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CHAPTER - 6

SYSTEM DOCUMENTATION

USER'S MANUAL
WEIGHING & BAGGING MACHINE

Contents G.A. Drawings ......................................................................................................................................... 2 System Description .................................................................................................................................. 3 Operation ................................................................................................................................................. 4 System Specifications ............................................................................................................................. 7 Erection & Installation .............................................................................................................................. 8 Termination Details .................................................................................................................................. 9 Key Operations ...................................................................................................................................... 10 Settings & Calibration ............................................................................................................................ 11 Site Installation Details .......................................................................................................................... 14 Notes ..................................................................................................................................................... 15

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G.A. Drawings

Weighing & Bagging Machine

Weight Controller & Feed Controller Panels


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System Description PRINCIPLE OF OPERATION A typical weighing and bagging system comprises of the following items 1. Load cells 2. Belt Conveyor 3. Motor 4. Clamps 5. Damper 6. Feed Controller 7. Weight Controller

A bag is held between the clamps and the clamping shell. The shell is suspended from two load cells. When the material falls in the bag, the load is sensed by the load cells and the output in mV is fed to the Weight Controller. Thus the weight of material is directly displayed on the Weight Controller display.

The required filling quantity, as well as the values for coarse and dribble feed can be set in the Weight Controller and Feed Controller. There are three filling modes a) Coarse feeding, for time T1, b) Dribble feeding, till set point 1, and, c) Fine feeding, till set point 2.

A user settable de-clamp delay is also provided (time T2) so that enough time is allowed for the in-flight material to fall in the bag. With the incorporation of strain gauge type industrial load cells having superior technical parameters with international standards and high precision industrial grade electronic components, high reliability and linearity is achieved to operate under any hostile environmental conditions.

MAIN FEATURES Simple installation Load cells with standardised output making replacement easy without change in calibration Excellent mechanical design with high side load immunity Microcontroller based design, ensuring highest reliability Software calibration through key pad operation Status indication by LED annunciators Easy servicing due to modular concept Weatherproof housings and cable glands for any type of environment
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Operation

a) Feed Controller Settings In the feed controller, the following settings are done 1. Timer T1 2. Timer T2 3. Timer T3 : : : Coarse feed time De-clamp delay time Auto interval time

Both the above times are set directly on the dials of the two timers in the feed controller.

b) Weight Controller Settings 1. Set Point 1 2. Set Point 2 : :

In the weight controller, the following settings are done -

Dribble feed weight (SP1) Fine feed weight (SP2)

3. Time Constant : 4. Digital Filter :

Set point 2 delay time

Weighing sampling rate

The above settings are done on the weight controller as per the following steps -

On the weight controller, press <F> key and then switch power on. Keep <F> key pressed till the display shows `SEt. Release the <F> key. The LED `SP1 will be flashing and the display will show some value with the leftmost digit flashing. The required value of Set Point 1 can be fed in this mode. Pressing the up and down arrow keys (T & G keys) will increase or decrease the value of the flashing digit. Pressing right arrow key (Z key) will move the cursor, to the right. That is, the digit flashing earlier will be set at the last value and the next digit to the right is available for changing. On reaching the fifth digit (rightmost digit), pressing <Z> will return the cursor to the leftmost digit again. Press <F> to store the value of the 1st Set Point.

The LED `SP2 will start flashing and the display will show some value with the leftmost digit flashing. The required value of Set Point 2 can be fed in this mode, in the same way as described above. Press <F> to store the value of the 2 Set Point.
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The LED `SP1 will be on and LED `SP2 will now be flashing, and the display will show some value with the leftmost digit flashing. A time constant can be fed in this mode, in the same way as described above. This time is a period after Set Point 1 for which time Set Point will not be activated, irrespective of the actual value (even if the actual value is equal to or more than Set Point 2). This facility is useful in high impact applications such as bagging machines where the weight value is momentarily higher than the actual weight on the load cells, due to impact. The time constant is denoted in counts. 1 count = 50 ms. Thus, if a delay of 2 seconds is desired, set the time constant to 40. Press <F> to store the value of the time constant.
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Both the LEDs `SP1 & `SP2' will be off, and the display will show `Ftr' and some value. This is the value of the digital filter, which can be changed between 1, 2, 4 & 8 by repeatedly pressing <T>. The digital filter, i.e. internal sampling rate, increases from 1 to 8. Select the value 4 for bagging machine and press <F> to store the value of the digital filter. The weight controller set-up is over and the display will revert back to weight display.

c) Combined settings

The actual sequence in which the above settings come into operation in a

bagging cycle is as follows (i) (ii) (iii) (iv) (v) (vi) Timer T1 Set Point 1 : : Coarse feed time Dribble feed weight (SP1) Set point 2 delay time Fine feed weight (SP2)

Time Constant : Set Point 2 Timer T2 Timer T3 : : :

De-clamp delay time Auto interval time

Regarding the settings of above values, it is best to keep the values lower than expected during the first time settings. Starting with the value of SP2, keep this value so that the desired accuracy is achieved, for a given combination of material and machine.

Then set the values of SP1 and the Time Constant so that the fine feed time is smallest, but without upsetting the cycle.

Then set the value of timer T1 so that the coarse feed time is fastest, but ensuring that the coarse feeding stops well in advance of SP1.

d) Bagging machine operation A bag is held between the clamps and the clamping shell, and the Start switch is pressed. The bag is clamped to the shell, and the motor starts the belt conveyor at full speed. This coarse feeding takes place for time T1 and then the motor speed reduces to a smaller preset value. This dribble feeding takes place till the weight reaches set point 1 (SP1). At this point, the damper is operated to reduce the opening on the belt and produce fine feed. This fine feeding takes place till the weight reaches set point 2 (SP2). At this point the motor, and the feeding, is stopped. The bag is de-clamped after a delay of T2 seconds, to allow the in-flight material to fall in the bag.

Some of the important points to be noted are 1. Start the settings in the reverse direction, as follows a) First set the Set Point 2, to ensure perfect accuracy and repeatability, considering the damper
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gap, and in flight material; b) Then set the Set Point 1 and time constant, ensuring that there is sufficient time delay between the operation of the two set points (ensure that the both the set points do not operate simultaneously); c) Then finally set the Timer T1 so that the fastest cycle time is obtained, but at the same time, ensuring that the Set Point 1 does not operate before timer T1 is complete.

2. Maintain the damper gap small enough to get best accuracy. Generally, a gap of 5 mm should be

maintained.

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System Specifications

1. 2. 3. 4. 5. 6. 7.

Load Cell No. of load cells Belt Drive Feed Controller Weight Controller Operating temperature (in C) System Accuracy

S-type 2 nos. 1 HP, AC Motor, 230 VAC, 3, 50 Hz 230 VAC, 1, 1 HP, Weatherproof housing 230 VAC, 1, 1 HP, 2 set point outputs, Weatherproof housing 1050 C 0.2 %

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Erection & Installation First check the following items at site 1. Availability of all items to be fitted to the storage silo such as gate, rubber pads, etc. 2. Availability of standard weight for calibration typically, 10 & 15 kg. 3. Availability of foundation bolts, non-shrink grouting material, etc. 4. Correctness of vertical clearances between bottom of silo and ground level as per drawing. 5. Availability of other erection tools such as water level, spirit level, measuring tape, welding machine, spanners/allen keys of required sizes, etc. 6. Availability of compressor & compressed air line at the bagging machine location. 7. Availability of 230 VAC mains supply through a 5 A /3 pin socket at the bagging machine location.

Once all the required items are available, proceed with the erection & installation as follows

a) Mechanical Erection Grout the foundation bolts into the foundation pockets with the non-shrink grouting material. Fix the machine in place and connect the pneumatic lines properly. Check operation of all pneumatic cylinders (clamp cylinders and damper cylinder) by pressing the solenoid valve knobs.

Fix the load cells and clamping shell in place (noting the serial numbers of load cells), ensuring that the load cells are perfectly in same level, with respect to gravity. Fix both the panels to the frame at the rear end of the conveyor. Route the load cell, solenoid, switches and motor cables through the conduit pipes and terminate their ends in the respective panels, as mentioned on the termination diagrams inside the panels. Charge the power supply to the Weight Controller Panel through the CVT.

b) Electrical Installation Ensure the following before putting on the power supply 1. 230 VAC +10% mains supply (to Weight Controller Panel through CVT, and to Feed Controller Panel directly), with proper earthing (Max. 3 V potential difference between neutral & earth); 2. Continuity between all earthing points from supply earth to indicator to junction box to load cells; 3. Connection of load cell, solenoid, switches and motor cables to panels as per termination diagrams.

Switch on the power supply and check that both instruments (Weight Controller and Variable Frequency Drive) switch on. Now press start switch to start the motor and check that it rotates in the correct forward direction. If not, reverse one phase of the motor and ensure correct rotation.

Check the individual mV outputs of the load cells. Both the load cells should give same mV outputs under dead load of clamp shell. If there is a difference, then the levels of load cells are not perfect. Correct the levels and then proceed with calibration.

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Termination Details

a) Feed Controller

Terminal No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 31 32 33 34 35 36 37 b) Weight Controller

Connection 230 VAC Live (I/P) 230 VAC Neutral (I/P) Mains Earth Motor R Motor Y Motor B Start Switch Start Switch Abort Switch Abort Switch Clamp Solenoid Clamp Solenoid Damper Solenoid Damper Solenoid Photo Sensor Supply Photo Sensor Common Photo Sensor Output SP1 / Coil 1 SP1 & SP2 / Coil 2 SP2 / Coil 1 Run Signal to PLC Run Signal to PLC Bag Counter to PLC Bag Counter to PLC

Terminal No. 1 2 3 4 5 6 7 8 9 10 11 12 16 17 18 31 32

Connection 230 VAC Live (I/P) 230 VAC Neutral (I/P) Mains Earth Load Cell Supply +ve Load Cell Sense +ve Load Cell Supply -ve Load Cell Sense -ve Load Cell Output +ve Load Cell Output ve Load Cell Shield 4 20 mA (+) 4 20 mA (-) SP1 / Coil 1 SP1 & SP2 / Coil 2 SP2 / Coil 1 External Input External Input
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Key Operations MOTOR CONTROL PANEL Keys <Select> <Enter> <> & <> <Start> <Stop> Frequency Potmeter Reverse Escape Controls Timer T1 Timer T2 Timer T3 Action Goes into programming mode Stores the entered data Up & down keys, to change parameter settings, to scroll through different operating parameters. No effect No effect Not used Not Used Exit from program mode. Action Sets coarse feed time Sets de-clamp delay time Sets auto interval time

WEIGH FEEDER CONTROLLER Keys Display <Func> <Tare/> <Zero/> <Net Gross/ > LEDs SP1 SP2 Tare Gross Action Shows actual weight in kg For set point selection For increasing a value For making display zero in weight mode, and for shifting the cursor right in menu For increasing a value Explanation Lights up when weight reaches Set Point 1 Lights up when weight reaches Set Point 2 Not used Not used

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Settings & Calibration VARIABLE FREQUENCY DRIVE SETTINGS given below. 1. P101 : Press <Enter> to display the value set previously. Press <> & < > arrow keys to set the The parameters required to be set in the VFD are

value to `230. This sets the rated voltage of the motor. Then press <Enter> to store the new value. 2. P102 : Set this value to 60.This sets the motor rated frequency. Repeat above steps to set

values for other parameters given below. 3. P103 4. P104 5. P105 6. P106 7. P107 8. P108 9. P110 10. t201 11. t202 12. t221 13. A410 14. A411 : Set to `1.8. This sets the motor full load current. : : : : : : : : : : : Set to `0. This sets the minimum frequency. Set to `60'. This sets the maximum frequency. Set to `3'. This sets the start source. Set to `1'. This sets the stop mode (coast). Set to `4'. This sets the speed reference (preset frequency). Set to 1. This sets the deceleration time. Set to 4. This sets the preset frequency mode for digital input1. Set to 4. This sets the preset frequency mode for digital input2 Set to 2. This sets the relay output of the VFD for run feedback. Set to 60.This sets the coarse frequency. Set to 20.This sets the fine frequency.

WEIGHT CONTROLLER SETTINGS & CALIBRATION After making the connections, when the power is switched on, the display shows `88888 then `123d0 and then `0. Instrument operation is to be started only after `0 is displayed.

A) INSTRUMENT SET-UP Various settings required for the instrument are done as follows 1) Full scale & resolution selection - Press <G> key and then switch power on. The instrument goes into initial settings mode, and display shows the default range-resolution combination of `nn-e, such as `10-1, which indicates nnx10 counts full scale and e counts resolution. For instance, `05-1 indicates 05x103=5,000 counts full scale and 1 count resolution. If the instrument has already being set for some range-resolution combination earlier, the last selected combination is displayed. Some commonly required combinations are pre-programmed in the memory. Pressing <T> (up arrow key) repeatedly will scroll through all the available combinations. Press <Z> to select the desired combination.
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2) Calibration

- Ensure that there is nothing on the load cells (except the dead weight). Switch

power on. After the power on sequence is over and display shows `0', press <Z> key for more than 5 seconds, till the instrument goes into calibration mode, by displaying `Pwrd? Release the
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<Z> key. The display will show `00000' with the leftmost digit flashing. Pressing <T> and <G> (up and down arrow keys) will increase or decrease the value of the flashing digit. Pressing <Z> (right arrow key) will move the cursor, to the right. That is, the digit flashing earlier will be set at the last value and the next digit to the right is available for changing. On reaching the fifth digit (rightmost digit), pressing <Z> will return the cursor to the leftmost digit again. Enter the password `07968' this way and press <F> to enter calibration mode.

If a wrong password is entered, the instrument will revert back to weighing mode. If the correct password is entered, the dead weight is zeroed automatically, and the display shows `Putwt'. At this point, pressing <T> and <G> together will show the ADC count on the display. Disregard the decimal point when reading the ADC counts. Note down the ADC count for zero (dead) weight. Put any known weight on the load cells and once again check the ADC count for that weight. The ADC count at full-scale load should NOT exceed 40,000. Extrapolate the ADC counts at dead weight & known weight to calculate the ADC count at full scale. If the ADC counts are either higher or lower, adjust the same by turning preset R36.

If the preset R36 is turned in any direction, the same will have effect only after the instrument is reset. Reset the instrument by putting it off and then on.

If the display shows exactly 20,000 counts (with Connector J13 shorted) or 40,000 counts (with Connector J12 shorted) , then it signifies that the load cell is not connected. If the display shows 65,535 counts, then it signifies that the load cell outputs are reverse connected. In both these cases, turning R36 will NOT have any effect on the display counts!

If the instrument is to be used in both directions (positive and negative) equally, with cyclic loads, on main board, connector J13 is shorted instead of J12. In this case, the ADC counts at full scale should NOT exceed 20,000.

After putting a known weight on the load cells, press <F>. Display will show `00000' with the leftmost digit flashing. Enter the value of known weight using <T>, <G> and <Z> (up, down and right shift keys). Press <F> to store the calibration weight. The instrument comes out of calibration mode and returns back to weigh mode. The display shows the actual weight, which will be the calibration weight that is still on the load cells. Remove the weight from the load cells and check that the display shows `0 at zero load. If not, press <Z> once to zero the display.

Calibrate the system once again for fine-tuning, if there is a big difference the actual weight and display readings. Use a calibration weight of minimum 10% of full scale and maximum 90% of full scale. Using a calibration weight between 50% and 75% of full scale will give the best results.
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3) Additional Settings - Set point, Digital Filter etc - Press <G> & <F> together. The display shows `SEt. Release the keys. The instrument goes into additional settings mode. All the following settings are done one after the other, as given below a) Set Point 1 (*) - On releasing <G> & <F> keys, the LED `SP1 will be flashing and the display will show some value with the leftmost digit flashing. Enter the required value of Set Point 1 using <T>, <G> and <Z> (up, down and right shift keys). Press <F> to store the value of the 1st Set Point. b) Set Point 2 (*) - On pressing <F> to store the value of Set Point 1, the LED `SP2 will be flashing and the display will show some value with the leftmost digit flashing. Enter the required value of Set Point 2 in the same way as described above. Press <F> to store the value of the 2 Set Point. c) Time Delay between set points (*) - On pressing <F> to store the value of Set Point 2, the LED `SP1 will be on and LED `SP2 will be flashing, and the display will show some value with the leftmost digit flashing. A time constant can be fed in this mode, in the same way as described above. This time is a period after Set Point 1 for which time Set Point 2 will not be activated, irrespective of the actual load on the load cells (even if the actual load is equal to or more than Set Point 2). This facility is useful in high impact or vibration applications such as filling machines, vessels with agitators, etc. where the weight value is momentarily higher than the actual weight on the load cells, due to impact or vibrations. The time constant is denoted in counts, where 1 count = 50 ms. Thus, if a delay of 2 seconds is desired, set the time constant to 40. The decimal point is to be disregarded. Thus the actual figures will be 00040. Press <F> to store the value of the time constant. d) Digital Filter (*) - On pressing <F> to store the value of Time Delay between set points,
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the display shows `Ftr 1' where the rightmost digit, i.e. `1' is flashing. 1 is the level of digital filter. Pressing <T> repeatedly will scroll this value between 1, 2, 4, 8 and again 1. Thus, four levels of filter can be applied. The values 1, 2, 4 & 8 denote the no. of counts that will be averaged (filtered). Press <F> to store the displayed digital filter value. e) Baud rate (*) - On pressing <F> to store the value of instrument ID number, the display

shows `b1200 where `1200 is flashing. 1200 bps is the communication baud rate (for RS232C or RS485). Pressing <T> repeatedly will scroll this value between 1200, 2400, 4800, 9600 and again 1200. Thus, one of the four baud rates can be selected. Press <F> to store the displayed rate.

The instrument comes out of set mode and returns to weigh mode. Now, whenever the weight on load cells crosses the set values, the corresponding LEDs will light up and two 12 VDC/60 mA (max) signals are available at Connector J7 to operate any field equipment such as relay, contactor, etc.
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Site Installation Details Record the various equipment serial numbers here for future reference Weighing & Bagging M/c Sr. No. Load Cells Capacity & Sr. Nos. kg 2 nos. Geared Motor RPM & Sr. No. rpm Motor Control Panel Sr. No. Weigh Feeder Controller Sr. No.

Record the various equipment data here for future reference Parameter Timer T1 Set Point 1 Set Point 2 Time Constant Digital Filter Timer T2 Cal. Weight VFD High Freguency 9. VFD Low Frequency 10. Timer T3 1. 2. 3. 4. 5. 6. 7. 8. Cal. 1 Cal. 2 Cal. 3 Cal. 4 Cal. 5 Cal. 6

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Notes

Service Manual - Weighing & Bagging Machine

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