RCU-1000 OPERATION MANUAL MANUAL

Transcription

1 with RCU-1000 OPERATION MANUAL MANUAL No. GC48108G0002 YAMATO SCALE CO., LTD. GC48108G0002 (CPC 1/10) Operation RCU-1000 Ver.1.XX 08,'11

2 DATAWEIGH OMEGA series OPERATION MANUAL RECORD OF ISSUE DATE ISSUE NO. SOFTWARE VERSION Aug. 1, 2011 GC48108G0002 RCU-1000 Ver RECORD OF REVISION DATE ISSUE NO. REVISION PART YAMATO SCALE CO., LTD. Copyright 2010 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. GC48108G0002 (CPC 2/10) Operation RCU-1000 Ver.1.XX 08,'11

3 PREFACE This OPERATION MANUAL contains all the instructions for operation of the Ω 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 Ω 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. GC48108G0002 (CPC 3/10) Operation RCU-1000 Ver.1.XX 08,'11

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. GC48108G0002 (CPC 4/10) Operation RCU-1000 Ver.1.XX 08,'11

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 loading 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 operation or check. 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. GC48108G0002 (CPC 5/10) Operation RCU-1000 Ver.1.XX 08,'11

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. GC48108G0002 (CPC 6/10) Operation RCU-1000 Ver.1.XX 08,'11

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 operation or check, 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. GC48108G0002 (CPC 7/10) Operation RCU-1000 Ver.1.XX 08,'11

8 TABLE OF CONTENTS PREFACE Installation Note and Safety Instruction Danger, Warning, and Caution Notice Chapter 1 INTRODUCTION DATAWEIGH OMEGA series Systems... p. 1 Main Components... p. 2 RCU p. 4 The DATAWEIGH Concept... p. 5 THE DATAWEIGH OF OMEGA F1 FRONTIER CONCEPT... p. 6 Operation Cycle... p. 7 Model Designation... p. 8 Major Model Names... p. 9 Scale Intervals... p. 10 Login and Operation Mode and How to Login p. 11 Menus and Keypads... p. 12 Data Entry... p. 13 Chapter 2 Level 1 - OPERATOR PROCEDURES Overview... p. 14 Daily Operation Cycle... p. 16 Main Menu... p. 17 Zero Adjustment (REZERO)... p. 19 Program Selection... p. 20 Automatic Operation... p. 21 Histogram... p. 30 Clean... p. 32 Check... p. 33 Recommended Actions at Errors... p. 38 Daily Inspection... p. 39 GC48108G0002 (CPC 8/10) Operation RCU-1000 Ver.1.XX 08,'11

9 TABLE OF CONTENTS (continued) Chapter 3 CLEAN-UP PROCEDURES Removal of Parts... p. 48 Clean Removed Parts... p. 50 Install Removed Parts... p. 50 Chapter 4 Level 2 - CHIEF OPERATOR PROCEDURES How To Alter Preset Parameters... p. 52 Chapter 5 Level 3 - SUPERVISOR PROCEDURES Overview... p. 53 How To Save Scale Setup Values... p. 55 Program Selection... p. 56 Setup... p. 57 Date / Time... p. 70 Print Setting... p. 71 Chapter 6 TROUBLE SHOOTING Overview p. 73 Sample Test... p. 74 Software Version..... p. 77 I/O Check... p. 78 A/D Check... p. 79 Piezo Sensor... p. 80 Temp Sensor..... p. 81 Trouble Shooting for general problem... p. 82 GC48108G0002 (CPC 9/10) Operation RCU-1000 Ver.1.XX 08,'11

10 TABLE OF CONTENTS (continued) Chapter 7 ENGINEERING MODE (LEVEL 4) Overview p. 90 SYSTEM MENU... p. 91 I/O ALLOCATION p. 92 INITIAL CALIBRATION... p. 94 USER SETTING... p. 97 FEED SETTING..... p. 98 WEIGH SETTING... p.103 DUMP SETTING... p.110 AUTO TUNING... p.114 SETUP... p.115 Annex SUPPLEMENTARY DESCRIPTION Overview... p.118 Related To Setup p.119 Related To Printer Setup... p.129 Related To DATAWEIGH Operation... p.132 GC48108G0002 (CPC 10/10) Operation RCU-1000 Ver.1.XX 08,'11

11 Chapter 1 INTRODUCTION DATAWEIGH OMEGA series Systems The Ω series DATAWEIGH combination weighers are the result of over twenty years of accumulated experience in design and manufacture of the multi-head weigher for the food industry. The Ω series DATAWEIGH meet the needs of today's world markets. The major features of the Ω 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 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 Ω series is literally the machine to meet --- "The sum of all your needs" --- for the 21st century. The Ω series is truly the benchmark by which all others will be judged. GC48108G0002 ( 1/145) 1 Operation RCU-1000 Ver.1.XX 08,'11

12 1 INTRODUCTION MAIN COMPONENTS 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. GC48108G0002 ( 2/145) 2 Operation RCU-1000 Ver.1.XX 08,'11

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) 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. 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 RCU 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. GC48108G0002 ( 3/145) 3 Operation RCU-1000 Ver.1.XX 08,'11

14 1 INTRODUCTION MAIN COMPONENTS RCU-1000 ACCESS PORT COVER TOUCH SCREEN / COLOR LCD PRINTER 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 RCU-1000 unit, so that no additional cover is required for wash down applications. GC48108G0002 ( 4/145) 4 Operation RCU-1000 Ver.1.XX 08,'11

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 GC48108G0002 ( 5/145) 5 Operation RCU-1000 Ver.1.XX 08,'11

16 1 INTRODUCTION THE DATAWEIGH OF Ω FRONTIER CONCEPT The example below shows a partial listing of the total number of combinations possible using all of the weigh buckets on a Ω 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 GC48108G0002 ( 6/145) 6 Operation RCU-1000 Ver.1.XX 08,'11

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 RCU-1000 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 common bed 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. GC48108G0002 ( 7/145) 7 Operation RCU-1000 Ver.1.XX 08,'11

18 1 INTRODUCTION MODEL DESIGNATION ADW O Max. Pack Volume (2 digits) 01: 1.0 liters and over 03: 3.0 liters and over 06: 6.0 liters and over 12: 12.0 liters and over 18: 18.0 liters and over Number of Weigh Heads (2 digits) Example - 08: 8 Heads 14: 14 Heads Model S: Circular arrangement and Standard buckets M: Circular arrangement and Memory buckets F: F1 Frontier Blank: other model GC48108G0002 ( 8/145) 8 Operation RCU-1000 Ver.1.XX 08,'11

19 MODEL NAME 1 INTRODUCTION MAJOR MODEL NAMES Number of Heads Max. Pack Volume Bucket Configuration Protection Grade DATAWEIGH OMEGA ADW O-0114S 1 liters 14 Standard ADW O-0116M 1 liters 16 Memory ADW O-0120S 1 liters 20 Standard ADW O-0124M 1 liters 24 Memory ADW O-0128S 1 liters 28 Standard ADW O-0132M 1 liters 32 Standard ADW O-0114F 1 liters 14 Frontier ADW O-0120F 1 liters 20 Frontier ADW O-0128F 1 liters 28 Frontier ADW O-0132F 1 liters 32 Frontier ADW O-0310S 3 liters 10 Standard ADW O-0312M 3 liters 12 Memory ADW O-0314S 3 liters 14 Standard Waterproof ADW O-0316M 3 liters 16 Memory ADW O-0320S 3 liters 20 Standard ADW O-0324M 3 liters 24 Memory ADW O-0328S 3 liters 28 Standard ADW O-0332M 3 liters 32 Memory ADW O-0314F 3 liters 14 Frontier ADW O-0320F 3 liters 20 Frontier ADW O-0324F 3 liters 24 Frontier ADW O-0610S 6 liters 10 Standard ADW O-0614S 6 liters 14 Standard Waterproof ADW O-0616M 6 liters 16 Memory ADW O-0620S 6 liters 20 Standard ADW O-0620M 6 liters 20 Memory ADW O-0624M 6 liters 24 Memory ADW O-0614F 6 liters 14 Frontier ADW O-0620F 6 liters 20 Frontier ADW O-1214S 12 liters 14 Standard Waterproof ADW O-1220S 12 liters 20 Standard ADW O-1224M 12 liters 24 Memory ADW O-1214F 12 liters 12 Frontier ADW O-1220F 12 liters 20 Frontier ADW O-1814S 18 liters 14 Standard GC48108G0002 ( 9/145) 9 Operation RCU-1000 Ver.1.XX 08,'11

20 1 INTRODUCTION SCALE INTERVALS (1) Scale intervals, e 1 for check and e 2 for automatic operation, are to be selected depending on model as shown in the table below. Model e 1 at check (g) e 2 at auto. Op. (g) Span (g) 1 liters (01XX) liters (03XX) liters (06XX) , liters (12XX) , liters (18XX) ,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 check 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) 1 liters (01XX) liters (03XX) liters (06XX) liters (12XX) 0.1 1, liters (18XX) 0.1 1,500 GC48108G0002 ( 10/145) 10 Operation RCU-1000 Ver.1.XX 08,'11

21 1 INTRODUCTION LOGIN and OPERATION MODE and HOW TO LOGIN The RCU-1000 operation is divided into four modes; the parameter that can be set in each mode is different. When the operator who logs it in on the login screen is chosen, RCU-1000 becomes the operator s operation mode. The LOGIN screen is automatically selected when the power is turned ON. Select the operator who is logging in. Then touch "CONNECT" pad. Then, a pop up window for password entry will appear as shown in the illustration below. Enter the password of the operator who is logging in. When the correct password is entered, the automatic operation screen will appear. Select the operator who is logging in, then touch the "CONNECT" pad. The password entry window will be displayed as shown in the illustration right-hand: Touch characters on the alphanumeric pad to enter the password of the operator. Then press the "ENT" pad. To change to another operator, touch the "LOGOUT" pad. The screen will return to the login screen. GC48108G0002 ( 11/145) 11 Operation RCU-1000 Ver.1.XX 08,'11

22 1 INTRODUCTION MENUS and KEYPADS The RCU-1000 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: 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 "BACK" pad or MENU pad or HOME pad on the right f of the screen. (3) Sometime a series of menus covers multiple pages. In this case, small-boxed pads will appear at the left of the window with the menu. The Set-up menu shown in the illustration to the right is an example. Touch the desired menu pad to call up that menu in the series. Another Set-up menu will be displayed. (4) The "START" keypad will become small and "STOP" keypad become large during machine operation. To stop operation, just touch the pad, "STOP", which will become small and "START" pad will become large when the machine stops. GC48108G0002 ( 12/145) 12 Operation RCU-1000 Ver.1.XX 08,'11

23 1 INTRODUCTION MENUS and KEYPADS (continued) (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 touch HOME pad, you will return to the automatic operation screen. (7) When touch MENU pad, you will return to the screen in the upper tier. (8) When touch BACK pad, you will return to the previous screen. (9) When touch pad, the pop up screen will close 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. Touch ESC pad, the value is not entered, and the keypad closes. The data value doesn't change. 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. But when the operator mode is low, the data cannot be entered with "SAVE" pad. GC48108G0002 ( 13/145) 13 Operation RCU-1000 Ver.1.XX 08,'11

24 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 MAIN MENU ( AUTOMATIC OPERATION) Daily Operation Cycle 16 Main Menu Infeed pad Customer Eye pad Machine Model Program Select Date And Time Language pad Help pad Status pad Voice Memo pad Menu pads REZERO Zero Adjustment (Re-zero) 19 PROGRAM SELECTION Procedures 20 AUTOMATIC OPERATION CLEAN Procedures 21 Multi Function Screen 23 Zooming 24 Scale Graphic Display 25 Symbol Definitions 27 Fine Adjustments Of Product Flow Overview How To Adjust Product Flow 29 Histogram Clean Terms Procedures GC48108G0002 ( 14/145) 14 Operation RCU-1000 Ver.1.XX 08,'11

25 2 Level 1 OPERATOR PROCEDURES OVERVIEW MENUS/SCREENS PROCEDURES PAGE Check 33 CHECK RECOMMENDED ACTIONS AT ERROR DAILY INSPECTION Bucket Selection 34 Manual Combination Inhibit Operation Manual Operation 35 Cycle Operation Clear Zero And Re-Zero 36 Re-Zero Recover Filter Original Point Check 37 Continuous Operation Overweight 38 Zero Error Actuator Error Blank Out Daily Inspection 39 Pre- operation Inspection 40 Inspection During Operation 45 Inspection During Clean-up Cautionary Instruction 46 GC48108G0002 ( 15/145) 15 Operation RCU-1000 Ver.1.XX 08,'11

26 2 Level 1 OPERATOR PROCEDURES DAILY OPERATION CYCLE A typical daily operation in level 1 is as follows: Turn on the Cross Head Feeder, if equipped, by touching the "INFEED" pad. Select the desired program number in the "PROGRAM SELECTION" screen. (See p. 17) (See p. 20) Return "AUTOMATIC OPERATION" screen. (See p. 21) Start the operation with the "START" pad. (See p. 21) View the operation status via the various displays. (See p. 21) Stop the operation with the "STOP" pad. (See p. 21) Check the machine via the "CHECK" menu, if necessary. (See p. 33) Clean out the machine via the "CLEAN" PROCEDURES. (See p. 32) Turn off the packaging machine and the infeed equipment. To shut down the power supply, turn off the Main Switch. GC48108G0002 ( 16/145) 16 Operation RCU-1000 Ver.1.XX 08,'11

27 2 Level 1 OPERATOR PROCEDURES MAIN MENU ( AUTOMATIC OPERATION ) When the power is turned on, the Operator Mode is automatically selected and the automatic operation screen will be displayed. The automatic operation screen contains the operation monitor, MENU PADS, PROGRAM SELECTION and OPERATION START & STOP, CHECK". Touch each pad, each screen will appear. DATE & TIME LOGOUT PROGRAM SELECT LANGUAGE MENU PADS 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 switch 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 switch ON or OFF the CUSTOMER EYE. GC48108G0002 ( 17/145) 17 Operation RCU-1000 Ver.1.XX 08,'11

28 2 Level 1 OPERATOR PROCEDURES MACHINE MODEL The model name of the machine is indicated. PROGRAM SELECT The program number currently selected along with its product name is indicated. DATE & TIME The current date and time are shown at the right below screen. The format for date & time are set in the System Installation. STATUS pad Touch this pad, the machine condition will be displayed. VOICE MEMO pad Touch this pad, the voice memo will be displayed MENU1 MENU pads LANGUAGE pad REZERO CHECK CLEAN TROUBLE SHOOT SYSTEM MENU2 DATE/ TIME ERROR LOG PRINT SETTING MANUAL 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.) HELP pad MENU3 CIRCLE RECORD HISTO- GRAM CAMERA SETUP ALL MENU GC48108G0002 ( 18/145) 18 Operation RCU-1000 Ver.1.XX 08,'11

29 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 SETUP / WEIGH. (1) Touch the "REZERO" pad. 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 become small and "STOP" pad will become large. (3) When the zero adjustment is finished, the "STOP" pad will become small and "START" pad will become large. (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 "HOME" 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. GC48108G0002 ( 19/145) 19 Operation RCU-1000 Ver.1.XX 08,'11

30 2 Level 1 OPERATOR PROCEDURES PROGRAM SELECTION Touch the "PROGRAM NAME" pad, in a screen. The "PROGRAM SELECTION" screen will be displayed. The Program Selection screen is used to select a program for operation. When the screen is initially entered, the currently selected program is always high-lighted. PROCEDURES (1) To select a program, 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 "SELECT" 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 "HOME" pad. SELECT pad GC48108G0002 ( 20/145) 20 Operation RCU-1000 Ver.1.XX 08,'11

31 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION Touch the "AUTOMATIC OPERATION" pad, 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 become small and "STOP" pad will become large. (2) To stop the operation, touch the "STOP" pad. The machine will stop and the "STOP" pad will become small and START" pad will become large. (3) Touch HOME pad, the multi-function-graphic menu for Automatic Operation will be displayed. GC48108G0002 ( 21/145) 21 Operation RCU-1000 Ver.1.XX 08,'11

32 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION There are three screens for AUTOMATIC OPERATION, the multi function screen, the semi-graphic (CIRCLE) screen and the operation record (RECORD) screen. Semi-Graphic (Circle) Screen Operation Record Screen When you touch a pad in the screen, other automatic operation screens will be displayed. When you touch the HOME pad, the multi function screen will be displayed. When you touch the CIRCLE pad, the semi graphic screen CIRCLE will be displayed. When you touch the RECORD pad, the operation record screen RECORD will be displayed. The total pack number, statistics summary, operation speed and the setup value of the main feeder and liner feeder are displayed in the multi function screen. GC48108G0002 ( 22/145) 22 Operation RCU-1000 Ver.1.XX 08,'11

33 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION MULTI FUNCTION SCREEN Multi Function screen displays one of four windows: (a) Total pack number (b) Statistics summary (c) Operation speed (d) Setup value of the main feeder and liner feeder The scroll bar can switch these windows. (a) Total pack number screen displays PACK NO. which is the count of the packs discharged since the current sampling cycle for histogram has been started. (c) Operation speed screen shows the current operation speed in packs per minute. When you touch + pad, it shows product level on the Main Feeder(s) in the range of 0 to "VALUE", "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 61. (b) The pack (combination) weight and statistics summary screen displays the target weight and the pack weight of each cycle and the combination results. Those combination results are shown by highlighted pads of accepted, over, or under weight based on the preset limit values. (b) Setup value of the Main Feeder Liner Feeder: The figures represent amplitude or time of the Main feeder(s) and the Linear Feeders. When you touch AMP or TIME, the pad will change TIME or AMP. When you touch pad, amplitude or time of the Main feeder(s) and the Linear Feeders will change. When you touch + pad, the statistics summary screen is displayed. The statistics summary screen contains; 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, MAXIMUM WEIGHT MINIMUM WEIGHT STANDARD DEVIATION ACCEPT PACK OVER PACK GC48108G0002 ( 23/145) 23 Operation RCU-1000 Ver.1.XX 08,'11

34 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION ZOOMING Three screens displayed on the multi function screen (Total pack number, Statistics summary, Operation speed) are enlarged to the screen of the twice in length size. Each of them will be zoomed when the + pad is touched, and they will be unzoomed when the - pad is touched. No Zooming screen GC48108G0002 ( 24/145) 24 Operation RCU-1000 Ver.1.XX 08,'11

35 2 Level 1 OPERATOR PROCEDURES AUTOMATIC OPERATION SCALE GRAPHIC DISPLAY MAIN FEEDER SCALE HEAD NUMBER WEIGH BUCKET The circle represents the whole weigher and each segment represents a scale head with its number. The outer ring corresponds to the weigh buckets. The center circle represents the product level on weight sensor. Several function pads are arranged at the right of the screen. 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. GC48108G0002 ( 25/145) 25 Operation RCU-1000 Ver.1.XX 08,'11

36 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) 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. (b) Available combination (AVAILABLE) pad, when touched and highlighted, indicates "Available buckets" by the " " mark along with the selected buckets with " "(green) symbol. (d) The number of combinations (NO. OF COMBINATION) 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. 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. 67 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. GC48108G0002 ( 26/145) 26 Operation RCU-1000 Ver.1.XX 08,'11

37 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 OMEGA 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 OMEGA F1 FRONTIER model is selected. Indicates the scale under zero adjustment during automatic operation. RECHARGE AVAILABLE COMBINATION CALCULATION INHIBITED 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 check, or the bucket has been removed in automatic operation. (Red) E OVERWEIGHT ZERO ERROR Indicates the weigh bucket filled with product over the target weight plus high limit during automatic operation or check. Indicates the scale of which zero deviation from the initial zero exceeds the range of ±2% scale capacity during automatic operation or check. 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 operation or check. 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 RCU SETTLE ERROR Indicate a bucket not settled when auto tuning is executed. 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 38. (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.) GC48108G0002 ( 27/145) 27 Operation RCU-1000 Ver.1.XX 08,'11

38 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 90 (packs per minute) STANDARD BUCKET MODEL MEMORY BUCKET MODEL More than 90 (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. GC48108G0002 ( 28/145) 28 Operation RCU-1000 Ver.1.XX 08,'11

39 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 looks excessive, decrease the main feeder amplitude and time using the Scale Setup 2 screen or Window B1 screen. If the 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. 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). GC48108G0002 ( 29/145) 29 Operation RCU-1000 Ver.1.XX 08,'11

40 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 GC48108G0002 ( 30/145) 30 Operation RCU-1000 Ver.1.XX 08,'11

41 2 Level 1 OPERATOR PROCEDURES HISTOGRAM 1. TERMS (continued) MAXIMUM Represents the maximum weight of a pack among the sampled packs. MINIMUM 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. GC48108G0002 ( 31/145) 31 Operation RCU-1000 Ver.1.XX 08,'11

42 2 Level 1 OPERATOR PROCEDURES CLEAN CLEAN The "CLEAN" 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, "CLEAN" pad on the main menu. The "CLEAN" screen will be displayed. PROCEDURES (1) Before starting the CLEAN 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 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 OPEN" or "ALL OPEN / CLOSE" pad so that no product may remain in any bucket. (5) The functions of "ALL OPEN" or "ALL OPEN / CLOSE" are useful for clean out of wash down type machines. IMPORTANT The pack weight discharged during the clean operation will be random. Do not mix these packages with the regular production packages. GC48108G0002 ( 32/145) 32 Operation RCU-1000 Ver.1.XX 08,'11

43 2 Level 1 OPERATOR PROCEDURES CHECK CHECK Touch the "CHECK" pad on the automatic operation. The CHECK 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 " TOTAL WT. " display near the top of 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 CHECK. GC48108G0002 ( 33/145) 33 Operation RCU-1000 Ver.1.XX 08,'11

44 2 Level 1 OPERATOR PROCEDURES CHECK BUCKET SELECTION To select an individual weigh (or memory) bucket, touch the desired segment of the outer ring (or inner ring) of the 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. INHIBIT OPERATION 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. (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. If you have trouble with a bucket, either weigh or memory bucket, such as "ZERO ERROR", "ACTUATOR ERROR" or "SPAN ERROR" and want exclude it from combination and continue operation using rest of the buckets, you can inhibit the bucket in this PROCEDURES. (1) Touch the weigh (or memory) bucket to be disabled, which will highlight, and (2) Touch the "HEAD INHIBIT" pad, which will be highlighted, then (3) Touch the "START" pad. The disabled bucket will be indicated with the symbol " ". GC48108G0002 ( 34/145) 34 Operation RCU-1000 Ver.1.XX 08,'11

45 2 Level 1 OPERATOR PROCEDURES CHECK 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 "HEAD INHIBIT" 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 OPERATION A pad in the individual scale graphic to the right is used to select an individual actuator as follows: 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. (1) Select the desired scale head segment, either weigh or memory bucket, in the scale graphic, which will be highlighted. (2) Touch the desired bucket (for example, feed bucket, FB) pad to the left (only one pad can be selected), which will be highlighted. (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. (1) Select the desired scale head segment, by touching weigh bucket, in the scale graphic, which will be highlighted. (2) Touch the "CYCLE" pad, which will be highlighted. (3) Then, touch the "START" pad. The scale head will perform one cycle of operation. (4) To select the collection gate, the PROCEDURES (1) above can be skipped. GC48108G0002 ( 35/145) 35 Operation RCU-1000 Ver.1.XX 08,'11

46 2 Level 1 OPERATOR PROCEDURES CHECK 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. (2) Select the desired scale head segment or touch the "SELECT ALL WEIGH BUCKETS" pad. Or touch the main feeder in the graphic. REZERO 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". (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 The zero deviation will be indicated in each weigh bucket segment. RECOVER FILTER If you have "SETTLE ERROR" ( ) of a scale, select the bucket number and touch RECOVER FILTER pad. Then touch the "START" pad. The scale will obtain the best filter or timing. GC48108G0002 ( 36/145) 36 Operation RCU-1000 Ver.1.XX 08,'11

47 2 Level 1 OPERATOR PROCEDURES CHECK 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 OPERATION 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 scale graphic, (3) Touch the "ORIGINAL POINT" pad, which will highlight, (4) Touch the "START" pad. (2) Touch the desired graphic pad in the 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. (5) To stop the actuation, touch the highlighted "STOP" pad. Note: Make sure no product is on the vibrator feeder or in the bucket. GC48108G0002 ( 37/145) 37 Operation RCU-1000 Ver.1.XX 08,'11

48 2 Level 1 OPERATOR PROCEDURES CHECK 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 OPERATION in CHECK 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 scale graphic in the Automatic Operation or CHECK 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 CHECK 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 this 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 CHECK. (2) Touch the scale segment with the error symbol in the scale graphic circle. (3) If product or its fragments have found to be trapped in the bucket doors, 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. GC48108G0002 ( 38/145) 38 Operation RCU-1000 Ver.1.XX 08,'11

49 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 GC48108G0002 ( 39/145) 39 Operation RCU-1000 Ver.1.XX 08,'11

50 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. 1 2 GC48108G0002 ( 40/145) 40 Operation RCU-1000 Ver.1.XX 08,'11

51 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. 1 2 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 1 2 GC48108G0002 ( 41/145) 41 Operation RCU-1000 Ver.1.XX 08,'11

52 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 CHECK and check that open and close motion of bucket doors is smooth. GC48108G0002 ( 42/145) 42 Operation RCU-1000 Ver.1.XX 08,'11

53 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 CHECK and check that open and close motion of bucket doors is smooth. GC48108G0002 ( 43/145) 43 Operation RCU-1000 Ver.1.XX 08,'11

54 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 CHECK and check that open and close motion of bucket doors is smooth. (5) Zero Adjustment Perform Zero Adjustment (REZERO) of all weigh heads in CHECK after confirming that no product in any weigh bucket. See display of scale graphic on the RCU-1000 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 CHECK after confirming of no product on the main feeder. See display of scale graphic on the RCU-1000 screen and confirm that product level is approximately 0. GC48108G0002 ( 44/145) 44 Operation RCU-1000 Ver.1.XX 08,'11

55 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 CHECK 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-01XX) (For ADW-12XX) GC48108G0002 ( 45/145) 45 Operation RCU-1000 Ver.1.XX 08,'11

56 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 for example by stepping 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, 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. GC48108G0002 ( 46/145) 46 Operation RCU-1000 Ver.1.XX 08,'11

57 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. 2 1 For ADW-2XX/3XX, Pull the catch clip to the right to release and pull the liner feeder pan out horizontally and then slightly upwards as shown in the illustration below. 1 2 GC48108G0002 ( 47/145) 47 Operation RCU-1000 Ver.1.XX 08,'11

58 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. 2 1 GC48108G0002 ( 48/145) 48 Operation RCU-1000 Ver.1.XX 08,'11

59 3 CLEAN-UP PROCEDURES 5. REMOVAL OF CHUTES Remove each 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. 7. REMOVAL OF BUCKETS To remove buckets, lift each bucket upwards first and then take it horizontally as shown in the illustration below. GC48108G0002 ( 49/145) 49 Operation RCU-1000 Ver.1.XX 08,'11

60 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 (0.3 bar). 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 the two bars in the rear bucket stay securely on the hangers. (b) Be sure the pin of bucket door link arm is securely and stays 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 damaged 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. GC48108G0002 ( 50/145) 50 Operation RCU-1000 Ver.1.XX 08,'11

61 3 CLEAN-UP PROCEDURES The illustration below shows installation of a feed bucket as an example. GC48108G0002 ( 51/145) 51 Operation RCU-1000 Ver.1.XX 08,'11

62 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 Operation (or CHECK) 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 operation or CHECK. To save the altered parameters, perform the same settings at Level 3. Refer to the section, "HOW TO SAVE SETUP VALUES" in the next chapter. HOW TO ALTER PRESET PARAMETERS Automatic operation and CHECK screens in Level 2 contain the "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 "SETUP" pad. The Scale Setup screens will be displayed. These screens allow you to temporarily alter preset parameters for tuning the performance during Automatic operation and CHECK. 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 Setup in Level 3 (Supervisor PROCEDURES). GC48108G0002 ( 52/145) 52 Operation RCU-1000 Ver.1.XX 08,'11

63 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 How To Save Setup Values 55 PROGRAM SELECTION SETUP (BASIC) SETUP (FEED) Op. Pattern No. Speed Target Weight Nominal Weight (g) High Limit WT. (g) T.N.E. Combination Mode Bias Weight (g) Multi-Dump Count MF AMP MF TIME LF AMP LF TIME Weigh Sensor Weigh Sensor High Limit Weigh Sensor Low Limit Weigh Sensor Low Low Limit Auto Feed Control (AFC) Reset Interval Target WB No. (AFC-T/AFC-TR) Limit WB No. (AFC-T/AFC-TR) AFC-Target Weight (AFC-I/AFC-IR) AFC Limit WT. (AGFC-I/AFC-IR) CF AMP LF Time (AFC-R/AFC-TR) Diverter Motor Pattern GC48108G0002 ( 53/145) 53 Operation RCU-1000 Ver.1.XX 08,'11

64 5 Level 3 SUPERVISOR PROCEDURES MENUS/SCREENS PROCEDURES PAGE 65 FB Motor Pattern 66 FB Open Time WB (Inside) Motor Pattern WB (Outside) Motor Pattern WB Open Time MB Motor Pattern MB Open Time SETUP (WEIGH) FB Delay 2 (WB FB) WB Discharge Delay Settle Time No Load Detect (%) 67 Auto Zero Auto Zero Time (min) Stagger Dump Time (ms) Over Discharge No Select Detect Collection Gate ON/OFF 68 Collection Gate Stock / Pass CB Motor Pattern CB open Time (ms) Dump Signal (ms) 69 Dump Signal Delay (ms) CB Discharge Delay (ms) CB1B Discharge Delay (ms) CB2 Motor Pattern SETUP (DUMP) CB2 open Time (ms) CB2 Discharge Delay (ms) CB3 Motor Pattern CB3 open Time (ms) CB3 Discharge Delay (ms) Middle Shutter Middle Shutter Motor Pattern Middle Shutter Open Time Middle Shutter Delay Time Date 70 DATE / TIME Time Sample Count 71 Sample Time Individual Weight Send of Shift Timer PRINT SETTING Sample Print End of Shift Time 72 End of Current Shift Print Program Listing Advance Print Paper GC48108G0002 ( 54/145) 54 Operation RCU-1000 Ver.1.XX 08,'11

65 5 Level 3 SUPERVISOR PROCEDURES HOW TO SAVE 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. (4) Touch the "CANCEL" pad. GC48108G0002 ( 55/145) 55 Operation RCU-1000 Ver.1.XX 08,'11

66 5 Level 3 SUPERVISOR PROCEDURES PROGRAM SELECTION Touch the "PROGRAM NUMBER SELECTION" pad 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 "COPY", "DELETE", and "SAVE" other than those on the Program Number Selection screen in Level 1 (Operator Mode). 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. DELETE Used to delete the highlighted program. 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 automatic operation, touch the "HOME" 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. GC48108G0002 ( 56/145) 56 Operation RCU-1000 Ver.1.XX 08,'11

67 5 Level 3 SUPERVISOR PROCEDURES SETUP Touch the "SETUP", pad in the automatic operation menu. The "SETUP" screen is displayed. SCROLL BAR The SETUP screen contains PBASIC setting pad, FEED pad, WEIGH pad and DUMP pad.. GC48108G0002 ( 57/145) 57 Operation RCU-1000 Ver.1.XX 08,'11

68 5 Level 3 SUPERVISOR PROCEDURES SETUP (BASIC) Touch the "BASIC" pad on the left hand of the "SETUP" screen. The "BASIC SETUP" screen will be displayed. The following preset parameters will be set in this screen. Touch the "PROGRAM NAME" pad. The pop-up menu for alphanumeric value entry will be displayed. Touch characters on the alphanumeric pad to enter the desired program name. Touch the other numeric pad. The pop-up menu for numeric value entry (10-key pad) will be displayed. Touch the scroll bar at the right of the screen, the screen moves up and down. PROGRAM NAME Used to register or change the product name for the program number currently selected. (1) Touch the "PROGRAM 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 program name. This program 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 entered. (4) Confirm if it is correct, then touch the "ENT" pad. The pop-up menu will disappear and the chosen program name will be displayed in the program name pad on the PROGRAM NAME pad. GC48108G0002 ( 58/145) 58 Operation RCU-1000 Ver.1.XX 08,'11

69 5 Level 3 SUPERVISOR PROCEDURES SETUP/BASIC 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. SPEED Used to set operation speed. TARGET WEIGHT Used to set or alter the target weight for the currently selected program number. Note: (1) No value smaller than the Nominal Weight can be set 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. 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. 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. 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. 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). 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. GC48108G0002 ( 59/145) 59 Operation RCU-1000 Ver.1.XX 08,'11

70 5 Level 3 SUPERVISOR PROCEDURES SETUP/BASIC 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 GC48108G0002 ( 60/145) 60 Operation RCU-1000 Ver.1.XX 08,'11

71 5 Level 3 SUPERVISOR PROCEDURES SETUP/FEED SETUP (FEED) Touch the "FEED" pad in right hand of the "SETUP" screen. The "FEED SETUP" screen will be displayed. The SETUP(FEED) screen contains two groups of menus (a group in blue frame and a group outside blue frame). Graphic of each unit that composes the device and pad for the parameter setting are arranged in the left screen blue frame. 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. MVF TIME MVF AMP LVF TIME LVF AMP WEIGHT SENSOR No. WEIGHT SENSOR LOW LOW LIMIT WEIGHT SENSOR HIGH LIMIT WEIGHT SENSOR LOW LIMIT GC48108G0002 ( 61/145) 61 Operation RCU-1000 Ver.1.XX 08,'11

72 5 Level 3 SUPERVISOR PROCEDURES SETUP/FEED 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. 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. WEIGHT SENSOR HIGH LIMIT Use to set a high limit for operating point. WEIGHT SENSOR LOW LIMIT Use to set a low limit for operating point. 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) AUTO FEED CONTROL (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/AFC-TR) 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/AFC-TR) 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/AFC-IR) 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. AFC LIMIT WT. (AFC-I/AFC-IR) 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. GC48108G0002 ( 62/145) 62 Operation RCU-1000 Ver.1.XX 08,'11

73 5 Level 3 SUPERVISOR PROCEDURES SETUP/FEED 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. LF TIME (AFC-R/AFC-TR) Used to determine a difference time between individual linear feeders for AFC-R. Set 200 msec as standard. 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. GC48108G0002 ( 63/145) 63 Operation RCU-1000 Ver.1.XX 08,'11

74 5 Level 3 SUPERVISOR PROCEDURES SETUP 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 SETUP (FEED) 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 SETUP (FEED) screen, touch the 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. GC48108G0002 ( 64/145) 64 Operation RCU-1000 Ver.1.XX 08,'11

75 5 Level 3 SUPERVISOR PROCEDURES SETUP/WEIGH SETUP (WEIGH) Touch the "WEIGH" pad in right hand of the "SETUP" screen. The "WEIGH SETUP" screen will be displayed. The SETUP(WEIGH) screen contains two groups of menus (a group in blue frame and a group outside blue frame). Graphic of each unit that composes the device and pad for the parameter setting are arranged in the left screen blue frame. 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. FB MOTOR PATTERN FB OPEN TIME WB MOTOR PATTERN WB OPEN TIME GC48108G0002 ( 65/145) 65 Operation RCU-1000 Ver.1.XX 08,'11

76 5 Level 3 SUPERVISOR PROCEDURES SETUP/WEIGH FB MOTOR PATTERN 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 (INSIDE) MOTOR PATTERN 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 (OUTSIDE) MOTOR PATTERN 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 PATTERN 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. 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. WB DISCHARGE DELAY Used to set a delay time for staggered dump for mixing application. Set this value to 0 for normal application. 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. 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". GC48108G0002 ( 66/145) 66 Operation RCU-1000 Ver.1.XX 08,'11

77 5 Level 3 SUPERVISOR PROCEDURES SETUP/WEIGH 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 apply when European requirements are not used. 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 CHECK. 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. 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 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. 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. 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. 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 GC48108G0002 ( 67/145) 67 Operation RCU-1000 Ver.1.XX 08,'11

78 5 Level 3 SUPERVISOR PROCEDURES SETUP/DUMP SETUP (DUMP) Touch the "DUMP" pad in right hand of the "SETUP" screen. The "DUMP SETUP" screen will be displayed. The SETUP(DUMP) screen contains two groups of menus (a group in blue frame and a group outside blue frame). Graphic of each unit that composes the device and pad for the parameter setting are arranged in the left screen blue frame. This 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 functions of the graphic menus are labeled in the illustration below. CB ON/OFF CB MOTOR PATTERN CB OPEN TIME CB STOCK/PASS COLLECTION GATE ON/OFF The 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". COLLECTION GATE STOCK/PASS When "ON" is selected as COLLECTION GATE ON/OFF, two additional operation modes can be selected with the second pad. This 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. 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. GC48108G0002 ( 68/145) 68 Operation RCU-1000 Ver.1.XX 08,'11

79 5 Level 3 SUPERVISOR PROCEDURES SETUP/DUMP 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. CB1B DISCHARGE DELAY (ms) Used to set the delay time the collection gate1b discharges product after the "READY" signal has been sent from the packaging machine below. CB2 MOTOR PATTERN (OPTIONAL FUNCTION) Used to set the MOTOR PATTERN of the optional CB2 buckets. CB2 OPEN TIME (ms) (OPTIONAL FUNCTION) Used to set the OPEN TIME the optional CB2 buckets open in ms. CB2 DISCHARGE DELAY (ms) Used to set the delay time the collection gate2 discharges product after the "READY" signal has been sent from the packaging machine below. CB3 MOTOR PATTERN (OPTIONAL FUNCTION) Used to set the MOTOR PATTERN of the optional CB3 buckets. 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 DISCHARGE DELAY (ms) (OPTIONAL FUNCTION) Used to set the delay time the collection gate3 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 MOTOR PATTERN (OPTIONAL FUNCTION) Used to set a motor pattern for motor driven middle shutter. 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. GC48108G0002 ( 69/145) 69 Operation RCU-1000 Ver.1.XX 08,'11

80 5 Level 3 SUPERVISOR PROCEDURES DATE / TIME Touch the "DATE / TIME" pad, in the automatic operation menu. The "DATE / TIME" setup screen is displayed. SETUP PROCEDURE 1. SETUP YEAR(YY), MONTH(MM), DAY(DD), HOUR(HH), MINUTE(MM) with pad. 2. Touch "CLEAR" pad to set SECOND(SS) to Touch "SET" pad, date and time are set, and returns to the Automatic Operation screen. 4. Touch pad, date and time are NOT set, but returns to the Automatic Operation screen. GC48108G0002 ( 70/145) 70 Operation RCU-1000 Ver.1.XX 08,'11

81 5 Level 3 SUPERVISOR PROCEDURES PRINT SETTING Touch the "PRINT SETTING" pad, in the automatic operation menu. The "PRINT SETTING" screen is displayed. 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 127. 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. (1) Hourly Report will be printed out every hour. (2) The printout interval will be fixed. (3) SAMPLE PRINT will be fixed to ON. 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. GC48108G0002 ( 71/145) 71 Operation RCU-1000 Ver.1.XX 08,'11

82 5 Level 3 SUPERVISOR PROCEDURES PRINT SETTING 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. PRINT PROGRAM LISTING Touch this pad to print out the preset parameters of the currently selected program for record. ADVANCE PRINT PAPER Touch this pad to advance print paper. END OF 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. Note that the description of PRINTOUT Mode and PRINTOUT samples are given in Supplementary Description of Annex. GC48108G0002 ( 72/145) 72 Operation RCU-1000 Ver.1.XX 08,'11

83 Chapter 6 TROUBLE SHOOTING OVERVIEW This chapter contains the instructions for using TROUBLE SHOOTING screens. The troubleshooting methods for general problems are shown in this chapter. You can only see the screens if you are an operator who is Level 1 or Level 2. Please log in as an operator more than Level 3 if you execute the test etc. MENUS/SCREENS PROCEDURES PAGE SAMPLE TEST Sample Test Screen 74 Vibration Waveform 76 SOFTWARE VERSION 77 I/O CHECK 78 A / D CHECK 79 PIEZO SENSOR 80 TEMP SENSOR 81 TROUBLE SHOOTING FOR GENERAL PROBLEMS 82 GC48108G0002 ( 73/145) 73 Operation RCU-1000 Ver.1.XX 08,'11

84 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. GC48108G0002 ( 74/145) 74 Operation RCU-1000 Ver.1.XX 08,'11

85 6 TROUBLE SHOOTING SAMPLE TEST (2) Select the kind of the sampling data as follows; <LOAD CELL>, <FILTER>, <DUMMY CELL>. Then 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. WAITING message appears. (4) When getting the sample data succeeds, the vibration wave form graph is displayed. Push SELECT GRAPH pad, other type graph will be appeared. SAMPLE DATA TYPE : LOAD CELL <RAW DATA> SAMPLE DATA TYPE : FILTER <FILTER> <RAW DATA> <DUMMY CELL> SAMPLE DATA TYPE : DUMMY CELL <DUMMY CELL> <RAW DATA> (5) Touch BACK pad, the SAMPLE TEST MODE screen will be displayed. GC48108G0002 ( 75/145) 75 Operation RCU-1000 Ver.1.XX 08,'11

86 6 TROUBLE SHOOTING SAMPLE TEST VIBRATION WAVEFORM (1) In the FILTER GRAPH, the horizontal axis represents TIME (msec), and the vertical axis represents A/D counts. 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 possi ble 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 ADW-O-01XX (1liters) 36.5 ADW-O-03XX (3liters) 36.5 ADW-O-06XX (6liters) 18.2 ADW-O-12XX (12liters) 18.2 ADW-O-18XX (18liters) 18.2 GC48108G0002 ( 76/145) 76 Operation RCU-1000 Ver.1.XX 08,'11

87 6 TROUBLE SHOOTING SOFT VERSION SOFT VERSION (1) Touch the SOFTWARE pad on the TROUBLESHOOTONG menu. The each software version number in the board of Weigh/Actuator unit, I/O unit, and RCU-1000 will be displayed as the illustration below. (2) To return to the TROUBLESHOOTONG menu, touch the MENU pad. GC48108G0002 ( 77/145) 77 Operation RCU-1000 Ver.1.XX 08,'11

88 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 MENU 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. GC48108G0002 ( 78/145) 78 Operation RCU-1000 Ver.1.XX 08,'11

89 6 TROUBLE SHOOTING A/D CHECK A/D 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 A/D CHECK pad on the TROUBLESHOOTING menu screen. The A/D 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. GC48108G0002 ( 79/145) 79 Operation RCU-1000 Ver.1.XX 08,'11

90 6 TROUBLE SHOOTING PIEZO SENSOR PIEZO SENSOR This mode allows the engineer to check the piezo sensor of each head. (1) Select the HEAD number by touching " "or " " right-hand to check. (2) Touch the START pad. GC48108G0002 ( 80/145) 80 Operation RCU-1000 Ver.1.XX 08,'11

91 6 TROUBLE SHOOTING TEMP SENSOR TEMP SENSOR This mode allows the engineer to check the temperature with load cell, dummy cell and feeder of each head. These temperatures are converted with the A/D converter and then displayed this screen. Those values on the screen are not actual temperature, but converted values. (1) Touch the TEMP SENSOR pad on the TROUBLESHOOTING menu screen. The screen will be displayed as shown in the illustration below. GC48108G0002 ( 81/145) 81 Operation RCU-1000 Ver.1.XX 08,'11

92 6 TROUBLE SHOOTING GENERAL PROBLEMS TROUBLE SHOOTING FOR GENERAL PROBLEMS (1) DATAWEIGH DOES NOT WORK AT ALL No power PROBABLE CAUSE 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 RCU-1000 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 RCU Note: * lf communication error has occurred between RCU-1000 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. GC48108G0002 ( 82/145) 82 Operation RCU-1000 Ver.1.XX 08,'11

93 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 a) Check product flow and improve it. b) Check that parameters for operation are set properly and change them if necessary. c) 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. GC48108G0002 ( 83/145) 83 Operation RCU-1000 Ver.1.XX 08,'11

94 6 TROUBLE SHOOTING GENERAL PROBLEMS (3) NO VIBRATION OF MAIN FEEDER VIBRATOR (MVF) PROBABLE CAUSE 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 CORRECTIVE ACTION 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. 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 FEED screen in Scale Setup. 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. GC48108G0002 ( 84/145) 84 Operation RCU-1000 Ver.1.XX 08,'11

95 6 TROUBLE SHOOTING GENERAL PROBLEMS (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. CORRECTIVE ACTION Decrease Low limit in the FEED screen in Scale Setup 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 check 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 check 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 CHECK to return the cam follower to its home position. Perform proper adjustment of the bucket. Install the bucket again properly. GC48108G0002 ( 85/145) 85 Operation RCU-1000 Ver.1.XX 08,'11

96 6 TROUBLE SHOOTING GENERAL PROBLEMS (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 check of individual bucket. Incomplete connection between Weigh / Actuator unit and Memory unit. 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. Failure of I/O Board or Motor Drive Board. No I/O allocation for Collection Bucket in System Installation. Improper setting at SETUP. 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. Replace the fuse. Replace the board. Perform proper setting in System Installation. (See Installation Manual 2.) Perform proper setting at DUMP screen at SETUP. 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 CHECK. Refer to Item (8) above. Fasten the bolts. Remove the product buildup and take action to prevent the product buildup. GC48108G0002 ( 86/145) 86 Operation RCU-1000 Ver.1.XX 08,'11

97 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 WEIGH screen in Scale Setup. (13) OVERWEIGHT ERROR MARK " " IS DISPLAYED DURING AUTOMATIC OPERATION PROBABLE CAUSE CORRECTIVE ACTION Too high value setting for LVF amplitude and/or time. Reduce these setting value. 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. 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) SETTLE ERROR MARK " " IS DISPLAYED DURING AUTOMATIC OPERATION PROBABLE CAUSE CORRECTIVE ACTION During automatic operation the scale does not settle within the set time Execute RECOVER FILTER at CHECK screen. (15) 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 FEED screen at Setup. a) Increase product supply. b) Check if EXTERNAL INTERLOCK is properly set. C) Check that weight sensor setting is proper. GC48108G0002 ( 87/145) 87 Operation RCU-1000 Ver.1.XX 08,'11

98 6 TROUBLE SHOOTING GENERAL PROBLEMS (16)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. Adjust the fork position. Product remained in bucket due to short time setting for WB, MB, or CB open time. 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. Perform proper time setting at WEIGH screen and DUMP screen in Scale Setup. a) Set FB Delay 2 properly in WEIGH screen at Setup if product is caught in WB doors. b) Set WB Discharge Delay properly in WEIGH screen at Setup 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 WEIGH screen at Setup. 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. (17) 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. (18) 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. GC48108G0002 ( 88/145) 88 Operation RCU-1000 Ver.1.XX 08,'11

99 6 TROUBLE SHOOTING GENERAL PROBLEMS (19)PROBLEM WITH DISPLAY ON RCU-1000 SCREEN PROBABLE CAUSE CORRECTIVE ACTION Failure of LCD display. (Flickering of display or no partial display). Failure of LCD display and/or CPU board EVA0057F (No display on RCU-1000 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): Main Board : EVA-0067R1 for all models SUB CPU Board : EVA-0076 Motor Drive Board : EVA-0078 GC48108G0002 ( 89/145) 89 Operation RCU-1000 Ver.1.XX 08,'11

100 Chapter 7 ENGINEERING MODE (LEVEL 4) OVERVIEW This chapter contains the instructions required for preset of parameters and selection of functions using the SYSTEM MENU screens. The following table shows the screens along with the preset parameters and the functions that the operator from whom the access was permitted to the engineer mode should set.and select. MENUS/SCREENS PROCEDURES PAGE SYSTEM SYSTEM MENU 91 I/O ALLOC. I/O Allocation OUTPUT Signals INPUT Signals 92 Zero Setting 94 INITIAL CALIB. Span Calibration 95 Note for Zero setting and Span Calibration Weigh Sensor Zero setting 96 USER User Setting Menu 97 LVF Setting 98 FEED MVF Setting 100 Feeder Allocation 101 Sensor Allocation 102 Degital Filter Setting 103 WEIGH Motor Pattern Setting 105 Delay Timing Setting 107 Motor Allocation 109 Motor Pattern Setting 110 DUMP Dump Setting (Interlock) 111 Motor Allocation 113 AUTO TUNING 114 SETUP(FEEDER) 115 SETUP SETUP(FILTER 1) 116 SETUP(FILTER 2) SETUP(SENSOR) 117 GC48108G0002 ( 90/145) 90 Operation RCU-1000 Ver.1.XX 08,'11

101 7 ENGINEERING MODE (LEVEL 4) SYSTEM MENU SYSTEM MENU Touch the "SYSTEM" pad, in the automatic operation menu. The "SYSTEM MENU" screen is displayed. I/O ALLOC, INITIAL CALIB. USER FEED WEIGH DUMP AUTO TUNING The allocation of output signal and input signal to the desired port and selection of logic are altered. The Initial Zero Setting of each scale and the weigh sensors and the Span Calibration of each scale are provided for. The addition and deletion of user who logged in, and the user's setting, and the user s menu are set. The vibration of the feed units, the allocation of the feed unit and the allocation of the sensor are set. The digital filter, the motor pattern of the weigh buckets and the delay time are set. The motor pattern of the collection bucket and the allocation of the collection buckets and the interlock with the bag maker are set. The opening and closing pattern and the digital filter of various buckets are adjusted, and set automatically. The system menu is finished and the Automatic Operation screen is displayed. GC48108G0002 ( 91/145) 91 Operation RCU-1000 Ver.1.XX 08,'11

102 7 ENGINEERING MODE (LEVEL 4) I/O ALLOCATION I/O ALLOCATION Touch the "I/O ALLOCATION" pad, in the system menu. The "I/O ALLOCATION" screen is displayed. The screen is used to alter allocation of output signal to the desired port on the terminal TB1 and TB2 on I/O board EVA0069F and input signal to the port on the terminal TB3 on EVA0069F and selection of logic. INPUT from TB3 OUTPUT to TB2 OUTPUT to TB1 No. on the terminal (1) Touch "OUTPUT(TB1)" or "OUTPUT(TB2)" or "INPUT(TB3)" to select the terminal. When OUTPUT(TB1) or (TB2) are selected, the screen of the allocation of the output signal are displayed. When INPUT(TB3) are selected, the screen of the allocation of the input signal is displayed. (2) Touch the number pad of the desired output line (OUTPUT(TB1)or(TB2)) or input line (INPUT(TB3)) in the left-hand column. The pop-up menu of the signal list will be displayed. (3) Touch the desired signal name in the list, the screen will return to the menu and the selected signal name will be indicated in the desired line. The pad of the blank in the lower right of the list screen means the signal is not allocated. (4) Touch the Logic pad of the signal line to select its logic, "0" (negative) or "1" (positive). This pad, when touched, toggles between "0" and "1". When "0" is selected, low level of signal is assigned to "ON" and high level to "OFF", while high level is assigned to "ON" and low level to "OFF" when "1" is selected. (5) Another signal list screen is displayed when touching the number pad in the upper right of the signal list. GC48108G0002 ( 92/145) 92 Operation RCU-1000 Ver.1.XX 08,'11

103 7 ENGINEERING MODE (LEVEL 4) I/O ALLOCATION OUTPUT SIGNALS LIST-1 DUMP SIGNAL1 FEED 2 OVER WT. 2 REJECT DUMP SIGNAL2 FEED 3 AUTO OPE. MID. SHUTTER FIRST DUMP FEED 4 CLEAN OUT ALARM LAST DUMP FEED 5 INSERT DIVERTER EVERY DUMP FEED 6 CB1 FEED(DIVERTER) DW READY FEED 7 CB2 STORAGE DW READY2 FEED 8 CB3-A OVDISCHG STOP FEED 1 OVER WEIGHT CB3-B LIST-2 NO PRODUCT STOP DUMP SIGNAL 1B DUMP SIGNAL 2C DW READY 1H CLEAN OUT/REZERO DUMP SIGNAL 1C DUMP SIGNAL 2D DW READY 2B NOT AVAILABLE DUMP SIGNAL 1D DW READY 1B OVER WT. 1B CN7 OUT DUMP SIGNAL 1E DW READY 1C OVER WT. 1C CN8 OUT DUMP SIGNAL 1F DW READY 1D OVER WT. 1D CN7 OUT2 DUMP SIGNAL 1G DW READY 1E OVER WT. 1E CN8 OUT2 DUMP SIGNAL 1H DW READY 1F OVER WT. 1F METAL DETECTOR DUMP SIGNAL 2B DW READY 1G LIST-3 OVER WT. 1G CB1 G CB2 H REJECT C OVER WT. 1H CB1 H CB3 A-B REJECT D OVER WT. 2B CB2 B CB3 B-B REJECT E CB1 B CB2 C CB3 A-C REJECT F CB1 C CB2 D CB3 B-C REJECT G CB1 D CB2 E CB3 A-D REJECT H CB1 E CB2 F CB3 B-D BUTTON 1 CB1 F CB2 G REJECT B LIST-4 BUTTON 2 BUTTON 10 BUTTON 3 STORAGE bit:2 BUTTON 4 STORAGE bit:4 BUTTON 5 POWER CIRCUIT BUTTON 6 BUTTON 7 BUTTON 8 BUTTON 9 INPUT SIGNALS LIST-1 READY 1 CUST EYE 7 PH SENSOR6 PROGRAM NO.bit:4 READY 2 CUST EYE 8 PH SENSOR7 PROGRAM NO.bit:8 CUST EYE 1 MASTER RELAY PH SENSOR8 START/STOP CUST EYE 2 PH SENSOR1 EXT. FEEDER 1 AUTO OPE.SCREEN CUST EYE 3 PH SENSOR2 EXT. FEEDER 2 CLEAN OUT SCREEN CUST EYE 4 PH SENSOR3 METAL DETECTOR FEED DEVICE CUST EYE 5 PH SENSOR4 PROGRAM NO.bit:1 CUST EYE 6 PH SENSOR5 PROGRAM NO.bit:2 LIST-2 READY 1B EXT. MOTOR 1-1 EXT. MOTOR 2-4 READY 1C EXT. MOTOR 1-2 EXT. MOTOR 2-5 READY 1D EXT. MOTOR 1-3 ACCESS LEVEL A READY 1E EXT. MOTOR 1-4 ACCESS LEVEL B READY 1F EXT. MOTOR 1-5 ACCESS LEVEL C READY 1G EXT. MOTOR 2-1 READY 1H EXT. MOTOR 2-2 READY 2B EXT. MOTOR 2-3 GC48108G0002 ( 93/145) 93 Operation RCU-1000 Ver.1.XX 08,'11

104 7 ENGINEERING MODE (LEVEL 4) INITIAL CALIB INITIAL CALIBRATION MENU Touch the "INITIAL CALIB." pad in the SYSTEM menu. The INITIAL CALIBRATION menu will be displayed. The Initial Calibration menu provides for the Initial Zero Setting of each scale and the weigh sensors and the Span Calibration of each scale. Although these zero setting and calibrations are to be performed when the machine is installed, periodical check is necessary to ensure accurate operation. When the zero setting and calibration are performed, use calibrated weights and make sure there are no foreign matters in or on weigh buckets. "WT." in the upper left-hand portion of the screen will show the weight display of the scale currently selected (highlighted) or total weight when the "SELECT ALL WEIGH BUCKET" pad highlights. The procedures for zero setting and span calibration are as follows: (1) When you desire to perform zero setting of a scale, touch that segment in the circular scale graphic. When you desire to perform zero setting of all the scales together, touch the "ALL" pad. The desired segment or all the segments will highlight. (2) Touch "ZERO CALIB." pad. The pad will highlight. (3) Touch the "START" pad. Then the zero setting will be performed and all the weight displays will change to 0.0. (4) Touch the "STOP" pad. The zero calibration is interrupted. ZERO SETTING GC48108G0002 ( 94/145) 94 Operation RCU-1000 Ver.1.XX 08,'11

105 7 ENGINEERING MODE (LEVEL 4) INITIAL CALIB (1) To perform span calibration of a scale, touch that segment in the circular scale graphic. The selected segment will highlight. (2) Place the calibrated test weight of the scale capacity (which is indicated in the message box) on the weigh bucket to be calibrated on the screen as shown in the illustration below. Touch the "SPAN CALIBRATION" pad. The pad will highlight. SPAN CALIBRATION (3) Touch the "START" pad. Then the calibration will be performed. (4) Remove the test weight from the weigh bucket and confirm zero point. If zero point has drifted, perform the span calibration again after zero adjustment. IMPORTANT To perform the span calibration, a calibrated weight or weights must be used. A calibrated weight on the weigh bucket as shown below. GC48108G0002 ( 95/145) 95 Operation RCU-1000 Ver.1.XX 08,'11

106 7 ENGINEERING MODE (LEVEL 4) INITIAL CALIB NOTE FOR ZERO SETTING AND SPAN CALIBRATION (1) This zero setting procedure determines the zero of that scale(s) at the initial calibration. It is not allowed to perform the zero setting again once the installation has been finished, when DIP switch SW4-1 must be set to "ON" to inhibit access to the Initial Calibration and System Installation. (Ref. Installation Manual Part 1). This zero setting is different from the so-called initial zero, which will be set every time when power is on in operation of the machine. (2) When power is on, zero adjustment or tare setting within the range of ± 10 % the scale capacity is allowed. This zero is called "INITIAL ZERO". (3) If zero indicates a deviation exceeding the range of ± 2 % the scale capacity from the so-called initial zero during operation, the zero error mark " " will be displayed. Refer to the Operation Manual for details. This ± 2 % range is applied when European W & M application is selected (Option Bit 8-6), if not 16% range will be applied. (4) If span deviation exceeds 1 % from previous span calibration, the span error symbol " " will be displayed in the scale segment. Be sure to check the load cell separately if this occurs. (1) Touch the "WEIGH SENSOR ZERO CALIB." pad. The pad will highlight and the "WEIGH SENSOR" pad will automatically highlight. (2) Touch the "START" pad. Then the zero setting of the weigh sensor(s) for the distributor(s) (main feeder) will be performed. Note: No span calibration is performed for the weigh sensor. WEIGH SENSOR ZERO-SETTING GC48108G0002 ( 96/145) 96 Operation RCU-1000 Ver.1.XX 08,'11

107 7 ENGINEERING MODE (LEVEL 4) USER USER SETTING MENU Touch the "USER" pad in the SYSTEM menu. The USER SETTING menu will be displayed. The USER SETTING menu provides for the menu that the operator is permitted, the operator's new registration and the registration deletion of the operator. (1) When you will register the new user, touch NEW pad. When you change the user who has already been registered, touch number pad in user selection part and input user s number with tenkey. (2) When you change the access level, touch number pad at access level and input the changed access level. However, the access level can be input between 1 to 4. (3) When you touch the language pad of the display language, the language of the screen after log on can be set. (4) When you touch "2" pad on the right of the screen, the menu that the user can select can be permitted GC48108G0002 ( 97/145) 97 Operation RCU-1000 Ver.1.XX 08,'11

108 7 ENGINEERING MODE (LEVEL 4) FEED FEED DEVICE SETTING MENU Touch the "FEED" pad in the SYSTEM menu. The FEED device setting screen will be displayed. The FEED device setting screen provides for the frequency of LVF and MVF, and the allocation of the feeder and the sensor. LVF SETTING Touch the "LVF" pad in the Feed device setting screen. The LVF setting screen will be displayed. The frequency of the LVF FERQUENCY of LVF These are frequency of the LVF of the each head. The head whose display column is orange is "FORCED DRIVE, and the head of the solid color is RESONANCE DRIVE. When you touch the orange number of the head of FORCE DRIVE, the tenkey will be displayed. Set the the frequency with the tenkey. QUICK STOP COEF. The quick stop phase at the AUTO TUNING. Set Default is 260. (n/360). AMP.( TEMPORAY) LVF AMP at MANUAL mode 0-99 TIME(TEMPORAY) LVF TIME at MANUAL mode GC48108G0002 ( 98/145) 98 Operation RCU-1000 Ver.1.XX 08,'11

109 7 ENGINEERING MODE (LEVEL 4) FEED LVF SETTING (Continued) MANUAL OPERATION (1) Select MANUAL in the MODE (2) Touch the head number in the frequency parts. The head whose LVF will operate is highlighted. (3) Touch "START" pad. Selected LVF operates during the LVF TIME (TEMPORAY) by AMP of LVF (TEMPORAY). AUTO TUNING (1) Select AUTO TUNING or AUTO TUNING (RESONANT) or AUTO TUNING (FORCED) in the MODE. (2) Touch the head number in the frequency parts which is RESONANCE DRIVE because of selecting to AUTO TUNING. (3) Touch "START" pad. The AUTO TUNING of the selected head will begin. For several minutes the AUTO TUNING operates. GC48108G0002 ( 99/145) 99 Operation RCU-1000 Ver.1.XX 08,'11

110 7 ENGINEERING MODE (LEVEL 4) FEED MVF SETTING Touch the "MVF" pad in the Feed device setting screen. The MVF setting screen will be displayed. MVF operates by only FORCED DRIVE. MANUAL OPERATION (1) Select MANUAL in the MODE. (2) Touch "START" pad. MVF operates during the MVF TIME (TEMPORAY) by AMP of MVF (TEMPORAY). AUTO TUNING (1) Select AUTO TUNING or AUTO TUNING (RESONANT) or AUTO TUNING (FORCED) in the MODE. (2) Touch "START" pad. The AUTO TUNING of the selected head will begin. For several minutes the AUTO TUNING operates. GC48108G0002 ( 100/145) 100 Operation RCU-1000 Ver.1.XX 08,'11

111 7 ENGINEERING MODE (LEVEL 4) FEED FEEDER ALLOCATION Touch the "FEEDER ALLOCATION" pad in the Feed device setting screen. The FEEDER ALLOCATION setting screen will be displayed. The FEEDER ALLOCATION setting screen provides for the allocation of the feeder, and the frequency. The screen is used to alter allocation of main feeder signal and cross head feeder signal to the I/O port on I/O board EVAxxxxF. The number of "Node" displays the node number for the installed I/O board. (1) Touch FEEDER output signal pad. The list screen of the feeder name is displayed. (2) Touch the feeder name which you select in the list. The list screen disappears and the feeder signal name is displayed in the feeder name pad of the allocation screen. GC48108G0002 ( 101/145) 101 Operation RCU-1000 Ver.1.XX 08,'11

112 7 ENGINEERING MODE (LEVEL 4) FEED SENSOR ALLOCATION Touch the "SENSOR ALLOCATION" pad in the Feed device setting screen. The SENSOR ALLOCATION setting screen will be displayed. The SENSOR ALLOCATION setting screen provides for the allocation the sensor for feeder. The number of "Node" displays the node number for the installed I/O board. One Weigh sensor and two Photo Sensors can be allocated to one node. (1) Touch sensor signal pad. The list screen of the sensor name is displayed. (2) Touch the sensor name which you select in the list. The list screen disappears and the sensor signal name is displayed in the sensor name pad of the allocation screen. GC48108G0002 ( 102/145) 102 Operation RCU-1000 Ver.1.XX 08,'11

113 7 ENGINEERING MODE (LEVEL 4) WEIGH WEIGH DEVICE SETTING MENU Touch the "WEIGH" pad in the SYSTEM menu. The WEIGH device setting screen will be displayed. The WEIGH device setting screen provides for the digital filter, the motor pattern of the buckets, the delay time and the allocation of the motor. DEGITAL FILTER SETTING Touch the "DIGITAL FILTER" pad in the weigh device setting screen. The digital filter setting screen will be displayed. AUTO TUNING (1) Select the number of the head which executes AUTO TUNING. (2) Touch "START" pad. The AUTO TUNING of the selected head will begin. For several minutes the AUTO TUNING operates. GC48108G0002 ( 103/145) 103 Operation RCU-1000 Ver.1.XX 08,'11

114 7 ENGINEERING MODE (LEVEL 4) WEIGH GRAPH DEGITAL FILTER SETTING (Continued) The result of executing the auto tuning can be displayed in the graph. (1) Select the graph in the pull-down menu. FFT ANALYSIS AMPLITUDE CHARACTERISTIC SENSITIVITY RATIO (The graph is not displayed.) SAMPLE DATA (2) Touch "GRAPH" pad. The graph screen appears. GC48108G0002 ( 104/145) 104 Operation RCU-1000 Ver.1.XX 08,'11

115 7 ENGINEERING MODE (LEVEL 4) WEIGH MOTOR PATTERN SETTING Touch the "MOTOR PATTERN" pad in the weigh device setting screen. The motor pattern setting for the weigh devices screen will be displayed Motor of the bucket 2 The motor pattern 3 Pattern Number 4 ERROR pad HEAD SELECT pad GRAPH pad POLARITY INVERSION pad DEFAULT pad COPY pad The bucket where the motor pattern is displayed is highlighted (BLUE). The pattern of the motor pattern number that is selected is displayed. The motor pattern number that is selected is highlighted (BLUE). Touching this pad, select the head that sets the pattern. The graph screen of the motor pattern that is selected appears. Touching this pad, the polarity of the motor pattern that is selected inverts. (The sign of the speed are inverted.) Touching this pad, the motor pattern that is selected changes into the default value. The motor pattern is copied onto the pattern of other motor pattern numbers. GC48108G0002 ( 105/145) 105 Operation RCU-1000 Ver.1.XX 08,'11

116 7 ENGINEERING MODE (LEVEL 4) WEIGH MOTOR PATTERN SETTING (Continued) MODE (1) When MANUAL is selected in mode, touch "START" pad. The selected motor moves by the selected motor pattern. (2) When AUTO TUNING is selected in mode, touch "START" pad. The auto tuning of the selected motor begins. GRAPH (1) Touch "GRAPH" pad. The graph of the selected motor pattern is displayed. COPY (1) Touch "COPY" pad. The motor pattern copy screen is displayed. (2) Select the motor pattern number at the copy destination. Some of the numbers can be selected. (3) Touch "OK" pad. The motor pattern selected on the former screen is copied. (4) Touch "CANCEL" pad. The motor pattern copy screen disappears without copying the motor pattern, and the motor pattern setting screen is displayed. GC48108G0002 ( 106/145) 106 Operation RCU-1000 Ver.1.XX 08,'11

117 7 ENGINEERING MODE (LEVEL 4) WEIGH DELAY TIMING SETTING Touch the "DELAY" pad in the weigh device setting screen. The motor delay timing setting for the weigh devices screen will be displayed. This screen provides for the digital filter constants and delay time for the buckets open/close timing. 1 MOVING FILTER 2 FB DELAY 1 (LVF FB) 3 WB DELAY (MB WB) 4 TRANSFER (WB MB) 5 MB DELAY (DISCHARGE) AVE. This constants is determined based on the natural frequencies of the weigh bucket including product in it and disturbance. To prevent product from directly dropping into the weigh bucket below, the linear feeder starts vibrating to feed product into the feed bucket a certain time after the feed bucket door starts closing. Set this delay time so that no product may drop directly into the weigh bucket through the feed bucket. To prevent product from directly dropping onto collating chute, the weigh bucket starts opening to discharge product into the empty memory bucket below a certain time after the memory bucket starts closing. Set this delay time so that no product may drop from the weigh bucket directly onto collating chute through the memory bucket. This pad is used to set the product transfer time from a weigh bucket to the memory bucket below. Set transfer time from the weigh bucket starting to open to product reaching to the memory bucket. The memory bucket will be effective after this Transfer Time. Because of distance between weigh buckets and memory buckets, the timing of product discharge from memory buckets should be delayed from that of the weigh buckets. Default=1 Default=1 Default=1 Default=1 GC48108G0002 ( 107/145) 107 Operation RCU-1000 Ver.1.XX 08,'11

118 7 ENGINEERING MODE (LEVEL 4) WEIGH MOTOR CURRENT SETTING DELAY TIMING SETTING (Continued) The current value of each motor is set by the figure. Figure Current Value (A) The default value of each motor of 3L model is the following. BUCKET Figure Current Value (A) FB WB TIMING CHART MEMORY BUCKET Open Close WEIGH BUCKET 3 4 Open Close FEED BUCKET 5 Open 1 Close 2 Open Close 1 LINEAR FEEDER Vibrates Vibrates 1: LVF Delay 2: FB Delay 3: WB Delay 4: Transfer (WB->MB) 5: FB Delay 2 - This delay time (WB->FB) can be set on the Setup 3 screen. The door will not open until FB discharged product into WB and weighing has completed. GC48108G0002 ( 108/145) 108 Operation RCU-1000 Ver.1.XX 08,'11

119 7 ENGINEERING MODE (LEVEL 4) WEIGH MOTOR ALLOCATION SETTING Touch the "MOTOR ALLOC" pad in the weigh device setting screen. The motor allocation setting for the weigh devices screen will be displayed. GC48108G0002 ( 109/145) 109 Operation RCU-1000 Ver.1.XX 08,'11

120 7 ENGINEERING MODE (LEVEL 4) DUMP DUMP DEVICE SETTING MENU Touch the "DUMP" pad in the SYSTEM menu. The dump device setting screen will be displayed. The dump device setting screen provides for the motor pattern of the collection buckets, the interlock with bag maker. MOTOR PATTERN SETTING Touch the "MOTOR PATTERN" pad in the dump device setting screen. The motor pattern setting for the dump devices screen will be displayed motor of the The bucket where the motor pattern is displayed is highlighted collection bucket (BLUE). 2 The motor pattern The pattern of the motor pattern number that is selected is displayed. 3 Pattern Number The motor pattern number that is selected is highlighted (BLUE). 4 GRAPH pad The graph screen of the motor pattern that is selected appears. POLARITY Touching this pad, the polarity of the motor pattern that is INVERSION pad DEFAULT pad selected inverts. (The sign of the speed are inverted.) Touching this pad, the motor pattern that is selected changes into the default value. Touch "START" pad. The selected motor moves by the selected motor pattern. GC48108G0002 ( 110/145) 110 Operation RCU-1000 Ver.1.XX 08,'11

121 7 ENGINEERING MODE (LEVEL 4) DUMP GRAPH MOTOR PATTERN SETTING (Continued) (1) Touch "GRAPH" pad. The graph of the selected motor pattern is displayed. DUMP SETTING (INTERLOCK) Touch the "SETTING" pad. The Interlock and other setting screen will be displayed. The Setting screen is used to set interlocks between the machine and the packaging machine, and collection gate. 1. INTERLOCK MODE SELECTION Select, by touching a pad for Interlock Selection, one of the following modes of interlock with the packaging machine. Refer to DATAWEIGH Sequence in Supplementary Description. STROKE F1 DOUBLE In this mode, the "DW Ready" signal is sent from the machine to the packaging machine when a combination calculation has been made. Then, the machine will discharge product when it receives a "Ready" signal from the packaging machine. F1 SINGLE In this mode, the "DW Ready" signal is sent from the machine to the packaging machine when a combination calculation has been made. Then, the machine will discharge product when it receives a "Ready" signal from the packaging machine. In this mode, the "DW Ready" signal is sent from the machine to the packaging machine when 2 combination calculations has been made. Then, the machine will discharge product when it receives a "Ready" signal from the packaging machine. F1 TRIPLE In this mode, the buckets selected in 3 combinations after the machine received the "Ready" signal from the packaging machine. They will open to discharge product at the same time and send the dump signal to the packaging machine GC48108G0002 ( 111/145) 111 Operation RCU-1000 Ver.1.XX 08,'11

122 7 ENGINEERING MODE (LEVEL 4) DUMP DUMP SETTING (INTERLOCK) continued 2. READY SIGNAL There are two items to be set for "Ready Signal"; one is the initiating method (the first pad) and the other the duration time (the second pad). Select the initiating method and set the duration time of the "Ready" signal referring to the following descriptions: Refer to DATAWEIGH Sequence in Supplementary Description. INITIATING METHOD Initiating methods are divided into two; one is "LEVEL", which allows the "Ready" signal to initiate the function when the "Ready" signal is "ON". The other is "EDGE" which allows the "Ready" signal to initiate only when the "Ready" signal has risen up. TIME The "Time" represents the duration time in milli-seconds of the "Ready" signal effective when "LEVEL" is selected as Initiating Method. 3. COLLECTION GATE Select one of the following items concerning the collection bucket. NOT USED Touch this pad if the collection bucket is not to be used. The pad will highlight. STANDARD "STANDARD" means a type of the collection gate, which just holds product discharged from DATAWEIGH buckets and dump the product into the packaging machine to minimize the operation cycle. To select the "STANDARD" function, touch such labeled pad. The pad will highlight. REJECT "REJECT" means an optional function of the collection gate which can reject product in bad combinations, discharging it outside the packaging machine. To select the "REJECT" function, touch such labeled pad. The pad will highlight. 2 POINT "2 POINT" means an optional function of the collection gate which discharge product into two directions. To select the "2 POINT" function, touch such labeled pad. The pad will highlight. 4. COLLECTION GATE TIMING The CG Timing means the collection bucket-opening mode for multi dump operation. There are two modes; one is "EVERY" and the other is "SINGLE". When "EVERY" is selected, the collection bucket will open every time the "Ready" signal has been sent, not collecting the product dumped over one multi-dump cycle. When "SINGLE" is selected, the collection bucket will collect product dumped over one multi-dump cycle. Select the "CG TIMING" referring to this description. GC48108G0002 ( 112/145) 112 Operation RCU-1000 Ver.1.XX 08,'11

123 7 ENGINEERING MODE (LEVEL 4) DUMP MOTOR ALLOCATION SETTING Touch the "MOTOR ALLOC" pad in the dump device setting screen. The motor allocation setting for the dump devices screen will be displayed. The ALLOCATION OF MOTOR screen is used to alter allocation of driving output of optional motors to the desired I/O port on the I/O board. Four I/O boards can be used to drive motor outputs and each board has three output ports. The node number indicates the node number of the I/O board installed. The procedure to alter the allocation is as follows: (1) Touch the desired motor driving output port pad. The pop-up menu of optional motor list will be displayed as shown in the illustration above. (2) Touch the desired motor pad in the pop-up list. And then the motor name will be indicated in the motor driving output port pad. Note: a) "CB1" and "CB2" mean optional collection buckets, which will use in two-point discharge. b) "REJECT" means an optional collection gate which rejects product of wrong combination outside of packaging machine. c) "MIDDLE SHUTTER" is an optional gate to be installed in the collection chute to prevent product from shock to minimize the breakage in fragile product application. d) CB3A, CB3B are used two-point three-bucket system. e) Diverter is used to divert product at Twin System. GC48108G0002 ( 113/145) 113 Operation RCU-1000 Ver.1.XX 08,'11

124 7 ENGINEERING MODE (LEVEL 4) AUTO TUNING AUTO TUNING Touch the "AUTO TUNING" pad in the SYSTEM menu. The AUTOTUNING screen will be displayed. IN the AUTO TUNING screen the motor pattern and the filter of each head are automatically adjusted. (1) Touch "START" pad. The auto tuning will start. GC48108G0002 ( 114/145) 114 Operation RCU-1000 Ver.1.XX 08,'11

125 7 ENGINEERING MODE (LEVEL 4) SETUP SETUP Touch the "SETUP" pad in the SYSTEM menu screen. The SETUP screen will be displayed. SETUP (FEEDER) Touch the "FEEDER" pad in the setup screen. The setup screen concerning the feeder will be displayed. GC48108G0002 ( 115/145) 115 Operation RCU-1000 Ver.1.XX 08,'11

126 7 ENGINEERING MODE (LEVEL 4) SETUP SETUP (FILTER 1) Touch the "FILTER 1" pad in the setup screen. The setup screen concerning the filter will be displayed. GC48108G0002 ( 116/145) 116 Operation RCU-1000 Ver.1.XX 08,'11

127 7 ENGINEERING MODE (LEVEL 4) SETUP SETUP (FILTER 2) Touch the "FILTER 2" pad in the setup screen. The setup screen concerning the filter will be displayed. SETUP (SENSOR) Touch the "SENSOR" pad in the setup screen. The setup screen concerning the sensor will be displayed. GC48108G0002 ( 117/145) 117 Operation RCU-1000 Ver.1.XX 08,'11

128 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 SETUP RELATED TO PRINTER SETUP 1.1 Limitations Of The Parameter Settings Auto Programming (Typical Parameter Settings) 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) 133 RELATED TO DATAWEIGH OPERATION 3.3 Stagger Dump Multi Dump Operation Cycle Combination Search DATAWEIGH Sequence 140 GC48108G0002 ( 118/145) 118 Operation RCU-1000 Ver.1.XX 08,'11

129 Annex SUPPLEMENTARY DESCRIPTION 1. Related to SETUP 1.1 Limitations of the Parameter Settings There are limitations in parameter settings of SETUP as follows. Settle time (msec) Total time of Feed-bucket motor pattern (*1) + Feed-bucket stationary open time (WEIGH at SETUP) msec Minimum limitations of the settle time for each model are as follows: 2 liter models: 600 msec 5 liter models: 650 msec 10 liter models: 700 msec 16 liter models: 800 msec Cycle (msec) Weigh-bucket discharge delay time (WEIGH at SETUP) + 20 ms Cycle (msec) Total time of Collection gate motor pattern (*1) (if air then zero) + Open time of the Collection gate (DUMP at SETUP) + 20 msec Cycle (msec) Cycle (msec) Cycle (msec) Where Collection gate discharge delay time (DUMP at SETUP) + 20 msec Dump signal time (DUMP at SETUP) + 20 msec Dump signal delay time (DUMP at SETUP) + 20 msec Cycle (msec) = 60,000 msec / Speed (BASIC at SETUP) If scale model is 10 heads with non-memory-bucket; Cycle (msec) Settle time (WEIGH at SETUP) + Total time of Weigh-bucket open motor pattern (*2) + Open time of the Weigh-bucket (WEIGH at SETUP) + Feed-bucket delay 2 (WEIGH at SETUP) + Weigh-bucket discharge delay time (WEIGH at SETUP) + 50 msec GC48108G0002 ( 119/145) 119 Operation RCU-1000 Ver.1.XX 08,'11

130 Annex SUPPLEMENTARY DESCRIPTION Related to SETUP - Limitations of the Parameter Settings 2 litter model and target weight setting 100 g: 2 X Cycle (msec) Settle time (WEIGH at SETUP) + Total time of Weigh-bucket open motor pattern (*2) + Open time of Weigh-bucket (WEIGH at SETUP) + Feed-bucket delay 2 (WEIGH at SETUP) + Weigh-bucket discharge delay time (WEIGH at SETUP) + 50 msec If scale model is 14 heads with non-memory-buckets: 2 X Cycle (msec) Settle time (WEIGH at SETUP) + Total time of Weigh-bucket open motor pattern (*2) + Open time of the Weigh-bucket (WEIGH at SETUP) + Feed-bucket delay 2 (WEIGH at SETUP) + Weigh-bucket discharge delay time (WEIGH at SETUP) + 50 msec 2 litter model and target weight setting 100 g 3 X Cycle (msec) Settle time (WEIGH at SETUP) + Total time of Weigh-bucket open motor pattern (*2) + Open time of the Weigh-bucket (WEIGH at SETUP) + Feed-buckets delay 2 (WEIGH at SETUP) + Weigh-bucket discharge delay time (WEIGH at SETUP) + 50 msec If Insert option is selected in System Installation: Cycle (msec) Cycle (msec) Insert signal time (SETUP) + 20 msec Insert signal delay time (SETUP) + 20 msec GC48108G0002 ( 120/145) 120 Operation RCU-1000 Ver.1.XX 08,'11

131 Annex SUPPLEMENTARY DESCRIPTION Related to 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 pneumatic then zero) + Open time of the Mid-shutter (DUMP at SETUP) + 20 msec Cycle (msec) Mid-shutter delay time (DUMP at SETUP) + 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 (DUMP at SETUP) + 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. GC48108G0002 ( 121/145) 121 Operation RCU-1000 Ver.1.XX 08,'11

132 Annex SUPPLEMENTARY DESCRIPTION Related to SETUP 1.2 Auto Programming (Typical Parameter Settings) INPUT PARAMETERS (1) Target weight (g) 2 liter model: from 8 to 1000 g 5 liter model: from 20 to 2000 g 10 liter model: from 20 to 3000 g 16 liter model: from 40 to 5000 g (2) Speed (p/min) (*1) All model: from 1 to 200 p/min SET FIXED (3) Operation Pattern No. = 1 (4) Over discharge = ON (5) Auto Zero = ON (6) Auto zero 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 GC48108G0002 ( 122/145) 122 Operation RCU-1000 Ver.1.XX 08,'11

133 Annex SUPPLEMENTARY DESCRIPTION Related to SETUP - Auto Programming (25) AFC = AFC-T ON (26) Reset Interval for AFC-T/AFC-I = 10 (27) Limit weigh head number for AFC-T = 2.0 (28) Weigh-bucket discharge 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 GC48108G0002 ( 123/145) 123 Operation RCU-1000 Ver.1.XX 08,'11

134 Annex SUPPLEMENTARY DESCRIPTION Related to 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 = Pneumatic: 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 liter model: then 350 msec 5 liter model: then 400 msec 10 liter model: then 500 msec 16 liter model: then 500 msec (54) Middle shutter delay time = Dump signal delay time / 2 (55) Histogram degree weight = 2 liter model: then 1.0 g 5 liter model: then 2.0 g 10 liter model: then 5.0 g 16 liter model: then 10.0 g (56) Bias weight = 2 liter model: then 0.5 g 5 liter model: then 1.0 g 10 liter model: then 1.5 g 16 liter model: then 2.0 g GC48108G0002 ( 124/145) 124 Operation RCU-1000 Ver.1.XX 08,'11

135 Annex SUPPLEMENTARY DESCRIPTION Related to SETUP - Auto Programming SET BASED ON VOLUME OF WEIGH BUCKET AND TARGET WEIGHT (57) Settle time = 2 liter model: 8 < target 50 g then 750 msec 50 < target 500 g then 800 msec 500 < target 1000 g then 900 msec 5 liter model: 20 < target 50 g then 800 msec 50 < target 500 g then 850 msec 500 < target 2000 g then 900 msec 10 liter 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 liter 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 liter model: 8 < target 200 g then 0 msec 200 < target 500 g then 50 msec 500 < target 1000 g then 100 msec 5 liter model: 20 < target 500 g then 0 msec 500 < target 1000 g then 50 msec 1000 < target 2000 g then 100 msec 10 liter model: 20 < target 1000 g then 0 msec 1000 < target 2000 g then 100 msec 2000 < target 3000 g then 200 msec 16 liter model: 40 < target 1000 g then 0 msec 1000 < target 3000 g then 100 msec 3000 < target 5000 g then 200 msec GC48108G0002 ( 125/145) 125 Operation RCU-1000 Ver.1.XX 08,'11

136 Annex SUPPLEMENTARY DESCRIPTION Related to 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 liter model: 20 < target 1000 g then 0 msec 1000 < target 2000 g then 50 msec 10 liter model: 20 < target 2000 g then 50 msec 1000 < target 3000 g then 100 msec 16 liter 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 Ω Series DATAWEIGH 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. GC48108G0002 ( 126/145) 126 Operation RCU-1000 Ver.1.XX 08,'11

137 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. GC48108G0002 ( 127/145) 127 Operation RCU-1000 Ver.1.XX 08,'11

138 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. GC48108G0002 ( 128/145) 128 Operation RCU-1000 Ver.1.XX 08,'11

139 Annex SUPPLEMENTARY DESCRIPTION Related to PRINTER SETUP 2. 5 PRINTOUT SAMPLES "SAMPLE" mode in MINIMUM SYSTEM GC48108G0002 ( 129/145) 129 Operation RCU-1000 Ver.1.XX 08,'11

140 Annex SUPPLEMENTARY DESCRIPTION Related to PRINTER SETUP 2. 5 PRINTOUT SAMPLES (continued) "SAMPLE" mode in AVERAGE SYSTEM GC48108G0002 ( 130/145) 130 Operation RCU-1000 Ver.1.XX 08,'11

141 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 GC48108G0002 ( 131/145) 131 Operation RCU-1000 Ver.1.XX 08,'11