unit) Motor Drive Board for MB : EVA0010F for ADW-2XX, 3XX, 514SN (in Common Bed) EV200 for ADW-4XX, 5XX (in Weigh/Actuator unit) EV162 for ADW-7XX, 8XX (in Weigh/Actuator unit) Motor Power Supply Board : EV210 for all models except for ADW-2XX, 3XX, 514SN Feeder Control Board : EV208F for all models Feeder Power Supply Board : EV207 for all models except for ADW-2XX, 3XX, 514SN Sensor Board : EV205 for all models GB48108G0021 ( 107/137) 107 Operation SE Ver.2.XX 7,'09

118 Annex SUPPLEMENTARY DESCRIPTION OVERVIEW This supplementary section describes detailed technical information of DATAWEIGH functions and operation timings so as to provide technical aides in preset parameter setting and function setup. This section contains the following items: ITEM PROCEDURES PAGE RELATED TO 1.1 Limitations Of The Parameter Settings 109 SCALE SETUP 1.2 Auto Programming (Typical Parameter Settings) 112 RELATED TO PRINTER SETUP 2.1 Printout Modes 2.2 SAMPLE TIME and SAMPLE COUNT E.O.S. Mode 2.4 Hourly Print Printout Samples Average System Auto Feed Control (AFC) 123 RELATED TO DATAWEIGH OPERATION 3.3 Stagger Dump Multi Dump Operation Cycle Combination Search DATAWEIGH Sequence 130 GB48108G0021 ( 108/137) 108 Operation SE Ver.2.XX 7,'09

119 Annex SUPPLEMENTARY DESCRIPTION 1. Related to SCALE SETUP 1.1 Limitations of the Parameter Settings There are limitations in parameter settings of SCALE SETUP as follows. Settle time (msec) Total time of Feed-bucket motor pattern (*1) + Feed-bucket stationary open time (SCALE SETUP 2) msec Minimum limitations of the settle time for each model are as follows: 2 litter models: 600 msec 5 litter models: 650 msec 10 litter models: 700 msec 16 litter models: 800 msec Cycle (msec) Weigh-bucket discharge delay time (SCALE SETUP 3) + 20 ms Cycle (msec) Total time of Collection gate motor pattern (*1) (if air then zero) + Open time of the Collection gate (SCALE SETUP 2) + 20 msec Cycle (msec) Collection gate discharge delay time (SCALE SETUP 4) + 20 msec Cycle (msec) Dump signal time (SCALE SETUP 4) + 20 msec Cycle (msec) Dump signal delay time (SCALE SETUP 4) + 20 msec Where Cycle (msec) = 60,000 msec / Speed (PROGRAM SETUP) If scale model is 10 heads with non-memory-bucket; Cycle (msec) Settle time (SCALE SETUP 2) + Total time of Weigh-bucket open motor pattern (*2) + Open time of the Weigh-bucket (SCALE SETUP 2) + Feed-bucket delay 2 (SCALE SETUP 3) + Weigh-bucket discharge delay time (SCALE SETUP 4) + 50 msec GB48108G0021 ( 109/137) 109 Operation SE Ver.2.XX 7,'09

120 Annex SUPPLEMENTARY DESCRIPTION Related to SCALE SETUP - Limitations of the Parameter Settings 2 litter model and target weight setting 100 g: 2 X Cycle (msec) Settle time (SCALE SETUP 2) + Total time of Weigh-bucket open motor pattern (*2) + Open time of Weigh-bucket (SCALE SETUP 2) + Feed-bucket delay 2 (SCALE SETUP 3) + Weigh-bucket discharge delay time (SCALE SETUP 4) + 50 msec If scale model is 14 heads with non-memory-buckets: 2 X Cycle (msec) Settle time (SCALE SETUP 2) + Total time of Weigh-bucket open motor pattern (*2) + Open time of the Weigh-bucket (SCALE SETUP 2) + Feed-bucket delay 2 (SCALE SETUP 3) + Weigh-bucket discharge delay time (SCALE SETUP 4) + 50 msec 2 litter model and target weight setting 100 g 3 X Cycle (msec) Settle time (SCALE SETUP 2) + Total time of Weigh-bucket open motor pattern (*2) + Open time of the Weigh-bucket (SCALE SETUP 2) + Feed-buckets delay 2 (SCALE SETUP 3) + Weigh-bucket discharge delay time (SCALE SETUP 4) + 50 msec If Insert option is selected in System Installation: Cycle (msec) Insert signal time (SCALE SETUP 4) + 20 msec Cycle (msec) Insert signal delay time (SCALE SETUP 4) + 20 msec GB48108G0021 ( 110/137) 110 Operation SE Ver.2.XX 7,'09

121 Annex SUPPLEMENTARY DESCRIPTION Related to SCALE SETUP - Limitations of the Parameter Settings If Mid-shutter is selected in System Installation: Cycle (msec) Total time of Mid-shutter motor pattern (*1) (if air then zero) + Open time of the Mid-shutter (SCALE SETUP 4) + 20 msec Cycle (msec) Mid-shutter delay time (SCALE SETUP 4) + 20 msec If two-points -three -buckets option is selected in System Installation: Cycle (msec) Total time of Collection gate 3 motor pattern (*1) (if air then zero) + open time of the Collection gate3 (SCALE SETUP 4) + 20 msec Motor pattern cycle is as shown in the illustration below: *2 TOTAL BUCKET DOOR OPEN TIME *1 TOTAL TIME OF MOTOR PATTERN CYCLE Note *1: If any of these equations is not satisfied, error message, "REDUCE SPEED" will be displayed on the Automatic Operation screen. Even in this case, scale can still be run. Note *2: Scale settings by the Auto Programming will be influenced by the above equation. GB48108G0021 ( 111/137) 111 Operation SE Ver.2.XX 7,'09

122 Annex SUPPLEMENTARY DESCRIPTION Related to SCALE SETUP 1.2 Auto Programming (Typical Parameter Settings) INPUT PARAMETERS (1) Target weight (g) 2 litter model: from 8 to 1000 g 5 litter model: from 20 to 2000 g 10 litter model: from 20 to 3000 g 16 litter model: from 40 to 5000 g (2) Speed (p/min) (*1) All model: from 1 to 200 p/min SET FIXED (3) Mixing Pattern No. = 1 (4) Over discharge = ON (5) Auto Zero = ON (6) Auto zero interval time = 3 min (7) TNE (Low limit weight) = 0.0 g (8) Stagger dump time = 0 m sec (9) Multi-dump count = 1 (10) Collection -gate installed: = ON/STOCK else: = OFF (11) Order of combination for mixing Group A: = 1 Group B: = 2 Group C: = 3 Group D: = 4 Group E: = 5 (12) Operation for mixing mode all groups: = ON (13) Combination mode = Weight (14) No load detection (*2) = 3 % (15) No select detection = 10 (16) Feed-bucket motor pattern number = (17) Weigh-bucket (outer) motor pattern number = (18) Weigh-bucket (inner) motor pattern number = (19) Memory-bucket motor pattern number = (20) Collection-gate (standard) motor pattern number = (21) Collection-gate 2 (optional) motor pattern number = (22) Collection-gate 3 (optional) motor pattern number = (23) Diverter motor pattern number = (24) Middle-shutter motor pattern number = 1 GB48108G0021 ( 112/137) 112 Operation SE Ver.2.XX 7,'09

123 Annex SUPPLEMENTARY DESCRIPTION Related to SCALE SETUP - Auto Programming (25) AFC = AFC-T ON (26) Reset count for AFC-T/AFC-1 = 10 (27) Limit weigh head number for AFC-T = 2.0 (28) Weigh-bucket open delay time = 0 msec (39) Product sensor Installed: = ON else: = OFF (30) High limit piece for counting = 0 (31) Low limit piece for counting = 0 (32) Trend weight mode for counting = OFF (33) Histogram degree piece for counting = 1 (34) Middle-shutter Installed: = ON else: = OFF (35) Insert signal delay time = 0 msec (36) Insert signal time = 50 msec SET BASED ON TARGET WEIGHT (37) Nominal weight = Target weight (38) Limit weight for AFC-T = Target weight / 2 (39) High limit weight (*3) Min < target 50 g then 3.0 g 50 < target 100 g then 4.0 g 100 < target 200 g then 5.0 g 200 < target 500 g then 10.0 g 500 < target 1000 g then 20.0 g 1000 < target Max g then 30.0 g (40) Cross Head Feeder amplitude = (41) Main feeder amplitude = (42) Linear feeder amplitude = Min < target 100 g then < target 500 g then < target Max g then 60 (43) Main feeder feed time = (44) Linear feeder feed time = Min < target 50 g then 300 msec 50 < target 100 g then 350 msec 100 < target 200 g then 450 msec 200 < target 500 g then 550 msec 500 < target 1000 g then 700 msec 1000 < target Max g then 800 msec GB48108G0021 ( 113/137) 113 Operation SE Ver.2.XX 7,'09

124 Annex SUPPLEMENTARY DESCRIPTION Related to SCALE SETUP - Auto Programming (45) Dump signal time Min < target 500 g then 200 msec 500 < target 1000 g then 250 msec 1000 < target Max g then 300 msec (46) Collection-gate open time (standard) = (47) Collection-gate 2 open time (optional) = (48) Collection-gate 3 open time (optional) = (59) Middle-shutter open time = by air: then Dump signal time else: then 0 msec (50) Weight sensor lower limit = target weight 3 (51) Weight sensor upper limit = target weight SET BASED ON VOLUME OF WEIGH BUCKET (52) Collection-gate open delay time = (53) Dump signal delay time = Collection-gate installed: then 0 msec else: 2 litter model: then 350 msec 5 litter model: then 400 msec 10 litter model: then 500 msec 16 litter model: then 500 msec (54) Middle shutter delay time = Dump signal delay time / 2 (55) Histogram degree weight = 2 litter model: then 1.0 g 5 litter model: then 2.0 g 10 litter model: then 5.0 g 16 litter model: then 10.0 g (56) Bias weight = 2 litter model: then 0.5 g 5 litter model: then 1.0 g 10 litter model: then 1.5 g 16 litter model: then 2.0 g GB48108G0021 ( 114/137) 114 Operation SE Ver.2.XX 7,'09

125 Annex SUPPLEMENTARY DESCRIPTION Related to SCALE SETUP - Auto Programming SET BASED ON VOLUME OF WEIGH BUCKET AND TARGET WEIGHT (57) Settle time = 2 litter model: 8 < target 50 g then 750 msec 50 < target 500 g then 800 msec 500 < target 1000 g then 900 msec 5 litter model: 20 < target 50 g then 800 msec 50 < target 500 g then 850 msec 500 < target 2000 g then 900 msec 10 litter model: 20 < target 50 g then 900 msec 50 < target 100 g then 950 msec 100 < target 1000 g then 1000 msec 1000 < target 2000 g then 1050 msec 2000 < target 3000 g then 1100 msec 16 litter mode: 40 < target 50 g then 1000 msec 50 < target 100 g then 1050 msec 100 < target 1000 g then 1100 msec 1000 < target 3000 g then 1150 msec 3000 < target 5000 g then 1200 msec (58) Feed-bucket stationary open time = (59) Weigh-bucket (outer) stationary open time = (60) Weigh-bucket (inner) stationary open time = (61) Memory-bucket stationary open time = 2 litter model: 8 < target 200 g then 0 msec 200 < target 500 g then 50 msec 500 < target 1000 g then 100 msec 5 litter model: 20 < target 500 g then 0 msec 500 < target 1000 g then 50 msec 1000 < target 2000 g then 100 msec 10 litter model: 20 < target 1000 g then 0 msec 1000 < target 2000 g then 100 msec 2000 < target 3000 g then 200 msec 16 litter model: 40 < target 1000 g then 0 msec 1000 < target 3000 g then 100 msec 3000 < target 5000 g then 200 msec GB48108G0021 ( 115/137) 115 Operation SE Ver.2.XX 7,'09

126 Annex SUPPLEMENTARY DESCRIPTION Related to SCALE SETUP - Auto Programming (62) Feed-bucket delay time 2 = 2 litter model: 8 < target 500 g then 0 msec 500 < target 1000 g then 50 msec 5 litter model: 20 < target 1000 g then 0 msec 1000 < target 2000 g then 50 msec 10 litter model: 20 < target 2000 g then 50 msec 1000 < target 3000 g then 100 msec 16 litter model: 40 < target 3000 g then 50 msec 3000 < target 5000 g then 100 msec SET BASED ON SPEED AND HOW MANY HEADS (63) Target WH number for AFC-T (a) Non-memory type less than 11 heads: then 5.0 else: single shift operation then 6.0 double shift operation then 4.0 (b) Memory type less than 11 heads: 1 < speed 40 then < speed 60 then < speed 80 then < speed 200 then 3.0 else : 1 < speed 40 then < speed 60 then < speed 80 then < speed 200 then 4.0 (64) Target WH weight for AFC-I = target weight / Target WH number for AFC-I NOTE (*1): The Auto Programming will check all limitations stated on Limitation of Series DATAWEIGH program setting. If anything is not satisfied, the Auto Programming will be aborted and shown an error message "REDUCE SPEED". (*2): If W&M option for European regulation is enabled, minimum number load detection will be 20 e1 / Target wt (%). (*3): If W&M option for European regulation is enabled, maximum High limit weight will be 25 % of Nominal weight. If Austrian regulation is enabled, maximum will be 9 % of Target weight. GB48108G0021 ( 116/137) 116 Operation SE Ver.2.XX 7,'09

127 Annex SUPPLEMENTARY DESCRIPTION 2. Related to PRINTER SETUP 2.1 PRINTOUT MODES Three printout modes are available, which are SAMPLE, E.O.S. and INDIVIDUAL. (1) The SAMPLE mode is selected when detailed data of a certain sample size is required in specific purpose such as test of process or packaging system including DATAWEIGH. This mode is selected when "SAMPLE PRINT" is set "ON". In the SAMPLE mode, either SAMPLE COUNT or SAMPLE TIME, or both of them, can be set at the same time. Relationship between them is described in the next paragraph. (2) The E.O.S. mode is selected when statistical data for shift operation is required for production management or quality assurance. This mode is enabled when "END OF SHIFT PRINT" is set "ON". Both E.O.S. and SAMPLE modes can be selected at the same time. (3) The INDIVIDUAL mode is selected when individual pack weights for a certain number of samples are required for a purpose of test of process or packaging system. This mode can be selected only in the SAMPLE mode. 2.2 SAMPLE TIME and SAMPLE COUNT Typical example: SAMPLE TIME (T) > SAMPLE COUNT (S) T T S S Individual Count Printing Data 2.3 E.O.S. mode (1) PARAMETER SETTING Three shift times are to be selected in 24-hour time for automatic printout of statistical data for the shift at each end of shift. (2) PRINT START The E.O.S. data is printed automatically when the selected E.O.S. TIME has come. (3) Printout will be performed in the following manners: a) The sampling data will be stopped under the following conditions: When the sampling number reaches the maximum number of 999,999. When any HISTOGRAM BAR reaches maximum number of 65,535. b) The sampling data will be cleared under the following conditions: When the E.O.S. data is printed out. When the CLEAR pad is touched on the Histogram screen. c) Printout of INDIVIDUAL WEIGHT and E.O.S. data. If SAMPLE and INDIVIDUAL WT are selected across an end of shift, the E.O.S. data will be printed after the INDIVIDUAL WT data has been printed out. If SAMPLE and INDIVIDUAL WT are selected across two or more end of shift, only the last data will be printed out. GB48108G0021 ( 117/137) 117 Operation SE Ver.2.XX 7,'09

128 Annex SUPPLEMENTARY DESCRIPTION 2.4 HOURLY PRINT When an option for NMI requirements is selected in Option Selection of Installation manual Part 2 (Option Selection 8-6 and 8-3), hourly report will be automatically printed out every hour. When (1) The printout interval will be fixed to one hour. (2) Setting of SAMPLE PRINT on DATE/TIME PRINT screen will be fixed to "ON". (3) Setting of SAMPLE COUNT on DATE/TIME PRINT screen will be disappeared. (4) When the following happens, the production data will be printed out along with setting data and then the production data will be erased: a) When Program No. is changed and production start again with this Program. b) When one of the parameters listed below is changed: Target Weight, Nominal weight, High Limit, TNE, Histogram Degree, and NO LOAD DETECT value c) When one of the other parameters is changed and saved. GB48108G0021 ( 118/137) 118 Operation SE Ver.2.XX 7,'09

129 Annex SUPPLEMENTARY DESCRIPTION Related to PRINTER SETUP 2. 5 PRINTOUT SAMPLES "SAMPLE" mode in MINIMUM SYSTEM GB48108G0021 ( 119/137) 119 Operation SE Ver.2.XX 7,'09

130 Annex SUPPLEMENTARY DESCRIPTION Related to PRINTER SETUP 2. 5 PRINTOUT SAMPLES (continued) "SAMPLE" mode in AVERAGE SYSTEM GB48108G0021 ( 120/137) 120 Operation SE Ver.2.XX 7,'09

131 Annex SUPPLEMENTARY DESCRIPTION Related to PRINTER SETUP 2. 5 PRINTOUT SAMPLES (continued) "E.O.S" mode in MINIMUM SYSTEM "E.O.S" mode in AVERGE SYSTEM GB48108G0021 ( 121/137) 121 Operation SE Ver.2.XX 7,'09