CONTENTS 1. PREFACE...1 1.1 BASIC INTRODUCTION.3 1.2 NOTICE.4 2. SPECIFICATIONS...5 3. WORKING THEORY.5 3.1 FEEDING...5 3.2 PRODUCT DISTRIBUTION AND WEIGHING... 6 3.3 COMBINATION... 6 3.4 DISCHARGE... 7 4. MACHINE STRUCTURE... 10 4.1 MAIN PARTS... 10 4.2 EXTERNAL SPECIFICATION... 11 4.3 COMMON PARTS INSTALLATION. 12 4.3.1 HOPPER INSTALLATION 12 4.3.2 LINEAR VIBRATION PAN INSTALLATION..13 5. DAILY OPERATION... 14 5.1 DISPLAY INTRODUCTION... 14 5.2 HELP... 14 5.3 ZERO OPERATION... 18 5.4 EMPTY OPERATION... 19 5.5 START TO RUN... 19 1
5.6 MANUAL TEST... 24 5.7 PRODUCTION RECORD... 27 6. PROGRAM SETUP FOR OPERATOR... 28 6.1 PROGRAM SETUP-1... 28 6.2 PROGRAM SETUP-2... 34 7. SYSTEM SETUP FOR TECHNICIAN... 38 7.1 SYSTEM SETUP... 38 7.2 MOTOR-MODEL SETUP.. 42 7.3 SCREEN CORRECTION 44 7.4 CALIBRATION.46 8. SELF-DIAGNOSE AND SOLVE OF FAILURE... 51 9. MAINTENANCE AND REPAIR... 53 10. TRANSPORTATION AND STORAGE... 53 11. CRATE-OPENING AND CHECK... 53 12. ELECTRIC PRINT..54 2
1. PREFACE Thank you for using our touch screen A Series Multihead Combination Weighers. As one of the leading multihead weigher manufacturers, we have been specializing in R&D, manufacturing, marketing various waterproof multihead weighers with the combination of high speed and accuracy, and providing our customers with professional and all-round services. This manual is dedicated to help our customers operate and maintain the machine, which also specifies the regular usage and basic maintenance methods. 1.1 BASIC INTRODUCTION This machine adopts factorial theory, chooses one combination which is closest to the target weight from plenty of qualified combinations. This machine is particularly applicable for weighing granular products in pipelining operation. This machine s model is JW-A -, which is explained as follows: JW - A - Combination weigher: layer of hopper, 1 is single layer, default as double layer. Linear weigher: layer of linear VB, 1 is single layer, default as double layer. Product generation: default as the first generation, B stands for the second generation, etc. Heads Qty Default as standard plain hopper, H means standard Dimple hopper. M means larger plain hopper, HM means larger dimple hopper. Model: Default as multihead weigher, X means linear scale. A -filling & weighing Machine, B -weighing& packaging system, C -Packaging machine; D - Conveying machine, E -Finished products checking device. Abbreviation of company name 3
1.2 NOTICE 1. Please read this manual carefully before operation 2. Environmental requirements: Temperature:-5 ~ 40 C; Humidity:35-85%; Power:AC 220±5V, 50-60HZ; Installation place:on rigid, horizontal and no vibration surface; Earth line:make sure the machine is connecting effectively to the earth; Keep away from the disturbing sources; Food packaging should be operated under aseptic and non-dust environment.. 3. No bumping or strong pressures on weigh hoppers. 4. Check and empty the rest product inside the machine before running. 5. Press C to empty hoppers before the first running. 6. Turn off the power before repairing and cleaning the machine. 7. When electronic part fails, non-electronic-engineer is prohibited to repair the machine. 8. Be careful and cautious when cleaning and repairing the machine, because there is certain distance between the weigher and the ground if the weigher is installed on the top of the packaging machine. 9. Direct current for the connection signals with other equipments (packing machine, conveyor, etc.), should be no more than 30V, the overloading current should be no more than 100mA. 10. It is prohibited to touch the hopper while the machine is running. 4
2. SPECIFICATIONS Machine Model ITEM A16 A14 AHM14 A12 A10 AHM10 A8 Voltage AC110/220V AC110/220V AC110/220V AC110/220V AC110/220V AC110/220V AC110/220V Power Frequency 50/60HZ 50/60HZ 50/60HZ 50/60HZ 50/60HZ 50/60HZ 50/60HZ Required Current 12A 10A 12A 9A 8A 9A 7A Power 2KW 1.5KW 2KW 1.2KW 1.0KW 1.2KW 0.9KW Weigh Head Nos. 16 14 14 12 10 10 8 Max weight range 6500G 6500G 6500G 6500G 6500G 6500G 6500G Single weigh Range 10-1200g 10-1200g 100-2500g 10-1000g 10-1000g 10-2000g 10-500g Weigh Volume 1300ml 1300ml 5000ml 1300ml 1300ml 5000ml 1300ml Max. Weigh Speed 180WPM 130WPM 130WPM 120WPM 70WPM 60WPM 60WPM Preset Program 50 50 50 50 50 50 50 Machine Size (L) 1500mm 1235mm 1600mm 1100mm 1105mm 1455mm 959mm Machine Size (W) 1450mm 1182mm 1630mm 1000mm 1027mm 1427mm 959mm Machine Size (H) 1400mm 1385mm 2042mm 1200mm 1250mm 1850mm 1320mm Machine Weight 460kg 420kg 520kg 380kg 330kg 430kg 280kg 3. WORKING THEORY 3.1 FEEDING Chart 3-1-1 5
Product is firstly delivered by Conveyor into upper storage funnel, then discharged and distributed to linear vibrator pans with the help of the top cone. Product thickness can be adjusted by adjusting the height of storage funnel post. As shown in Chart 3-1-1. 3.2 PRODUCT DISTRIBUTION AND WEIGHING Chart 3-2-1 Product is distributed evenly from Top Cone into each Linear Feeder Pan and stored in Feed Hopper. When Weigh Hopper finishes the previous weighing and discharges the combination, the products in Feed Hopper will be dropped to Weigh Hopper to be weighed and combined. As shown in Chart 3-2-1. 3.3 COMBINATION The machine CPU will process the weight data received from each Weigh hopper, and calculate out numerous qualified combinations which comply with the target weight, then choose the best one to discharge. 1. The parameters related with weight in weigh hopper : AFC, MAIN AMP, LIN AMP, AV COMB HPS, SGL HP WGT.(Refer to 6.2 Parameter-Setup for details) AFC0:The bigger Main AMP (Main VB Amplitude) and Lin AMP (Linear VB Amplitude) are, the heavier weigh hoppers are. AFC1:The bigger AV COMB HPS is, the lighter Single Hopper Weight is. AFC2:The bigger SGL HP WT is, the heavier each hopper weitght is. 2. The parameters related with combination: OPTIMUM, Combined Hoppers OPTIMUM :the bigger this value is, the higher the accuracy is. As shown in chart 3-3-2, if the OPTIMUM is 98, then the best combination 6 will be selected and there is no need finding other 6
combinations. Combined hoppers:the bigger this value is, the higher the pass rate is. As shown in Chart 3-3-2, if there is no qualified combination weight, and if the actual combined hoppers number Preset Combined HOPPERS, then it will be forced to discharge in order to increase the whole running continuity. If the actual combined hoppers number Preset Combined HOPPERS, then it will wait for the discharged hoppers to make combination again. Chart 3-3-1 Chart 3-3-2 3.4 DISCHARGE There are four ways to discharge weighed products to next equipment: 1. Direct Discharge (Timing Hopper Model 0): Product is directly discharged from the discharge chute gate. 7
2. Discharge by Timing Hopper (Timing Hopper Model 1): Product is firstly stored in timing hopper after dropping from weigh hopper, and then dumped to next equipment. This function is to collect products and shorten the drop time. As shown in Chart 3-4-1 Chart 3-4-1 3. Timing Hopper Distribution (Timing Hopper Model 2): Product is firstly stored in timing hopper after dropping from the weigh hopper, and then dumped to next two packaging machines according to the dumping asking signals. This function is to make full use of the high speed of combination weigher. As shown in Chart 3-4-2 Chart 3-4-2 8
4. One timing hopper + AUTOMATIC CHECKER (Timing Hopper Model 3): Product is firstly stored in timing hopper after dropping from Weigh Hopper; the timing hopper shortens the drop time of the products. When there are unqualified products, the automatic checker will be on and discharges the reject to the retriever to prevent it from entering the next procedure. As shown in Chart 3-4-3 Chart 3-4-3 9
4. MACHINE STRUCTURE 4.1 MAIN PARTS Chart 4-1-1 Part No. Description Note Part No. Description Note 1 Machine Frame 15 Lower Holder 2 Weigh Hopper 16 Timing Hopper Board 3 Feed Hopper 17 Control Panel 4 Pro. Level Sensor 18 Discharge Chute 5 Support Post 19 Timing Hopper/Bucket Optional 6 Clamps 20 Discharge Chute Gate 7 Upper Bracket 1 21 Discharge Chute Holders 8 Upper Storage Funnel 22 Machine Base Cover 9 Upper Bracket 2 23 Lower Post Bracket 10 Main Vibrator Pan 24 Handling Ring 11 Linear Vibrator Pan Printer Optional 12 Waterproof Cover Dimple Plate Optional 13 Actuator Diverter Device Optional 14 Crank Arm Rotary top Cone Optional 10
4.2 EXTERNAL SPECIFICATION: 1.Packaging Size: JW-A14: 1682(L) 1182(W) 1272(H) mm JW-A10: 1482(L) 1080(W) 1116(H) mm JW-AHM14: 2179(L) 1382(W) 1805(H) mm JW-A8: 1226(L) 880(W) 1270(H) mm 2.Packaging Weight: 490Kg (14 HEAD), 400Kg(10 HEAD), 650Kg (AHM14 HEAD), 360Kg (8 HEAD) 3.Installation Size: As shown in Chart 4-2-1,4-2-2, 4-2-3 Chart 4-2-1 11
Chart 4-2-2 Chart 4-2-3 12
4.3 PARTS INSTALLATION 4.3.1 HOPPER INSTALLATION 1. As shown in Chart 4-3-1,put the upper lever of the hopper on the U shape slot of the lower actuator axis. Chart 4-3-1 Chart 4-3-1 2. As shown in the chart 4-3-2, push the lower lever of the hopper into the groove of the lower actuator axis. Chart 4-3-2 Chart 4-3-2 3. As shown in the chart 4-3-3, fix the complete hopper on the lower axis of the actuator. Chart 4-3-3 13
4.3.2 LINEAR VIBRATION PAN INSTALLATION Waterproof vibration pan: As shown in Chart 4-3-4, loosen the locking handle, and then insert slanting section a of the Feeder Pan into section b of the Vibrator. Level the Feeder Pan and tighten the locking handle. NOTICE: Each Linear Feeder Pan should be well installed without bumping with each other. Chart 4-3-4 5. DAILY OPERATION 5.1 DISPLAY INTRODUCTION Touch screen display is the control panel of the multihead combination weigher. With the combination of display function and touching operation, you can touch the keys to operate the machine. It will automatically enter the main menu after turning on the machine, as shown in Chart 5-1-1. 14
Chart 5-1-1. 5.2 HELP 1. Press Help on the main menu, and you can get help for every parameter. As shown in chart 5-2-1 Chart 5-2-1 15
2. There are definitions of the different parameters, which will give you advices on the operation, system setup, etc. In this way, you can make full use of it to create big efficiency. As shown in chart 5-2-2 and 5-2-3. Chart 5-2-2 Chart 5-2-3 16
3. Besides, there is an EXIT button on the menu, you can press it to go back to the main page when you finish the HELP advices, which is more convenient for your other operation. As shown in chart 5-2-4 and 5-2-5. Chart 5-2-4 Chart 5-2-5 17
5.3 ZERO OPERATION 1. After turning on the machine, an attention of PLS Press Zero will be displayed on the homepage, which reminds you that you have not made manual Zero Operation. As shown in chart 5-3-1. (Because when you turn on the machine, the auto zeroing control has made a zeroing to the hoppers which are actually not emptied yet in last operation, which will result in inaccurate zeroing.) Chart 5-3-1 After this operation, as shown in chart 5-3-2, it will display Be in zeroing, pls wait. Chart 5-3-2 18
2. Press Zero on the homepage with opening all weigh hoppers and emptying the rest products in the weigh hoppers. And each load cell will have a zeroing by turns in five seconds. 3. After zeroing, an attention of PLS Press Zero will automatically disappear on the homepage and it will display the current date on the screen. As shown in chart 5-3-3. Chart 5-3-3 Failure-analyses during the zeroing operation: Tick one time means the zeroing operation is OK. Tick two times means that there is a load cell with 0.5-20g float after zeroing operation; Tick three times means that there is something wrong with a load cell with above 20g float, and it will display E on the screen and stop the hopper during the running. 5.4 EMPTY EMPTY can be used to clean out the rest products in the weigher after one operation. Press Empty on the main page, the multihead weigher will run in turn from its VB, feed hoppers, weigh hoppers to timing hopper as per the preset parameters to discharge the rest products. Press any key to exit. As shown in chart 5-4-1. 19
Chart 5-4-1 5.5 START TO RUN 1. On the homepage, press Start to run to access this item, as shown in Chart 5-5-1. Chart 5-5-1 20
2. On the right corner, press Run to start running and it displays RUN. As shown in chart 5-5-2. Chart 5-5-2 3. Press Run again to pause and it displays Pause. As shown in chart 5-5-3. Chart 5-5-3 4. Press Exit to go back to the homepage. 5. On the homepage, you can modify the value of Target speed (as shown in 5-5-4), Main AMP and Lin AMP (as shown in chart 5-5-5). Besides, the linear amplitudes can be adjusted independently. 21
Modification Methods: Pitch on the value after the parameter you want to modify, press + - to change the Target Speed, Main AMP and Lin AMP. Chart 5-5-4 Chart 5-5-5 6. Explanation for the icons of the hoppers in the running. C: Being selected in the combination D: The hopper is disabled E: Ineffective zeroing on the main page, and failure in zeroing in the running (Error) 22
e: Error in data-collection in the running (Error) U: The single hopper weight is over the target weight and forced to dump J: Being fed products L: The single hopper weight is less than the least preset single hopper weight Q: Being forced to dump due to no combination R: Ready for combination T: Communication error of the load cell (Error) W: No selection without combination Y: No selection with combination Z: Auto zeroing in the running 7. PASS will be displayed on the page if the product weight is qualified; OVERWGT will be displayed if the weighed product is overweight. 8. When there are not enough products, the screen will display LOW on the screen. 9. The displayed weight is the weight of the product which was discharged to the discharge chute gate. If there is no timing hopper, the displayed weight refers to the weight of product which the next equipment got; if there is a timing hopper, the displayed weight refers to the weight of products in the timing hopper. 10. If you want to exit the interface and do other operations, you can press the EXIT on the page to stop running. On the top right corner, PAUSE will be displayed. As shown in chart 5-5-6. Chart 5-5-6 23
11. Repress EXIT to go back to the main page. As shown in Chart 5-5-7. 5.6 MANUAL TEST Chart 5-5-7 1. On the homepage, press Manual Test to access this item. As shown in Chart 5-6-1. Chart 5-6-1 24
2. Main VB/Main Vibrator: Press Main VB to start testing. Then the main vibrator will vibrate according to the preset program. As shown in chart 5-6-2. Chart 5-6-2 3. Linear VB/Linear Vibrator: Press number key to select the linear vibrator number and press Linear VB to start testing. Then the selected linear vibrator will vibrate according to the preset program. Selecting 01-14 means to select the corresponding linear vibrator, and selecting 0 means to select all linear vibrators. Take Linear VB 2 as an example, as shown in Chart 5-6-2 and 5-6-3. Input 2 and press Linear VB, then No. 2 Linear VB will vibrate according to the preset program. The testing methods of other Linear Vibrators are as the same. Chart 5-6-3 25
Chart 5-6-4 4. Feed HP/Feed Hopper: Press number key to select the feed hopper number and press Feed HP to start testing. Then the selected feed hopper will run according to the preset program. Selecting 01-14 means to select the corresponding feed hopper, and selecting 0 means to select all feed hoppers. 5. Weigh HP/Weigh Hopper: Press number key to select the weigh hopper number and press Weigh HP to start testing. Then the selected weigh hopper will run according to the preset program. Selecting 01-14 means to select the corresponding weigh hopper, and selecting 0 means to select all weigh hopper. 6. Timing HP/Timing Hopper: Press number key select the timing hopper ways and press Timing HP to start testing. Then the selected timing hopper will run according to the preset program. Selecting 1-2 means to select the corresponding timing hopper ways, and selecting 0 means to select the two timing hopper motors. 7. Once Run: Press number key to select the hopper No. and press Once Run, the selected hopper will have a running from its vibrator, feed hopper, weigh hopper to timing hopper according to the preset program. Selecting 01-14 means to select the corresponding hopper, and selecting 0 means to select all hoppers. 8. Cont. Run/Continuous Running: Press number key to select the hopper No. and press Cont. Run. Then the selected hopper will have a continuous running from its timing hopper; weigh hopper, feed hopper to vibrator according to the preset program. 9. Load Cell: Press number key to select each hopper and start testing. Selecting 01-14 means to select the corresponding load cell, selecting 0 means to select all load cells. Then press Load Cell and the current value of each load cell will be displayed in the ATTN column. ( If the load cell is in failure, it will display 26
Err ) 10. Disable HP/Disable hopper: Press number key to select the No. of the hopper you want to disable. Selecting 01-14 means to select the corresponding hoppers, selecting 0 means to select all hoppers. And press Disable Hopper to change its primary condition. In the condition column, the current on-off condition will be displayed (1 means off and 0 means on). This function is mainly applied to repair the failure hopper. 11. Pro. Level Sensor/product level sensor: Press Pro. Level Sensor to start to test. The product lever sensor will give an indication when it is in running, and the corresponding icon on the storage hopper will sparkle. If it checks that there are not enough products, it will output the signal of feeding product. If it checks that there are enough products, it will give an indication of FULL and stop outputting the signal of feeding product. 12. Test: Press Test, it will go automatically to running interface. The machine will run with no products in it according to the preset program. It needs to input the dump asking signal and output all the normal running signals, which is mainly used for signal test by connecting with packaging machine. 13. Clean: Press Clean, all the hoppers will be opening, which can be used to clean the machine. Press any key to exit. 14. Zero: Press number key to select each load cell, press 0 means to select all load cells. Then press Zero to make zeroing to the load cell. 15. Pause: Press Pause to stop running. 5.7 RECORDS 1. On the main menu page, Press Records to access this item. As shown in Chart 5-7-1 and 5-7-2. Chart 5-7-1 27
Chart 5-7-2 2. Total records:to display the total records, the max value is 2000; 3. Display Record: Press the number after Display Record and it will display the number keys. Input the record No. and press E to confirm. Then it will display the record accordingly. 4. Date Search: Press the number and it will display the number keys. Input the date. Then it will display the data records of the date you input. 5. Delete Record: Press the number and it will display the number keys. Input the numbers of the records you want to delete, then press E to delete. 6. Print: Press Print to access this item and press OK to print the current records. 7. Transfer: Press the number to input the date. Press Transfer to access this item, and press OK to confirm. It will start to transmit one-day records to your computer through COM. 8. Del. All /Delete all records: Press Del. All and enter password to delete all records. 9. Exit: Press Exit to go back to main page 28
6. PROGRAM SETUP FOR OPERATOR 6.1 PROGRAM SETUP-1 1. On the main menu page, press Program Setup to access this item and input the Password 1(default as 181818). Then press E to confirm to access this page. As shown in the Chart 6-1-1, 6-1-2 and 6-1-3. Chart 6-1-1 Chart 6-1-2 29
Chart 6-1-3 2. Press NEXT to access program setup-2, as shown in chart 6-1-4 and 6-1-5. Press Prev. to go back to main page. Chart 6-1-4 30
Chart 6-1-5 3. Prod. Pic: Press Prod. Pic to access a dialog box, there are 50 different products pictures available, you can select one from them and confirm. As shown in chart 6-1-6.6-1-7 and 6-1-8. Chart 6-1-6 31
Chart 6-1-7 Chart 6-1-8 4. Program No./Program No.: press this item, there will be dialog box on the screen. In this dialog box, there are 50 (1-50) different parameters for your choice. Selecting one, then the parameters will have a corresponding change. 5. Prod. Name/Products Name: Press this item, there will be a key board for you to input the name of the product you choose. 32
6. Preset Sp: The preset speed of the combination weigher. There are some differences between the preset weighing speed and actual weighing speed. Input 10-150, unit is bags/min. 7. Target WT/Target weight: The target weight of the Products to be weighed. Press number key or +, - to input the required target weight from 1 to 6500. (the last number is a decimal digit, there is no need to input point, unit is gram) 8. Over WT/Over weight: The over limit weight of the weighed products. Press number key or +, - to input the required up limit weight from 0 to 999. (The last number is a decimal digit, there is no need to input point, unit is gram) 9. Under WT/Down weight: The down limit weight of the weighed products. Press number key or +, - to input the required down limit weight from 0 to 999. (The last number is a decimal digit, there is no need to input point, unit is gram) 10. Correct WT/Correct Weight: The weight of the packaging pouch. Press number key or +, - to input the correct weight from 0 to 999. (The last number is a decimal digit, there is no need to input point). Press + and - to change the sign. The accurate weight= the displayed weight- the correct weight. 11. Main AMP/Main Vibrator Amplitude: it refers to the strength of the main vibrator amplitude. Press number key to input value from 01 to 99. The bigger the value is, the stronger the main amplitude is. Recommendation: 40-90. 12. LIN AMP/Linear Vibrator Amplitude: it refers to the strength of the linear vibrator amplitude. Press number key to input value from 01 to 99. The bigger the value is, the stronger the linear amplitude is. Recommendation: 40-90. 13. VB Feed Tm/Vibrator Feed time: it refers to lasting time for the main and linear vibrators to feed products to the feed hopper. Input 01-999, unit is 10ms. Recommendation: 20-100. 14. Lin VB Delay/Linear Vibrator feed delay: it refers to the delay time for linear vibrator to feed products into the feed hopper after feed hopper opens. Input 01-999, unit is 10ms. Recommendation: 20-35. 15. Feed HP Dly/Feed hopper delay: it refers to the delay time for the feed hopper to feed products into the weigh hopper after weigh hopper opens. Input 01-999, unit is 10ms. Recommendation: 20-35. 16. Weigh HP Dly/Weigh Hopper Delay: it refers to the delay time for the weigh hopper to feed products into the timing hopper after timing hopper opens. Input 01-999, unit is 10ms. Recommendation: 0-30. 17. Time HP Dly/Timing hopper delay: it refers to the delay time for the timing hopper to discharge products into the packaging machines after weigh hopper opens, in order to make sure all the materials are in the timing hopper and then allow timing hopper to discharge. Input 01-999, unit is 10ms. 33
Recommendation: 50-80. 18. Over Sgl Tm/Overweight signal time: it means the lasting time for the combination weigher to send overweight signal to next equipment, when it dumps the overweight materials. Input 01-999, unit is 10ms. 19. Dump Sgl Dly/Dumping signal delay: under the circumstance of ready combinations, the combination weigher will discharge materials to the packaging machine at once, after receiving the dump asking signal from packaging machine. And then combination weigher delays a period of time to send a 100ms confirmed signal to the packaging machine. Input 01-999, unit is 10ms. Recommendation: 50-80. 20. Stgger Dump Tm: When there is a limit for Max Dump Hoppers, that s to say, one combination will be divided into several dumpings with a certain interval to discharge. Unit is 10ms. 21. Stable TM/Sample stable Time: in order to ensure weighing precision, after opening the feed hopper, it will wait a moment to stabilize the sample products in the weighing hopper and then begin to read the load cell data. Input 01-999, unit is 10ms. Recommendation: 70-100. 22. Multicomb TMS/Multi-combination Times: one target weight will be divided into many combinations. In this case, Weight of one combination = Target Weight / Multicomb Times. This function is used to weigh products with big target weight. 23. Max Dump HPS/Max dumping hoppers: In order to reduce the blockage of puffy products, one combination will be divided into many times to dump. Max Dump Hps refers to the max simultaneous dumping hoppers in a combination dumping. Input 1-9, 0 means this function is closed. Related Parameter: Stagger Dump Time 24. Min HP WT%/Minimum single hopper weight%: it means that the single hopper weight is less than the single combination weight percent, which is regarded as low product, and not allowed to attend the combination, and it needs feeding material. Input 1-99, unit is %. Recommendation: 11%--15%. 25. IDLE/No combination times: It refers to the times for one single hopper not attends in combinations, which is applicable to limit the products remaining times in the weight hopper. For example, we set IDLE as N, if one weigh hopper was not selected in continuous N combinations, in the N+1 combination, this weigh hopper have to attend combination. This function is ineffective when N is less than 11. 34
6.2 PROGRAM SETUP-2 On the page of Program setup-1, press NEXT to access Program setup-2, as shown in Chart 6-2-1 and 6-2-2. Chart 6-2-1 1. AFC: Automatic Frequency Control. Input 0-2. Chart 6-2-2 0: means to close this function. 35
1: AFCT, it will adjust the amplitudes according to the combination hoppers and it will give an auto adjustment to all linear vibrator amplitudes; 2: AFCW, it will adjust the amplitude according to the single hopper weight and it will give an auto adjustment to every linear amplitude and display the amplitude separately. -----------------AFCT ------------------ 2. Avg Comb Hps/AVG Combination hoppers: it refers to the average combination hoppers which are used in a successful combination weighing. Range: 01-99. Recommendation: 3.0-4.0. 3. Acpt Comb Err/Single Acceptable combination error hoppers: it refers to the average combination hoppers windages which are used in each successful combination. Range: 01-99. Recommendation: 0.1-1.0 4. Track Interval/Track Interval: After how many successful combinations, it will give an auto adjustment to all linear amplitudes. Range: 01-99. Recommendation: 10. ---------AFCT Working Procedures---------- A. The linear amplitudes are too strong which leads to less combination hoppers, and need adjusting. The actual total combination hoppers after the combination in a track interval< ((AV combination hoppers Single acceptable error) Track Interval) ==>All linear amplitudes 1. B. The linear amplitudes are too weak which leads to more combination hoppers, and need adjusting. The actual total combination hoppers after the combination in a track interval> ((AV combination hoppers Single acceptable error) Track Interval) ==>All linear amplitudes + 1. ---------------AFCW---------------- 5. Avg HP Wt%/ Single AVG Hopper weight percent: it refers to the ideal average weight of single hopper, and it was calculated as certain percent of single combination weight. Range: 01-99. Recommendation: 20%-40% 6. ACPT HP Wt Err/Single Hopper Acceptable Error Weight: it refers to the single allowable hopper weight error in the running. Range: 01-999. Recommendation: 10g 7. Track Interval/Track interval: After how many successful combinations for each single hopper, it will give an auto adjustment to the linear amplitude of the single hopper. Range: 01-99. Recommendation: 10 ---------AFCW Working Procedures-------- A. Single linear amplitude is too strong which leads to overweight of the single hopper, and needs adjusting. 36
The actual single hopper weight after the combination in a track interval > ((Single AV weight % Single target combination weight + Single acceptable error) Track Interval) ==>Single linear amplitude 1. B. Single linear amplitude is too weak which leads to light weight of the single hopper, and needs adjusting. The actual single hopper weight after the combination in a track interval < ((Single AV weight % Single target combination weight-single acceptable error) Track Interval) ==>Single linear amplitude + 1. 8. Auto Zero Tm/INTERVAL: Used to set interval Automatic Zero Resetting in the running process. Range: 01-99. Unit is 1 min. Recommendation: 5min. 9. FD HP Opn Tm/Feed hopper opened time: it refers to the period for the feed hopper cover to pause and then begin to close its cover in order to discharge all the products in the feed hopper. Range: 01-150. Unit is 10ms. Recommendation: 1-20. 10.WG HP Opn Tm/ Weigh hopper opened time: it refers to the period for the weigh hopper cover to pause and then begin to close its cover in order to discharge all the products in the weigh hopper. Range: 01-150. Unit is 10ms. Recommendation: 1-20. 11.Tm HP Opn Tm/Timing hopper opened time: it refers to the period for the timing hopper cover to pause and then begin to close its cover in order to discharge all the products in the timing hopper. Range: 01-150. Unit is 10ms. Recommendation: 1-30. 12.FD HP Motor/Feed hopper motor mode: it refers to the running model of the feed hopper motor; you can use the preset 5 kinds of feed motor model in the system setting menu. The default factory setting is that the bigger this value is, the faster the speed is. Range: 0-4. Recommendation: 0-3. 13. WG HP Motor/Weigh Hopper Motor Mode: it refers to the running model of the weigh hopper motor; you can use the preset 5 kinds of weigh motor model in the system setting menu. The default factory setting is that the bigger this value is, the faster the speed is. Range: 0-4. Recommendation: 0-3. 14. Tm HP Motor/ Timing hopper motor mode: it refers to the running model of the timing hopper motor; you can use the preset 5 kinds of timing motor model in the system setting menu. The default factory setting is that the bigger this value is, the faster the speed is. Range: 0-4. Recommendation: 0-2. 15. Main VB Motor/Main vibrators motor mode: it refers to the running model of Main VB Motor; you can use the preset 5 kinds of Main VB Motor model in the system setting menu. The default factory setting is that the bigger this value is, the faster the speed is. Range: 0-4. Related Parameter: Top Cone Model 16. Single Piece Wt/Standard piece weight: the single piece standard weight for the uniform products which is applicable to calculate the combination weight to finish the target pieces. Range: 0-500.00g. 37
17. Target Pcs: the target pieces of the weighing products. Range: 0-32000. Total weight=target Pcs Single Piece WT. (Total weight is no more than 6500.00g) Related Parameter: Piece Model 18. Over Pcs/Over pieces limit: the up allowable limit of the weighed products. Range: 0-32000. Related Parameter: Piece Model 19. Under Pcs/Under piece limit: the down allowable limit of the weighed products. Range: 0-32000. Related Parameter: Piece Model 20. Level Feed Time/Level products feed time: when the products photoelectric level sensor checks there is not enough product in the upper storage funnel, it will output feeding signal and till there is enough material in the upper storage funnel. So it refers to the lasting time of feeding signal. Range: 5-10. 21. Start Feed WT. /start feed weight: It refers to a weight for the machine to send 'feeding' signal when the product level sensor checks there is not enough products on the upper storage funnel. (Note: this is useful for the combination weighers using Main Vibrator with load cell). Range: 0-32000. Unit is 0.1KG. 22. Stop Feed WT:/Stop feed weight: It refers to a weight for the machine to stop 'feeding' signal when the product level sensor checks there are enough products on the upper storage funnel. (Note: this is useful for the combination weighers using Main Vibrator with load cell). Range: 0-32000. Unit is 0.1KG. 23. Copy To/copy this program to: it refers to the program No., to which the current programs will be copied. Default as the original program No. If you want to copy to another program, input the target program No., and press E to confirm. Range: 1-50. 7. SYSTEM SETUP FOR TECHNICIAN 7.1.SYSTEM SETUP On the homepage, press System Setup to access this item and input the password 2 (default as 282828). And press E to enter this menu, as shown in Chart 7-1-1, 7-1-2 and 7-1-3. 38
Chart 7-1-1 Chart 7-1-2 39
Chart 7-1-3 1. No Comb Action/ No Combination action: it refers to the methods to deal with unqualified combinations. Range: 0-1. Default as 0. 0: Auto enforced dumping. Recalculate all the combinations and choose the combination larger than and closest to the target weight to discharge. At the same time, it will output overweight signal. 1: Manual Interference. The machine stop automatically, notifying manual interfere is needed. Press E to confirm after manual interference, it will feed and recombine. 2. Multicomb TMS/Multi-Combination times: open or close the function of multicombination discharging. 0: allow this function. 1:stop this function 3. Piece Mode: selection between weighing method and counting method. Range: 0-1. Default as 0. 0: Weighing method: make combination as per target weight, unit is gram. 1: Counting method: make combination as per target pieces, unit is pcs. 4. Tm HP Mode/Timing hopper model: there are 4 ways of timing hopper mode for you to choose. 0: No timing hopper. 1: Single timing hopper motor. To be characteristic of the high speed packaging. 2: Double timing hoppers motor. Make full use of the high speed of the weigher by discharging products to two packaging machines through two timing hoppers. 3: Single timing hopper motor + weight checker mode. Combine the rejects checking with high speed of the packaging machine. 40
5. Top Cone MD/Top cone model: There are 2 Top Cone MD for you to make choice. Range: 0-1. 0. Vibrating model: suitable for weighing products with good fluidity. 1: Rotary model: suitable for weighing products with bad fluidity. 6. Optimum: When the qty of the qualified combination reached the Optimum times, the CPU will stop combinating and select one best combination. Optimum value can be used to improve the packaging accuracy. Range: 1-99. Recommendation: 98. 7. Combn HPS/Combined hoppers: if there is no successful combination, it will decide if re-feed products to recombine, or make an enforced combination to discharge according to the current actual combined hoppers. The judging formula is as follow. (This parameter is exclusive for 14 heads weighers) A. Actual combined hoppers preset combined hoppers ==>enforced discharge B. Actual combined hoppers < preset combined hoppers ==>load materials and combine This value can be used to control the pass rate and running continuity. (When this value is smaller, the running continuity will be better, but at the same time the pass rate will be lower. On the contrary, when this value is bigger, the running continuity will be worse, but the pass rate will be higher.) Range: 06-14. 8. Dump signal/discharge signal: Ways to receive the signal of dump asking from the packaging machine. Range: 0 3. 0: Pulse with memory. It refers to the pulse receiving the signal of dump asking as soon as the weigher discharges the last combination. (If weigher receives the signal of dump asking first, then finishes the weighing, it will discharge directly without outputting Ready signal.) 1: Pulse without memory. It refers to the pulse receiving the signal of dump asking after weighing the products. 2: Tension with memory. It refers to the tension receiving the signal of dump asking as soon as the weigher discharges the last combination. The weigher receives the signal of dump asking as soon as it discharges the last combination. (If weigher receives the signal of dump asking first, then finishes the weighing, it will discharge directly without outputting Ready signal.) 3: Tension without memory. It refers to the tension receiving the signal of dump asking after weighing the products. NOTE: Pulse takes effect when the signal switch goes from on to off. Tension takes effect when the signal switch is on. 9. Date setting: input the current date, then press E to confirm. 10. Time setting: input the current time, then press E to confirm. 41
11. Password 1: amend the password 1. Input the password, you can access to program setup. The default password 1 is 181818. 12. Password 2: amend the password 2. Input the password, you can access to system setup and calibration. The default password is 282828. (Pls keep this password safe and careful.) 13. Language: Input the language code 0-2 to choose various languages, press E to confirm. 14. BCKLGHT TM: The time for the LCD to be in a poor light due to no operation. Range: 1-99min. 15. Version Code: The code of the software version. 16. Combi. Module/combination module: It's only for 14 head weigher. 0: it refers to the remaining hoppers from the last combination can make the second combination, the speed can be up 120-130 bags/min. 1: it refers to make the combinations after all the hoppers have been fed, which is suitable for big target weight with low speed.. 17. No Prod. Pau. T.: The period time for the machine to pause when there is not enough products on the upper storage funnel. The machine will automatically run if there are enough products on the upper storage funnel. If you want to weigh all the rest products, pls press RUN to cancel this function. Range: 1-99S. 18. Sample Filter/ Sample filter value: it refers to the filtering grade of the load cells. The bigger the value is, the stabler the weighing datum is, and at the same time the lower the reaction speed is. Recommendation: 5-8. If you want to change this value, pls input new value and press E to confirm. It will display OK on the screen, and there will be a TICK notice after a successful operation. 19. Program Recovery: Press this key, all the parameters will be recovered to the default condition. 42
7.2.Motor Setup: It is to set the running mode of different motors. Press Motor Setup to enter this function menu. As shown in Chart 7-2-1 and 7-2-2. Chart 7-2-1 Chart 7-2-2 43
1. Feed hopper: Input 0-4 to select the motor model, and press E to confirm. The corresponding step and speed will be displayed on the screen, which can also be changed independently. 2. Weigh Hopper: Input 0-4 to select the motor model, and press E to confirm. The corresponding step and speed will be displayed on the screen, which can also be changed independently. 3. Timing Hopper: Input 0-4 to select the motor model, and press E to confirm. The corresponding step and speed will be displayed on the screen, which can also be changed independently. 4. Init. Move DRCT: the rotary direction of the front 5 segments (0-4). 1: anticlockwise rotary. 0: clockwise rotary. 5. Return Move DRCT: the rotary direction of the back 5 segments (5-9). 1: anticlockwise rotary. 0: clockwise rotary. 6. Steps: it means that the step motor runs how many pulses within this segment, for each pulse, the step motor rotary angle is 1.8 7. Speed: the rotary speed for each step within the segment. Range: 1-50. (Input the steps, the speed will change automatically) 8. Current: it refers to the motor current level during the running. Range: 1-15. The bigger this value is, the stronger the rotary strength is. 9. Front Move total steps: the total steps of the front segment. NOTICE: The back move total steps must be equal to the front move total steps. 10. Save: Used to save the amended parameters. It will display OK on the screen and there will be a TICK notice after a successful operation 11. ATTN: When you set the motor model, you can take below illustration for reference to get the graph, as shown in chart 7-2-3. A. The setting methods of the front 5 segments when the hoppers are opening. 1 the start speed of the motor should not be too fast. 2 the motor speed should be slow in order to reduce noise when it begins to touch the hopper pole.3 when it completely touches the hopper pole, the motor should be as fast as possible. 45 keep fast to save time. B. The setting methods of the back segment when the hoppers are closing. 1 the start speed of the motor should not be too fast. 2 the motor begins to speed up. 3 keep speeding up for a while. 4 begin to slow down and prepare to keep away from the hopper pole 5 keep slow down to keep away from the hopper pole at a stable speed to reduce noise and vibration. 44
. Chart 7-2-3 7.3 Screen Correction When the display place of screen key and the touch key are not in the same position, you need to make screen correction by moving. There will be a square on the screen, if the square is red, it means OK, please press Save to exit, if not, please remember to press Cancel, do not save it. As shown in Chart 7-3-1 ATTN: If you failed in screen correction, PLS DO NOT SAVE, you can restart the machine. Chart 7-3-1 Chart 7-3-2 Chart 7-3-3 Chart 7-3-4 45
Chart 7-3-5 Chart 7-3-6 Chart 7-3-7 1/. As shown in Chart 7-3-1, press center +, it shows the current coordinate; 2/. As shown in Chart 7-3-2, press left-up + it shows the current coordinate; 3/. As shown in Chart 7-3-3, press right-up + it shows the current coordinate; 4/. As shown in Chart 7-3-4, press right-down + it shows the current coordinate; 5/. As shown in Chart 7-3-5, press left-down + it shows the current coordinate; 6/. As shown in Chart 7-3-6, press center + it shows the current coordinate; 7/. Enter Chart 7-3-7, and test the screen, if there are two squares in the middle with corresponding red square display, it means correct, otherwise it is failure. 8/. After correction, press Save, or press Cancel to exit. 9/. If the screen correction fails, PLS RESTART THE MACHINE. Do not press in disorder or Save, or the screen can t be used. 46
7.4 CALIBRATION On the main menu, Press Calibration to access this item, input password 2 according to the attention, then press E to confirm. (This menu will be invalid if J2 switch on the mother board is set at ON). As shown in chart 7-4-1, chart 7-4-2 and chart 7-4-3. Chart 7-4-1 Chart 7-4-2 47
Chart 7-4-3 7.4.1 LOAD CELL TESTING: 1. Press number keys to choose the tested hopper NO. Then the current products weight in this weigh hopper will be displayed at once. If there is no product in the weigh hopper, it will display 0.0, if not, please make a zeroing operation to the load cell. 2. Put a standard weight ( 1000.0g) in a weigh hopper and observe whether the displayed weight is equal to the actual standard weight, if not, there is a requirement to make a calibration to this load cell. 3. Check other load cells. Press number keys to access the load cell NO. to check. 7.4.2 LOAD CELL ZEROING 1. Press number keys or to choose the tested hopper NO. Then the current weight in this weigh hopper will be displayed at once. Ensure that there is no product in the weigh hopper; press Zero to have a zeroing and it will display 0.0, if there is still a large error or skipping, please make a calibration to this load cell. 2. Have a zeroing to other load cells. Press number keys to access the load cell NO. to check and press Zero to have a zeroing. 48
7.4.3 LOAD CELL CALIBRATION 1. Input the hopper No. and then the current weight in the weigh hopper will be displayed at once, the icon will move to Zero. 2. Ensure that there is no remaining product in the weight hopper, and press Zero. 3. Put a standard weight ( 1000g) in a weigh hopper, and then press Full to confirm. As shown in chart 7-4-4, 7-4-5 and 7-4-6. Chart 7-4-4 Chart 7-4-5 49
Chart 7-4-6 4. Testing. Put a small standard weight ( 500.0g) in the weigh hopper, if the load cell will display its corresponding weight, which indicates the calibration is successful. As shown in chart 7-4-7. Chart 7-4-7 5. Press number keys to input next hopper No. and repeat operation as the above 2~4. ATTN: The whole calibration procedure must be done under the condition that there is no wind and vibration and the operator must be trained and professional. 7.4.4. MEMORY CALIBRATION If you have successfully made the calibration last time, you can press Memo Cal. to run the calibration automatically. 8. FAILURE SELF-DIAGNOSE & SOLVE 50
Icon Reason Check & Solve Refer Page U 1. AFC=0, reduce the LIN AMP Single hopper WGT 2.AFC=1,increase AV combination hoppers is bigger than the 3.AFC=2, reduce the value of AVG HP WT% target WGT 4. Adjust the big LIN VB so that average feeding product. P23 P23 P22 P22 Q E e W Y 1. Increase Combined hoppers ; P26 2. Adjust AMP to ensure the single HP WGT is 25%-33% of P22 No combination & the target WGT, and ensure the AV combination hoppers forced discharge is 3-4 hoppers. 3. Reduce packaging accuracy under acceptable condition, P22 increase Over/under WT 1. Empty the products on the weigh HP hanger; 2. Adjust WG HP MOTOR MODE to ensure all the P25 The WG HP is over products are discharged when the HP open; 20g after zeroing. 3. Power off the machine and restart it after ensuring the above 2 points without abnormity, press C and start to run again; 4. Re-calibration. P15 1. Empty the products on the Weigh HP hanger; Weigh Hopper with negative value in operation. 2. Adjust WG HP MOTOR Mode, ensure no product blocked when hoppers are closed. 3. Make a zeroing operation on the MANUAL TEST. 1. Increase NO Combination times/idle ; Failure in force 2. Set it within 0-09(This function can be closed if the combination on No P23 product won t be melted or can be un-sticky for a long combination times time) 1. Increase NO combination times/idle Success in force 2. Set it within 0-09. (This function can be closed if the combination on no P23 product won t be melted or can be un-sticky for a long combination times time) P25 Z L Auto zeroing 1. Increase ZERO INTERVAL properly when the product P23 is not sticky. 1. Increase AMP. Less products in 2. Reduce the SINGLE LESS WGT. Weigh Hopper 3. Increase LIN AMP to average feeding. D This DP is disabled. Restart the hopper in MANUAL TEST menu. P18 Failure in module 1. Some wrong with DC2 power switch. P34 T communication. 2. Some wrong with QF2 breaker. 3. Check if P031-6 connected correctly. Failure Check and Solve Failure Possible Reason Check and Solve Refer Page P18 P22 P22 51
Suddenly no products discharge or The power switch is off power off in running The difference between the displayed WT and the actual WT is too big 1. Check the power connected correctly. 2. Check if any loose wire terminals. 1. Groundings should be secure 1.Zero over-floating 2. Recalibration 3. Increase SAMPLE FILTER 2. The packed products are Set the Limit as a positive value too heavy. 3. The packed products are Set the Limit a negative value too light. 4. Products in WG HP are not 1. Increase the motor pause time. discharged completely. 2. Increase the hopper delay time. P34 P30 P27 P22 P22 P28 P24 Discharge with pause 5. Slow reaction of the load 1. Reduce SAMPLE FILTER value cell. Wait for the discharged 1. Reduce Combined Hopper hopper to combination 2. Increase Over/under WT The packing speed gets Improper AFC setting slower Low Rate Pass Poor combination P30 P26 P26 P24 1. In AFCT, AV Comb HP should be set 3-4 2. In AFCW, SINGLE HP WGT should be set within 25%-33% of the target WGT 1. Adjust AMP to make AV Comb HP within 3-4. P22 2. Increase Over/under WT 3. Adjust the vibrator to average feeding products. P22 Reduce the front move step speed in the motor P28 mode setting. Open hopper The opening speed of the weakly motor is too fast. The hopper The closing speed of the Increase the back half motor move speed in the door close P28 motor is too fast motor model setting. with noisy 1. If all motors like this, should check if the DC Fail in checking motor of 18V of DC2 is normal, or if lining of 34P Open hopper position ribbon wire is loose. P28 several times Can t enter load cell Hardware lock is switched on calibration 2. If individual motor likes this, should check if the relevant motor position board is normal. Set J1 on Mother position Boards as OFF to unlock Invalid displayer Fail in communication 1. If the earth line is connected. 2. If the displayer is connected properly 3. The switch power DC1 is normal or not. 4. QF1 is ON or OFF. 52
9. MAINTENANCE The machine must be powered off during maintenance and inspection, and should be operated by trained technician. To ensure the normal operation, prolong the usage life and to exert the economic value, the daily maintenance should be well performed. 1. Untrained person is prohibited to dismantle this machine. 2. The parts contacted with products, like main vibrator pan, liner vibrator pans, feed hoppers, weigh hoppers, etc. should be cleaned after daily use. 3. Check before using the machine if any unrelated products are on weigh hopper. Clean out dusty on the hanger after using. 4. Lubricate the joints of each hopper with edible oil every 7 days. 5. Clean the dust inside the actuator every 2 months. 10. TRANSPORTATION & STORAGE 1. Transport, install and dismantle the vibrators carefully. No throwing, bumping or reversing. Prevent from strong vibration and raining. 2. Vibrator should be kept in ventilated room with temperature range of -10 ~40, and without corrosive odors in the room. Humidity is no more than 90%. 11. CRATE-OPENING AND CHECK 1. To avoid damage to the machine surface when opening the crate, the top cover board should be removed firstly, and then comes to the siding wooden boards. 2. Check if the following documents are attached with the machine: 1Instruction manual; 2Spare parts List; 53