PN : 105 - 5359 - 05
MULTIHEAD WEIGHER
CCW-R-2** INSTRUCTION MANUAL
WARNING
• Do not carry out installation, operation, service, or maintenance until thoroughly understanding the contents of this manual. • Keep this manual available at all times for installation, operation, service, and maintenance.
Cautionary Items on Software Thank you for purchasing the product. This product is equipped with a special software program to meet user’s demands flexibly and promptly. The following contents are to ask the software users for their understandings and the precautions for use. This software is divided into two main branches: (1) Application Program (2) OS (Operation System) Actual operations (such as key input and print) are executed by following the established procedures on the Application Program (1), which is a proprietary program ISHIDA CO., LTD. designed. The OS (2) has a role to perform the basic function (such as data management) when executing the Application Program. The OS, unlike the Application Program, does not have to be exclusive to each product; rather it can be commonly used to different products. For this reason, a commonly used OS is effective, and ISHIDA CO., LTD. use Windows XP Embedded. The following points need to be noted: 1. 2. 3. 4.
Do not copy or transfer (use on other devices) Windows XP Embedded. Do not perform reverse engineering, reverse compiling, reverse assembling, or other translations on Windows XP Embedded. Windows XP Embedded is protected by copyright. Users are licensed to use it, which does not mean that the copyright is transferred to users. ISHIDA CO., LTD. are responsible for the all warranties including the warranty of merchantability and the warranty of fitness for special purpose in the use of Windows XP Embedded. Microsoft Corporation is not liable to any responsibility. In case that the above four contents are not understood/accepted or followed, ISHIDA CO., LTD. may have to ask to stop using the product. The actual OS is built in the weigher. Therefore, the above four items are not to be infringed unless the product is disassembled. *Windows is a registered trademark of Microsoft Corporation.
IMPORTANT CONSIDERATIONS
IMPORTANT CONSIDERATIONS
WARNING
It is imperative to read and understand the contents of this manual thoroughly when operating the machine or performing any service, maintenance, or inspection procedures. Please be aware of the hazards involved which may not be obvious, and follow the instructions detailed in this manual.
1. It is impossible to enumerate or predict all of the possible dangers of using this equipment and fully list all of them in an instruction manual. When operating the equipment or performing production in any way not specifically described in this manual, please contact the distributor where the equipment was purchased or your Ishida customer service representative before proceeding. Safety countermeasures not specifically described in this manual or indicated on the machine itself should be carefully considered and implemented before performing any operation, service, or maintenance procedures. 2. The copyright for the material in this document is held by Ishida Co., Ltd., and all information contained herein is protected by the Copyright Law. Any disclosure to third parties or unauthorized copying of the information contained herein is not permitted without prior written approval from Ishida Co., Ltd. 3. Although this manual has been carefully edited, if there are any mistakes, or if you have any questions, please contact your local Ishida Service representative or its local distributor/ representative. The model number and machine number are printed on the equipment plate attached to the equipment. 4. The information contained herein may be changed without prior notice.
Equipment Plate
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IMPORTANT CONSIDERATIONS
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WARRANTY CONDITIONS
WARRANTY CONDITIONS 1. Ishida Co., Ltd. only assumes responsibility for repairing or replacing components which are deemed to be defective due to improper design or manufacturing. The measures to be taken for defects whose origin is unclear shall be decided by mutual consultation between both parties. 2. Ishida assumes no responsibility for loss, injury or damage which are the result of unauthorized or unforeseen operational procedures. 3. The warranty period is stated in the Certificate.
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HOW TO USE THIS MANUAL
MANUAL OBJECTIVES AND STRUCTURE
1. Purpose of this manual This manual is designed to provide users with information about the operation, service, maintenance, and installation on the Ishida multihead weigher. 2. How to read this manual and how this manual is organized The early chapters of this manual contain basic information on safety consideration, structure, or the operation of this equipment. The latter chapters contain more specialized information on detailed descriptions of the weigher functions (including data setting), maintenance, or troubleshooting. In order to acquire information which is necessary for your service, personnel involved in daily production should read the early chapters, personnel involved in management and maintenance of the weigher should read all chapters thoroughly. The structure of this manual, the contents of each chapter, and the intended readers are described in the table below. All personnel involved in operations with the equipment should select the required information to make effective use of this manual.
Note ■ The definition for each intended reader described in the table below is as follows: • Operator:
Personnel who perform basic operations during daily production with the production line (i.e. Operator Level). Do not perform any work described in this manual if it is targeted to any personnel other than Operator.
• System manager:
Personnel who set weighing parameters or tune the equipment (i.e. Site Engineer Level). Do not perform any work described in this manual if it is targeted to Maintenance personnel.
• Maintenance personnel: Personnel who have specialized knowledge about the equipment and perform maintenance or inspection of the equipment (i.e. Installation Engineer Level). Do not perform any work described in this manual if it is targeted to Service personnel. • Ishida Service representative:
Personnel who perform tuning when installing the equipment. There is no limitation in performing works described in this manual unless specially.
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HOW TO USE THIS MANUAL
Chapter
Contents
Intention
Intended reader
1 Safety
• Locations of the warning labels • Precautions to be observed • Types and definitions of the warning indications
To maintain the security of personnel and familiarize with hazardous areas of the equipment.
• Owner of the equipment • All personnel involved in operations with the equipment
2 Introduction
• Intended use, features, and specifications of the equipment • Special terminology used in this manual • Main components and operation outline of the equipment
To understand the basic All personnel involved in configuration, operation outline, operations with the intended use, and scope and limit of equipment applications of the equipment
3 Remote control unit • Meanings of the indications displayed on the operation panel of the remote control unit • Description of the common operations of the remote control unit
To understand and master the basic and common operation procedures of the remote control unit
All personnel involved in operations with the equipment
4 Production
• Outline of production sequence and pre-production procedure • Adjustment procedures required during production
To understand and master the basic • Operators production procedure sequence and • System managers the adjustment procedures required during production
5 New products
• Menus for setting parameters for different products
To understand and master the procedures for setting parameters for weighing a new product
6 Functions of the operation panel
• Functions of each menu
To understand the functions of and • Operators operating procedures for each menu • System managers
7 Useful functions
• Advanced operations
To understand and master advanced • Operators operations • System managers
• System managers
8 Optional functions • Piece weighing • Parent and child weighing
To understand and master the optional functions
• System managers
9 Cleanup procedures • Cleanup procedures and period
To understand and master the mounting, removing, and cleaning procedures of each component in order to prevent foreign matters from getting in and to keep the equipment in hygienic condition
• Operators • Maintenance personnel
10 Periodic maintenance
• Daily and periodic inspection • Adjustment of the components
To understand and master the maintenance and inspection procedures for each component in order to keep the equipment in optimum condition and prevent production loss
• Operators • Maintenance personnel
11 Troubleshooting
• Error messages and corrective actions • Errors, causes, and actions
To understand and master the actions for errors which occur during production in order to enhance efficiency
• System managers • Maintenance personnel
12 Installation
• Installation conditions, lifting for shipping, and installation procedures
To understand and master proper • Maintenance personnel installation locations and • Ishida Service environments, safety transportation representatives and shifting of the equipment, and secure installation
13 Appendix
• Board location in the electric unit To provide information on servicing • Maintenance personnel • Overall wiring diagram and block of the weigher and replacement of • Ishida Service components. diagram representatives
End of the manual
• Index
To search necessary information with a keyword in this manual.
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All personnel involved in operations with the equipment
HOW TO USE THIS MANUAL
3. Illustrations and notations used in this manual
• Illustrations of the equipment The illustrations used to describe the operation procedures are drawn in the most general shapes. The actual equipment may differ slightly from the illustrations.
• Descriptions for key operations Most operations of the equipment are performed by pressing the virtual keys displayed on the operation panel of the remote control unit. In this manual, the operation by pressing these keys are described as follows: EX. Press the [XXX]
key.
• Notations used in this manual The following notations are used in this manual in order to make understanding of information easier.
Indication
Explanation
DANGER
If this hazard is not avoided, death or serious injury will probably result. This indicates a clear and immediate danger, and extreme caution must be exercised to prevent a mishap.
WARNING
If this hazard is not avoided, there is a possibility of death of injury resulting.
CAUTION
If this hazard is not avoided, there is a possibility that light or moderate injury may result. It may also indicate that a possibility of damage to equipment exists.
Note
Used to emphasize or clarify an important point in the manual.
TIP
Gives information which helps understanding. Indicates what you must not perform. Indicates what you must perform. Indicates pages for reference.
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CCW-R-2** INSTRUCTION MANUAL
Table of Contents
GENERAL TABLE OF CONTENTS 1 SAFETY 1.1
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2
Warning Indications -Types and Definitions . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3
General Precautions to be Observed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4
Special Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5
Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1.5.1 1.5.2
1.6
Warning Label Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Warning Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Drive Power Shutdown and Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
2 INTRODUCTION 2.1
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2
Intended Use of the Weigher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.3.1 2.3.2 2.3.3
Standard Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Outline Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Installation Location and Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5
Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6
Operation Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
3 REMOTE CONTROL UNIT 3.1
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2
Components and Functions of the Remote Control Unit (RCU). . . . . . . 3-2
3.3
Operation Panel and Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3.1 Operation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.2 Data Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.2.1 Entering Numeric Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.2.2 Entering English Alphabet Data, Numeral Data, and Symbols . . . . . . . . . . 3.3.3 Correction after Data Entry and Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3-3 3-6 3-6 3-8 3-9
CCW-R-2** INSTRUCTION MANUAL
4 PRODUCTION 4.1
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2
Emergency Stop and Restart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3
Outline of Production Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4
Production Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.4.8 4.4.9 4.4.10
4.5
Pre-Startup Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Weigher Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Control Unit Power ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Startup Assistant Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Select Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Zero Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Starting Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Stopping Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Draining the Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Weigher Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Displays during Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 4.5.1 Combination Weight Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 4.5.1.1 Display selection Menu on the Production menu . . . . . . . . . . . . . . . . . . . 4-21
4.6
Production Pause and Restart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 4.6.1 4.6.2
4.7
Production Status Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 4.7.1 4.7.2
4.8
Production Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Production Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Every output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Current Total Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Printer Paper Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
5 NEW PRODUCTS 5.1 5.2
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2.1 Setting Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.2 Registration Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.3 Preset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.3.1 Product Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.3.2 Setting the Machine performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.3.3 Setting the Weight Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3
5-2 5-4 5-5 5-5 5-8 5-9
Preset data Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
6 FUNCTION OF THE OPERATION PANEL 6.1
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2
Operation Keys and Operation Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
2
CCW-R-2** INSTRUCTION MANUAL
6.3
Upper Setting Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.3.1 Message Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6.3.2 Start-up Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 6.3.3 Selecting a Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 6.3.4 Selecting an Operation Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6.3.4.1 Switching to the Operator Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 6.3.4.2 Switching to the Site Engineer Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 6.3.4.3 Switching to the Installation Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.3.5 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 6.3.5.1 Screen Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 6.3.5.2 Password Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 6.3.5.3 Destination ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 6.3.6 Setting the Date & Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 6.3.7 Help function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.4
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6.5
Zero Adjustment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6.6
Production Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 6.6.1 Combination Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.1.1 Display Selection Menu on Production Menu . . . . . . . . . . . . . . . . . . . . . . 6.6.2 Feeder Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.3 Timing Adjut Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.4 Total Data Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.5 Weight Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 6.8
Drain Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Full Open Lock Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 6.8.1 6.8.2
6.9
6-32 6-33 6-34 6-34 6-35 6-36
Full Open Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Feeder Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Select Preset Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 6.9.1 6.9.2
Photo Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 List Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6.10 Preset Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 6.10.1 Product Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.1.1Product Tab Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.1.2Machine Tab Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.1.3Item Tab Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.1.4Others Tab Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.2 Feeder Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.3 Timing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.4 Weight Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.4.1Target Weight Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.4.2Upper Weight Limit Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.4.3Lower Weight Limit Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.5 Changing the Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10.6 Output the Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-45 6-45 6-48 6-49 6-51 6-52 6-54 6-55 6-55 6-56 6-56 6-57 6-58
6.11 Total Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60 6.11.1 Current Total Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
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CCW-R-2** INSTRUCTION MANUAL
6.11.2 6.11.3 6.11.4 6.11.5 6.11.6
X-bar Chart Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transitional Data of Weigher Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Participation Data per Head Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Total Setting Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-66 6-67 6-68 6-69 6-70
6.12 Feeder Adjustment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71 6.12.1 Feeder Adjustment Menu Display Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74 6.12.2 Auto Adjustment Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76 6.12.3 Auto Adjustment range Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
6.13 Timing Adjustment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83 6.14 Machine Set Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85 6.14.1 Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86 6.14.1.1 Weigh Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86 6.14.1.2Combination Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89 6.14.1.3Vibration Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90 6.14.2 Self-diagnosis Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91 6.14.2.1Device Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91 6.14.2.2Input / Output junction signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92 6.14.2.3Network Analyze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93 6.14.2.4Program number display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95 6.14.2.5Test Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96 6.14.3 Layout Setting / Data Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99 6.14.3.1Layout Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99 6.14.3.2Preset Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100 6.14.3.2.1Preset Manager and Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100 6.14.3.2.2Coping all presets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102 6.14.3.2.3Selection and Initialization of Preset. . . . . . . . . . . . . . . . . . . . . . . . 6-104 6.14.3.2.4Initialization of all presets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-105 6.14.3.3Machine Set edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107 6.14.3.3.1Selection and copy of the Machine Set items. . . . . . . . . . . . . . . . . 6-108 6.14.3.3.2Coping all Machine Set items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109 6.14.3.3.3Selection and initialization of the Machine Set item . . . . . . . . . . . . 6-111 6.14.3.3.4Initialization of all Machine Set items . . . . . . . . . . . . . . . . . . . . . . . 6-112 6.14.4 Parameters Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114 6.14.4.1Weight details setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114 6.14.4.2Combination details setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-116 6.14.4.3Section division setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118 6.14.5 Weigher setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119 6.14.5.1Participating Machine Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119 6.14.5.2AFD Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120 6.14.6 Peripheral devise setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121 6.14.6.1Packer interlock specification setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121 6.14.6.1.1Packer Interlock Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122 6.14.6.1.2Ring Shutter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123 6.14.6.1.3Reject Timing Hopper Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-125 6.14.6.1.4Timing Hopper Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-125 6.14.6.2Feeder Details Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126
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7 USEFUL FUNCTIONS 7.1 7.2
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 New product registration quoting registered product data . . . . . . . . . . 7-2 7.2.1
7.3
Copy and edition of registered product data. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Changing the Production Method Quickly . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.3.1 7.3.2
Using Feeder Adjustment Function on the DRAIN Menu . . . . . . . . . . . . . . . . . 7-4 Using the Full Open Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
8 OPTIONAL FUNCTIONS 8.1
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2
Parent and Child Weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8.2.1 Types of Parent and Child Weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.1.1 Parent and Child Mix Weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.1.2 Bonus Adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.2 Setting Items Related to Parent and Child Weighing . . . . . . . . . . . . . . . . . . . . 8.2.3 Procedures to Set Parent and Child Weighing . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.4 PRODUCTION Menu during Parent and Child Weighing. . . . . . . . . . . . . . . . .
8.3
8-2 8-2 8-2 8-4 8-7 8-9
Count Priority Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 8.3.1 8.3.2 8.3.3 8.3.4 8.3.5
Setting Items Related to Count Priority Program . . . . . . . . . . . . . . . . . . . . . . Piece Weight Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedures to Set Count Priority Program . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring Menus Displayed during Count Priority Program . . . . . . . . . . . . . Count setting output during driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10 8-12 8-14 8-15 8-17
9 CLEANUP PROCEDURES 9.1
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2
Before Washing and Sterilizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.3
Methods of Washing and Sterilizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4
Washing and Sterilizing Procedures for Each Unit and Component . . . 9-8 9.4.1 Removable unit cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.4.1.1 Inlet Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 9.4.1.2 Dispersion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 9.4.1.3 Radial Trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9.4.1.4 Pool and Weigh Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 9.4.1.5 Collection Chutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 9.4.1.6 Discharge Chutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13 9.4.1.7 Timing Hopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 9.4.2 Cleaning Unremovable Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 9.4.2.1 Main Unit, Dispersion Unit, and Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . 9-16 9.4.2.2 Remote Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
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10 PERIODIC MAINTENANCE 10.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2 Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.2.1 Pre-Startup Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.3 Periodic Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 10.3.1 10.3.2 10.3.3 10.3.4 10.3.5 10.3.6 10.3.7 10.3.8 10.3.9
Span Check (Monthly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Span Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Open/Close Operation Check for the Hopper Gate (Monthly) . . . . . . . . . . . . 10-9 Check for the Hopper Open/Close Roller (Monthly) . . . . . . . . . . . . . . . . . . . 10-10 Amplitude Check for the Radial Feeder (Monthly) . . . . . . . . . . . . . . . . . . . . 10-10 Crack Check (Annually) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Check for the Rubber Cover (Annually) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Replacement of Memory backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Fuse replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
11 TROUBLESHOOTING 11.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 11.2 Error Display Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 11.2.1 11.2.2 11.2.3 11.2.4 11.2.5 11.2.6 11.2.7 11.2.8 11.2.9
Pattern 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 Pattern 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9 Pattern 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11 Pattern 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13 Pattern 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14 Pattern 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14 Pattern 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15 Pattern 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15 Error Clear and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
11.3 Weigher Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17 11.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20 11.5 Handling Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24
12 INSTALLATION 12.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 12.2 Installation Location and Environment. . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 12.3 Shipment and Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 12.3.1 12.3.2 12.3.3 12.3.4
Shipment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weight, Center of Gravity, and Dimensions of the Weigher . . . . . . . . . . . . . . Lifting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3 12-4 12-5 12-6
12.4 Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7 12.4.1 Unpacking the Weigher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8 12.4.2 Checking the Weigher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
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12.4.3 Carrying In and Installing the Weigher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8 12.4.4 Connecting the Power Cable and the Remote Control Unit . . . . . . . . . . . . . . 12-8 12.4.5 Mounting the Timing Hopper Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11 12.4.6 Connecting the TH Signal Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11 12.4.7 Installation of the Timing hopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12 12.4.8 Mounting the Discharge Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12 12.4.9 Mounting the Collection Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12 12.4.10 Mounting the Radial Trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13 12.4.11 Mounting the Dispersion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13 12.4.12 Mounting the Weigh Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13 12.4.13 Mounting the Pool Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14 12.4.14 Connecting with the Interlocked Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
12.5 Post-Installation Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . 12-17 12.5.1 12.5.2 12.5.3 12.5.4 12.5.5 12.5.6
Checking Condition of Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turning the Power On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Access Level Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zero Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Span Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-17 12-18 12-19 12-21 12-23 12-25
13 APPENDIX 13.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 13.2 Electrical Unit Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 13.3 Overall Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 13.4 Remote Control BOX unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 13.4.1 RCU Board (P-970*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5 13.4.2 PRN Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7 13.4.3 TP-I/F Board (P-5573*). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
13.5 Main Electrical Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8 13.5.1 13.5.2 13.5.3 13.5.4
HUB Board (P-5535*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9 MPS Board (P-5436*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9 FDRV Board (P-5578*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10 FDC Board (P-5532*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10
13.6 Base Unit Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12 13.6.1 Preamp Board (P-5435*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
13.7 AFV Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 13.7.1 AFV Preamp Board (P-5488*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
13.8 Relay Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14 13.8.1 EXC Board (P-5426*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14 13.8.2 Relay Board (P-5506*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
13.9 PS-0 Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16 13.10 PS-2 Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17 13.11 Weight/Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-18
7
CCW-R-2** INSTRUCTION MANUAL
13.11.1 DUC Board (P-5428*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-18 13.11.2 DDU Board (P-5439*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-18
13.12 CAL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-19 13.12.1 ADC BOARD (P-5576*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20 13.12.2 WCU BOARD (P-5561*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-21 13.12.3 DMU board (P-5562 *) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-22
13.13 PS FEEDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24 13.13.1 FPS BOARD (P-5580 *) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24
13.14 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25 13.14.1 [TOTAL DIAGRAM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25 13.14.2 BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25
8
1 SAFETY 1.1
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2
Warning Indications -Types and Definitions . . . . . . . . . . . . 1-2
1.3
General Precautions to be Observed . . . . . . . . . . . . . . . . . . 1-3
1.4
Special Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5
Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.5.1 1.5.2
1.6
Warning Label Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Warning Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Drive Power Shutdown and Indication . . . . . . . . . . . . . . . . . 1-7
CCW-R-2** INSTRUCTION MANUAL
1
1 SAFETY
SAFETY
1.1
Summary
The information in this chapter is designed to instruct persons who own, install, operate, service or inspect this equipment on warning indications, precautions which must be observed, and warning labels attached to the machine. WARNING
•
Before attempting to perform any operation, maintenance or inspection of this equipment, it is imperative to read and understand the instructions in this manual and to carefully observe all safety precautions and warnings contained herein.
•
If there are any unclear points or questions concerning the information contained in this manual, please consult the distributor where the equipment was purchased or your Ishida customer service representative before proceeding.
•
Locations of the warning labels
•
Precautions to be observed
•
Types and definitions of the warning indications
To maintain the security of personnel and familiarize with hazardous areas of the equipment
•
Owner of the equipment
•
All personnel involved in operations with the equipment
1-1
1 SAFETY
1.2
CCW-R-2** INSTRUCTION MANUAL
Warning Indications -Types and Definitions
The warning indications contained in this manual, as well as the indications on the labels attached to the machine, are ranked into three categories according to the level of hazard involved. Sufficiently understand the meaning of the following warning indications and follow the instructions in this manual. Table 1-1 Warning Indications INDICATION DANGER
WARNING CAUTION
EXPLANATION If this hazard is not avoided, death or serious injury will probably result. This indicates a clear and immediate danger, and extreme caution must be exercised to prevent a mishap. If this hazard is not avoided, there is a possibility of death or injury resulting.
If this hazard is not avoided, there is a possibility that light or moderate injury may result. It may also indicate that a possibility of damage to equipment exists.
1-2
CCW-R-2** INSTRUCTION MANUAL
1.3
1 SAFETY
General Precautions to be Observed
This section describes the general safety precautions which must be observed when handling the equipment. DANGER
When opening the main body cover to perform work, do not touch the electrical components. There is a danger of electrical shock. All electrical work for the installation site must be performed by licensed electrical contractors. All maintenance and inspection work involving electrical components must be performed by qualified maintenance personnel. Electrical shock or equipment malfunction may result if unqualified personnel are permitted to perform maintenance or inspection of electrical components.
WARNING
Never touch any electrical switches or buttons with wet or damp hands. Electrical shock may occur when the equipment is not properly grounded or when there is electrical leakage. Do not operate the equipment with the cover of each part removed. Before starting operation of the equipment, make sure that all covers are securely shut and fastened. Do not touch any moving parts during operation. Failure to observe this warning may cause personal injury. Personnel with long hair using this equipment should tie up their hair securely and all personnel must wear a cap or hat as well as clothes and shoes suitable for the production environment. Unbound long hair or inappropriate clothing may become caught in moving parts, and injuries may result. Before performing any maintenance or inspection work on the equipment, especially work which is not specifically indicated in this manual, shut off and lock the main power switch. The person performing the maintenance should keep the key in his possession while performing the work. Injury or electrical shock may result if the equipment is turned on by other person while maintenance, etc. work is being performed. Turn off the main power switch then wait at least 3 minutes before performing any maintenance or inspection work on the equipment. Residual charge may remain in the machine even after the power has been turned off. Also, turn off the power of any upstream/downstream units which are connected or adjacent to the equipment, otherwise there is a danger of electrical shock.
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1 SAFETY
CCW-R-2** INSTRUCTION MANUAL
If maintenance or inspection work is to be performed with the main power switch ON, clearly indicate this situation by posting a sign in the work area. This is to prevent other personnel from accidentally starting up the equipment.
CAUTION
Do not press the operation panel of the remote control unit using a ball-point pen or other pointed object. Using a pointed object can damage the operation panel. Use finger to press the operation panel of the remote control unit. When performing maintenance and inspection work on the upper part of the equipment, use a sturdy ladder or foothold to avoid a hazardous fall. When starting production, make sure that there is no object such as a tool on the machine. If objects fall into moving parts, damage to the equipment may result.
1-4
CCW-R-2** INSTRUCTION MANUAL
1.4
1 SAFETY
Special Safety Precautions
This section describes special safety precautions for this equipment which, in addition to the previously mentioned precautions, should be carefully observed. WARNING
Before cleaning the equipment, shut off and lock the main power switch. The person performing the cleaning should keep the key in his/her possession while cleaning. Electrical shock or injury may result if the equipment is turned on by other person.
CAUTION
Do not use the same power supply for devices which may emit noise. Doing so may result in malfunction or damage. Do not apply insecticide or other foreign substances inside the main body, terminal boxes, motor boxes or other enclosed equipment compartments. Doing so may cause machine malfunction or damage. Do not apply excessive load to the weigh hoppers. Doing so may damage the weigh mechanism. Do not install wiring which permits load-related power fluctuations of more than ±10%. Overload may result in malfunction or damage. Weighing fresh meat or cut vegetables with this equipment under improper conditions may result in hygienic hazards. Perform cleaning under the proper procedures according to product conditions and weighing methods. Read through and understand Chapter 9 before performing cleaning.
1-5
1 SAFETY
1.5
CCW-R-2** INSTRUCTION MANUAL
Warning Labels
Warning labels which indicate points requiring particular caution are attached to the equipment at certain locations. Please take sufficient time to familiarize yourself thoroughly with the meanings and positions of these labels.
1.5.1
Warning Label Handling
First verify that all the warning labels are clearly legible. If the label text or graphic is difficult to read, clean or replace the label. Clean labels with a cloth, water, and neutral detergent. Do not use organic solvents or gasoline. Labels must be replaced if they are damaged, peeled, or illegible. Consult the distributor where the equipment was purchased or your Ishida customer service representative specifying the model number and machine number.
1.5.2
Warning Label Location
The diagram below shows the location of warning labels. (See Fig. 1-1 .)
Fig. 1-1 Warning Label Location
Table 1-2 Warning Label Location No.
Location
Type of hazard
1
Attached to the rear of the equipment
Electrical shock
2
Attached to the side of the equipment
Electrical shock
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CCW-R-2** INSTRUCTION MANUAL
1.6
1 SAFETY
Drive Power Shutdown and Indication WARNING
•
Before performing maintenance or inspection, electrical power should be shutdown to ensure the safety of personnel.
To prevent other personnel from starting operation while this work is being performed, the followings should be recommended. •The main power switch should be shut off and locked. •A tag clearly indicating that maintenance work is in progress should be prepared and posted on the power shutdown device. Lock the main power switch and attach the accident prevention tag as shown below.
•
NOTE The lock and tag should be prepared by the user.
Accident Prevention Tag (Example) FRONT
BACK
DO NOT OPERATE
DO NOT REMOVE THIS TAG!
Signed by: Date:
Fig. 1-2 Main Power Switch
Table 1-3 Main Power Switch No.
Name
1
Main power switch
2
Lock
3
Accident prevention tag
1-7
SEE OTHER SIDE
1 SAFETY
CCW-R-2** INSTRUCTION MANUAL
1-8
2 INTRODUCTION 2.1
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2
Intended Use of the Weigher . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.1 2.3.2 2.3.3
Standard Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Outline Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Installation Location and Environment . . . . . . . . . . . . . . . . . . . . 2-3
2.4
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5
Main Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6
Operation Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
CCW-R-2** INSTRUCTION MANUAL
2
2 INTRODUCTION
INTRODUCTION
2.1
Summary
This chapter describes the special terminology used in this manual, conditions of the heads, main components, and operation outline. This manual assumes that the weigher is installed with the software of the following program No.: •
RCU-MAIN : PROGRAM No. R6129
•
Intended use, features, and specifications of the weigher
•
Special terminology used in this manual
•
Main components and operation outline of the weigher
To understand the basic configuration, operation outline, intended use, and scope and limit of applications of the weigher
•
All personnel involved in operations with the weigher
2-1
2 INTRODUCTION
2.2
CCW-R-2** INSTRUCTION MANUAL
Intended Use of the Weigher
This weigher is used to weigh the products to the set value by the computer that controls combination calculation. This weigher is used to weigh a wide range of products such as snack foods, candies, or machine parts. *1 *1 The weighed material should be limited to those permitted by Ishida Co., Ltd. for the design of the weigher.
2-2
CCW-R-2** INSTRUCTION MANUAL
2.3
2 INTRODUCTION
Specification
In this section, the specifications of the weigher are described. Please read and understand this section thoroughly to use the weigher properly.
2.3.1
Standard Specification
Please verify the specifications for your weigher with the separately submitted specifications. Also, the standard specifications of this weigher can be verified with the product catalogues.
2.3.2
Outline Dimension
Please verify the outline dimension for your weigher with the separately submitted drawing. Designs and dimensions may be changed without prior notice.
2.3.3
Installation Location and Environment
The weigher should be operated under the following environments for using its function effectively and maintaining its precision as well as for performing the weighing operation safely. •
Indoors
•
Ambient temperature range: 0 to 40° C
•
Ambient humidity range: 35 to 85% (No condensation)
•
Installed on a hard horizontal surface with minimum vibration
•
Sufficient area around the weigher to perform maintenance
•
No electrical interference from such devices as a wireless transmitter
2-3
2 INTRODUCTION
2.4
CCW-R-2** INSTRUCTION MANUAL
Terminology
Some of the special terms used in this manual are explained below. Table 2-1 Terminology Term
Definition
Product
The food, etc., material which is being weighed
Infeeder
The upstream unit which feeds product to the weigher
Packer
The downstream unit which packages product
Section
The address of the separated head when selecting the participating machines
Span
After zero adjustment is executed, a standard "span" weight is memorized as a reference weight.
Drain
Weighing is not performed while all product is discharged from the weigher.
Head
Appellation for the radial troughs, pool hoppers, weigh hoppers, and weigh/drive unit
Interlock signal (IS)
Discharge request signal output from the packer to the weigher
Overweight
Product weight exceeds the upper limit.
Underweight
Product weight is below the lower limit.
Proper weight
Product weight is within the permissible range.
Discharge completion signal (DS)
Signal output from the weigher to an external unit to indicate that the product has been discharged.
Overscale
The state that the product exceeding the (set value + upper limit) weigh is supplied to the weigh hopper, or the weigh in the weigh hopper exceeds the head weigh
Stagger delay (STAGGER)
The time interval between successive discharges when product is discharged in separate sets to prevent product jam at the packer
Slave
Interlock mode in which the weigher discharge is initiated by one-shot signal from the packer
Master
Interlock mode in which the weigher discharge is initiated by continuous signals from the packer
Stroke-on-demand
Interlock mode in which the weigher and the packer exchange confirmation signals before discharge
Bag-on-demand
Interlock mode in which self-run calculation discharge is performed after a signal is received from the packer. The discharge completion signal is then sent to the packer.
AFV
Abbreviation for "Anti Floor Vibration mechanism." In an environment with floor vibration, the AFV cell detects vibration and offsets its influence on output of the load cell.
Range
The maximum weight to be weighed
Auto zero adjustment
During production, the weigh hoppers which are not used frequently for combination calculation are selected and adjusted automatically so that the weight reads zero.
Presetting
Data related to weighing is set in advance.
Combination calculation
Several weigh hoppers are selected so that their total weight is the closest to the target weight and discharge products from the selected hoppers.
Full-scale
Overloaded state of the weigh sensor due to an external factor
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CCW-R-2** INSTRUCTION MANUAL
2 INTRODUCTION
Table 2-1 Terminology (Continued) Term Multi dump
Definition In the case that the target weight exceeds the range, or the products overflow from the weigh hoppers to attain the target weight in one weighing, the target weight is attained by multiple weighing.
2-5
2 INTRODUCTION
2.5
CCW-R-2** INSTRUCTION MANUAL
Main Components
This section describes the main components and the functions. 1
2
3 4 5 6
7
13
8
15
9 14
10
11
12
Fig. 2-1 External View
Table 2-2 Unit Descriptions No.
Name
Functional description
1
Inlet chute (Optional)
Product inlet The funnel-shaped inlet chute guides product fed from the infeed equipment onto the center of the dispersion table.
2
Dispersion table
The dispersion table receives the vibration from the dispersion feeder and conveys product from the inlet chute to the radial troughs.
3
Dispersion feeder (DF)
A circular disk which vibrates to convey product onto the radial feeders. Product flow amount is controlled by means of the weigh sensor which measures the amount of product on the dispersion table.
4
Radial trough
The radial troughs receive vibration from the radial feeders and convey product to the pool hoppers.
5
Radial feeder (RF)
The radial feeder vibrates to move product across the radial troughs.
6
Pool hopper (PH)
Each pool hopper receives product fed from the radial troughs above it and holds it temporarily in synchronization with product weighing. The pool hoppers open or close according to the weighing operation to feed product into the weigh hoppers.
7
Weigh hopper (WH)
The weigh hoppers measure the weight of the infed products. These hoppers open or close according to the combination calculation result, and feed products to the collection chute or the booster hopper.
8
Weigh/drive unit (WDU)
The weigh/drive unit powers the open/close action of the pool, weigh, and booster hoppers. It also measures the weight of product in the weigh hoppers.
9
Collection chute
The collection chutes collect products rejected by the weigh hopper or the booster hopper, and convey them to the discharge chute.
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CCW-R-2** INSTRUCTION MANUAL
2 INTRODUCTION
Table 2-2 Unit Descriptions (Continued) No.
Name
Functional description
10
Discharge chute
The discharge chute collects product discharged from the collection chute and guide the product down into the timing hopper or the packer.
11
Timing hopper (TH) (Optional)
The timing hopper temporally pools the product from the weigh hoppers and controls the timing of discharge to the packer.
12
Timing hopper drive unit (Optional)
The timing hopper drive unit powers the open/close action of the timing hopper.
13
Remote control unit (RCU)
The remote control unit contains the touch screen used to operate and monitor the weigher.
14
Printer
Prints out setting data, weighing results, and statistical data.
15
Main power switch
Turns on and off the power to the weigher.
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2 INTRODUCTION
2.6
CCW-R-2** INSTRUCTION MANUAL
Operation Outline
This section describes the operation flow from the time the product is received from the infeed equipment to the time it is weighed, combination calculated, and discharged from the timing hopper.
Outline of the Product Flow and Combination Calculation. 1
2
3
4
5
6
7 8
Fig. 2-2 Operation Outline
1. Product is supplied to the inlet chute from the upstream infeed equipment. 2. Product is conveyed from the inlet chute to the dispersion table, and the dispersion table vibrates to convey product onto the radial troughs. 3. The radial troughs vibrate to convey product onto the pool hoppers. 4. The pool hoppers discharge product to the weigh hoppers as required. 5. Product is weighed in the weigh hoppers. 6. Select the weigh hoppers so that the weight is the closest to and not below the target weight. Then product is discharged from the selected hoppers. 7. Product is collected in the collection chute and discharged from the discharge chute. 8. If an optional timing hopper is installed, the timing hopper opens and product is drained on the drain request form the packer.
2-8
3 REMOTE CONTROL UNIT 3.1
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2
Components and Functions of the Remote Control Unit (RCU) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3
Operation Panel and Data Entry . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.1 Operation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3.2 Data Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.3.2.1 Entering Numeric Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.3.2.2 Entering English Alphabet Data, Numeral Data, and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.3.3 Correction after Data Entry and Setting . . . . . . . . . . . . . . . . . . . 3-9
CCW-R-2** INSTRUCTION MANUAL
3
3 REMOTE CONTROL UNIT
REMOTE CONTROL UNIT
3.1
Summary
This chapter describes the terminology and functions of the remote control unit and the operation outline and the displayed contents that are necessary for the operation. WARNING
•
Be sure to read this chapter carefully before attempting operation.
NOTE • Refer to "4 PRODUCTION" for the details on production method.
< Contents > •
Meanings of the indications displayed on the operation panel of the remote control unit
•
Description of the common operations of the remote control unit
< Intention > To understand and master the basic and common operation procedures of the remote control unit
< Intended reader > •
All personnel involved in operations with the weigher
3-1
3 REMOTE CONTROL UNIT
3.2
CCW-R-2** INSTRUCTION MANUAL
Components and Functions of the Remote Control Unit (RCU)
This chapter describes the components and functions of the remote control unit (RCU) using the figure below.
1 3
4
2
Fig. 3-1 Remote Control Unit
Table 3-1 Functional Description of the Remote Control Unit No.
Name
Functional description
1
Operation panel
Used to input settings and display data.
2
Printer
Used to print out statistical data, product settings, etc.
3
Main power switch
Used to turn ON and OFF the power supplied to the unit.
4
Camera
Used to take photos.
3-2
CCW-R-2** INSTRUCTION MANUAL
3.3
3 REMOTE CONTROL UNIT
Operation Panel and Data Entry
Enter data such as numerals, letters, and symbols on the operation panel. Enter data by displaying each setting menu whenever necessary.
3.3.1
Operation Panel
Fig. 3-2 Operation Panel
Table 3-2 Functions of the Operation Panel No.
Name
Function
1
Upper set key
It is always displayed at the top of the menu. Used to set the operating environment for the operation panel.
2
Menu key
The keys on the screen are box shaped to create a three-dimensional effect. Pressing these box portions will switch the screens and operate the weigher.
3
Status display
The box for set value indication is also displayed with a plane view. The current operating status and error content are displayed in this part.
NOTE • The above figure is an example. Menu keys and display area differ depending on each menu and operation level.
3-3
3 REMOTE CONTROL UNIT
CCW-R-2** INSTRUCTION MANUAL
