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CMW 8000 USER MANUAL - Cotswold Mechanical Handling

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2. 24 SETTLED WEIGHTS SCREEN 25 STATISTICS SCREENS 26 MENU 27 PRODUCT LIBRARY 2 8 STATIC CALIBRATION 29 MANUAL ZERO 2 10 EMPTY MACHINE 211 DIAGNOSTICS eerte 3 PRODUCT PARAMETERS 3 1 PRODUCT WEIGHTS 3 1 1 FEED BY WEIGHT e ne 3 1 2 FEED BY COUNT 32 PRODUCT OPTIONS 1 COTSWOLD MECHANICAL LTD CONTENTS 22 Za Sub 4 MACHINE i i 41 INPUT CONFIGURATION i 4 2 OUTPUT CONFIGURATION ie 43 WEIGHING i 4 3 1 WEIGHING UNITS 4 3 2 4 3 3 WEIGHING OPTIONS 4 3 4 WEIGHING 4 3 5 WEIGHING VIBRATOR FACTORS 44 SHIFT BATCH CONFIGURATION i iii 45 SERIAL COMMUNICATIONS SETUP 46 SETUP TIME 4 7 MAGRINE CONFIGURATION 4 7 1 MACHINE SINGLE TWIN 4 7 2 MACHINE VIBRATOR CONFIGURATION 4 7 3 MACHINE DISCHARGE CONFIGURATION 4 7 4 MA
3. 91 INOHI HOLVUSIA GI d O El ZI MINA LI 01 11320 01 6 jHVdS 8 1 2 LNOY4 1 9 0 S 30A YOLIANNOI AVM 9 SYOLOSNNOO AVM 9L H LIM TONLNOO OTSWOLD MECHANICAL LTD 012 3002 Main I O Board n 5 00000 41 zu B dit 6 23 Poot 4250772117 5 t wa 47 ITE 4 7 gt TIT mre M rr 4 1 gt Ia 7 F a SCA BL o ee ee 34 b ZA 2 111 COTSWOLD MECHANICAL LTD PAC 016 160 Power Supply Board 112 COTSWOLD MECHANICAL LTD PAC 008 Four Channel Vibrator Board 3 amp per Channel Option 1 Vibrator Control 113 n x p TA L_ i ON b 1 X 4 al a Cnn Mb adi L CI ER p m Pac 037 Four Channel Vibrator Board 6 amp per Channel Option 2 Vibrator Control 114 COTSWOLD MECHANICAL LTD Pac 031 Two Channel Variable Frequency Vibrator Board 5 amp per Channel Option 3 Vib
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5. Screw Feeder Conveyor to the hopper 1s switched off The hopper probes have adjustable mountings allowing them to be moved in order to obtain a correct product level reading Internally the hopper probes have the following features Normally open amp normally closed relay contacts Light on dark on switching Adjustable sensing range Selectable timing functions timing off on delay off delay on amp off delays selectable timing ranges COTSWOLD MECHANICAL LTD Hopper Probe Assembly optional extra Hopper Probe Timing Range Switch T1 0 02 2s T2 0 2 12s E 1 off 1 sens Output Turn On Adiustment Output Turn Off 5 Adiustment 4 Sensitivity Adiustment Timer Operating Mode amp Light Dark Selector Removal of the Hopper Probe Lid amp adjustment of the Probe should only be carried out by a suitably qualified electrician as up to 240v A C power in some instances can be present Adjusting The Probe Sensitivity 1 Move Timer Operating Mode Selector to position 4 2 Set Probe Stalk to approximately its mid way position within its adjustable mounting This 1s achieved by slackening the M6 lever and raising lowering the stalk amp probe to the desired position It 1s also desirable to adjust the probe to a shallow angle just off the vertical axis This helps to prevent a condition whereby reflected I R energy from the Probe can bo
6. CONFIGURATION 4 7 1 MACHINE SINGLE TWIN 2 Loadcell Digitizer LEL External YibsrEelts Lount Count Sample Mantua La 8 Inputs 16 Inputs Select number of physical inputs fitted to the machine On simple machines this entry cannot be changed 8 Outputs 16 Outputs Select number of physical outputs fitted to the machine On simple machines this entry cannot be changed Number of Weighers Toggle ENTER to select between a single or a twin weigher Count Option Toggle ENTER to ENABLE DISABLE the count option 80 COTSWOLD MECHANICAL LTD 4 7 2 MACHINE VIBRATOR CONFIGURATION Machine Configuration vibrator Configuration a Ne Vibrator Configuration Select the allocation of vibrator channels Select the image to represent the particular layout of the vibrator configuration 81 COTSWOLD MECHANICAL LTD 4 7 3 MACHINE DISCHARGE CONFIGURATION Machine Configuration Discharge Contiqurat Lon Discharge Configuration Select the method of discharge The weighers can be discharged by a common call input where the first weigher which was ready is discharged or each weigher can have an individual call 92 COTSWOLD MECHANICAL LTD 4 7 4 MACHINE USER LANGUAGE achine Configuration o Printer Fitted achine Identity 11 Printer Choose 40 COLUMN 80 COLUMN or NO PRINTER Machine Identity Enter identity name of up to 20 characters Used on printouts to ide
7. Enter test vibrator amplitudes Press to RUN STOP the vibrators 67 COTSWOLD MECHANICAL LTD 5 4 STATIC WEIGHING INFO Static Heighing Info Bits Height Hctual FU 1404 Filtered 1409 T259 Ha 702 1419 AC 4269 2 Shows current state of the loadcell a d output and its conversion into weight Press to reset the Minimum Maximum Variance information 58 COTSWOLD MECHANICAL LTD 5 5 DYNAMIC WEIGHING TRACE Dynamic Heighing Trace Setted Weight Press ENTER to select weigher of interest Press to reset the weighing trace information 99 COTSWOLD MECHANICAL LTD PRODUCT CODE OPTION FOR COUNTING FEED BY COUNT Product Product Huts Hverage Height Mode Item Ht When the Count Option is Enabled See Section 0 4 7 1 MACHINE SINGLE TWIN then the Feed by Count option may be selected within the product setup The entries below apply to Feed by Count Item Weight Weight of single item of the pieces to be counted Target Number of items to be counted as the target Based upon the Item Weight entered above the weigher calculates a target weight based upon this count Overweight Number of items to be rejected as overcount Underweight Number of items to be rejected as undercount End 90 COTSWOLD MECHANICAL LTD VARIABLE FREQUENCY VIBRATOR OPTION The variable frequency vibr
8. It is used to balance the vibrator outputs so that they feed at the same rate for the same amplitude 76 COTSWOLD MECHANICAL LTD SHIFT BATCH CONFIGURATION GhiftrBatcoch Config batch bu WUuant ity Eatch Interval Humber of Shifts End of Shift 1 End of Shift 2 End or Shift 5 IJ No Batch Statistics Batch By Time Batch By Quantity Toggle ENTER to select type of batch statistics required Batch Interval Frequency of batch statistics printout For Batch By Time ENTER For Batch By Quantity ENTER number of drops Number of Shifts Enter the number of shifts required followed by their start times as hours minutes 77 COTSWOLD MECHANICAL LTD SERIAL COMMUNICATIONS SETUP Serial Comms Config amp E24d2255 15 Loadcell 252 15 Printer Baud Fate Bits Parity atop Bits E ser For each of the serial communications channels shown setup the following parameters Baud Rate Press ENTER key until correct baud rate for the device is shown Data Bits Select either 7 or 8 data bits as required by the device Parity ODD EVEN or NONE Stop Bits Select O or 1 78 SETUP TIME DATE Setup Time 7 Date set ime 14 UL cet Date cdd 13 03 01 Setup current time and date The system clock is battery backed and will maintain the correct time even when the machine is switched off COTSWOLD MECHANICAL LTD 4 7 MACHINE
9. SPACER STAINLESS STEEL GASKET M8 SPRING WASHER STAINLESS STEEL M8x30 LG STAINLESS HEX HD BOLT Fig 2 Exploded Assembly V1 VIB SPRING 11 PLY 9PLY OR 7PLY 1 1 Fig 4 Exploded Assembly underside COTSWOLD MECHANICAL LTD Getting Started Setup The V1 Vibrator Unit is generally intended but not exclusively to be used in conjunction with the Cotswold CMW Controls Unit This set of controls is then used to govern the primary functions of the V1 Vibrator Unit such as speed amplitude and run times For further information see CMW Controls Manual Connection of the three core power supply lead from the V1 Vibrator Unit should only be carried out by a suitably qualified electrician Ensure that all power to any equipment being worked on has been switched off and fully isolated Fig 5 CMW Controls Getting Started Vibrator Tuning The V1 Vibrator Unit will have been tuned prior to leaving the factory and should not require adjustment However over a period of time the performance of the Vibratory V2 feed unit may diminish This is usually after a period of eight months or more and is more noticeable on applications requiring high vibration speed and amplitude to move the product Leaving the vibrators running at full load speed when a machine is empty or during a wash down can also exacerbate the condition Tuning is a relatively simple process and basically involves s
10. constantly switch on and off at the slightest change in the level of product within the hopper which the probe detects The Load cell Mechanism 132 Loadcell Cross Ss cI Bar b Loadcell Top Plate Weighpan Hanger Bars Overload Stops The Load cell Mechanism The Weigh pan hangers support the weighpan assembly on the Loadcell weighing mechanism The Load cell is a precision electronic weighing system The Loadcell weighing mechanism has an integral overload protection system this helps to avoid accidental damage due to excessive loading The overload system is factory set but may require future adjustment The overload system will not protect against shock loading therefore the Loadcell unit should be treated with care The Loadcell is a sealed unit no user adjustments are required for the Loadcell Mechanism Model 1250 Aluminum High DESCRIPTION Model 1250 is a single point load cell designed for direct mounting of large platforms The product is a cost effective load cell for use on counting weighing bench or floor scale products This high accuracy load cell is approved to OIML R60 NTEP and other stringent approval standards Suitable for use in hazardous environments these load cells can be provided with European approval to OUTLINE DIMENSIONS in mm Capacity Single Point Load Cell FEATURES e Capacities 50 1500kg e Aluminum con
11. e 5 99 RN12 o A N 9 4 m E 9 9 deste IP3 LED29 24V INPUT orange 8 DI XTI 000 3 ov 9 3 07 n mon LK14 LK16 LK17 amp LK18 Ax pid rel OV INPUT 1141 SY pad 2028 24V MACHINE orange LT DS B C 24V INPUT RIS RIS T 2 o LES E ue T E m 2848 N C 164 0 N LED26 12V MACHINE 00 g E953 E orange LED24 45V DIGITAL orange Z 2 VN TO es ae AL C6 REGI 2 20 L a i CON20 X oo x 44 00 dm gt 2 Hur 2e LED25 5V MACHINE orange 2 ayl 0 C47 i Y Lal LCD CONTRAST de gt lle oe BI n sese es 00 ic LEN o _ 5 00 00 00 T x 9 i X 9 U ae 52 50 2 op L IC12 t mo b ms n 00 n 00 R3 84 16 lt 2 0 Lo H N x SW2 DEMONSTRATION MODE Rage c6 4 NA o 4 i SW5 MANUFACTURER SECURITY 8 AL 1 o Loa SW4 5 E of 2 9 R75 3 5000 2 LK6 000 Bids O LK10 R34 CONIZ s CON23 BODIES 1024 R3BR44 SI ROO m7 02 x b 2 R32 R52 i 22 ic27 es Dj es gli LED1 amp 2 green SOFTWA
12. keys to select the physical input COTSWOLD MECHANICAL LTD 4 2 OUTPUT CONFIGURATION Configuration Bulk Door Fine Door ghpan Ready Fine Door Bulk Door qhpan This screen allows each digital logical output to be assigned to a physical output Use the ENTER key to select the logical output and the UP DOWN ARROW keys to select the physical output Inwerslohns Lane Lane Lane Lane Lane Lane Lane Lane CO TRI Po me Bulk Dar Fine Door Wei Ready Fine Door Bulk Door qhparn Ready E oa This screen allows the sense of each individual digital output to be inverted Use the ENTER key to toggle between YES NO 71 COTSWOLD MECHANICAL LTD 4 3 WEIGHING CONFIGURATION 4 3 1 WEIGHING UNITS e1ghing Configuration Units esolution of Units alibration Height alibration Tolerance Display Units Select the weighing units Grams or Kilograms with which the machine will operate Resolution of Units X X X X XX X XXX Select how the units are to be displayed Calibration Weight Enter the calibration weight with which the weighers are to be statically calibrated Calibration Tolerance Enter the calibration tolerance in a d bits used in determining when the weighing is settled and stable during calibration 12 COTSWOLD MECHANICAL LTD WEIGHING SETTLE Heighing Configuration Delay berore settle Settle Len
13. mode of operation and whilst the format style size and specification may differ to suit different applications the strip down procedure for cleaning 15 generally as follows 1 Release the over centre latches where fitted and remove hopper If latches are not fitted the hopper 15 usually cleaned in its normal working position but can be un bolted for complete removal see Fig 1 for a typical example of a latch 2 Release the over centre latches where fitted and remove the rear or bulk vibratory feed tray If latches are not fitted the tray 1s usually gc cleaned in its normal working position but can be un bolted from the rear vibrator unit for complete removal see Fig 2 for a typical ve example of a latch 98 Cleaning Schedule 3 Release the over centre latches where fitted and remove the front or fine vibratory feed tray If latches are not fitted the tray 15 usually cleaned in its normal working position but can be un bolted from the front vibrator unit for complete removal see Fig 2 for a typical example of a latch 4 Remove the outlet chute This 15 achieved by simply lifting the chute Mounting Key upwards and ensuring that the Hole Slot keyhole slots in the rear of the chute es clear the mounting studs located in Typical Outlet the machine frame See Fig 3 4 Chute 5 Remove the weighpan Before removal can commence the air supply pipes must be removed from the weighpan han
14. only applies to machines which do not have a weighpan Low in Product The low hopper input for the given weigher indicates low product and the vibrators are disabled 62 COTSWOLD MECHANICAL LTD 3 0 PRODUCT PARAMETERS 3 1 1 PRODUCT WEIGHT Product Average Weight Mode 140 Product Enter up to 20 characters to describe the current product Use the upper lower case button to change between capital and miniscule letters and the 0 to 9 keys to enter alphanumeric characters The space character is located on the 0 key and the CANCEL key may be used to correct mistakes Average Minimum Weight Mode Use the ENTER key to toggle between the two modes of weighing operation Target Product target weight Overweight Weight before which the weighing is to be rejected as overweight Underweight Weight before which the weighing is to be rejected as underweight in an AWS system Note Overweight gt Target gt Underweight 63 COTSWOLD MECHANICAL LTD 3 2 PRODUCT OPTIONS 1 Tare Interval Topup Ma imum Time In Flight Correction Autotare Use the ENTER key to toggle between the tare modes OFF autotare is not enabled EVERY CYCLE The weighpan is tared at the beginning of every weigh cycle TIMED The autotare is performed on a timed basis See next parameter Tare Interval range 0 20 minutes Frequency at which autotare is performed Topup Tu
15. vibration range needs altering This 1s achieved by altering the combination of springs used to that of a slightly thinner combination 1 e remove one 11 ply spring and add two 7 ply or one 7 and one 9 ply Essentially having previously achieved good amplitude of vibration the vibrator 1s now being restricted or de tuned in its overall performance in order to gain good linear range of control Overall tray speed 15 therefore a trade off over good linear range of control Be aware that below 40 load speed on the controls usually results in little or no vibration so generally these low end results are largely ignored The extent to which a vibrator unit 1s tuned 1s largely dependent on the flow characteristics of the product For instance an awkward product such as diced lettuce requires a high fast amplitude In such a case it is not so important that the vibrator exhibits good vibration range However a free flowing granular product such as grass seed requires little vibration to start it moving along the tray We would therefore suggest that a high fast amplitude 1s not that important Good range of control however 15 It is important that these characteristics are duly taken into consideration when tuning 25 COTSWOLD MECHANICAL LTD Health amp Safety Information The VI Vibrator Unit as illustrated on page one has been designed amp built to accurately perform for many years When handling the unit it is the responsibility o
16. 7 3 4 PRODUCT FEED Product 002 Ps gt x 40 0 X PEC oa 100 0 X n 40 0 26 00 9 2 90 4 15 00 4 x Vibrator Speeds range 0 0 100 0 Enter the fast and slow vibrator amplitudes for controlling the feed rate of the current product Bulk Cut off Weight range O target weight Enter the weight which the vibrators will switch from fast to slow feeding Fine Cut off Weight range O target weight Enter the weight at which the vibrators will stop feeding and the weigher start to settle Use the COPY button to copy the entered settings to all weighers If Accelerometers Are Enabled This button memorises the current vibrator amplitude COTSWOLD MECHANICAL LTD 4 MACHINE CONFIGURATION Configuration Menu Input konfiguration Output Configuration Weighing Configuration shift Batch Configuration serial Comma Configuration Setup Time Date Machine Conti guration m y 1 3 4 The detailed setup of the machine is done from these screens Usually this is only done when the machine is first installed 69 4 1 INPUT CONFIGURATION Input Configuration Lane 1 Discharge Call Lane 1 vib Probe 1 1 2 5 4 z T c This screen allows each digital logical input to be assigned to a physical input Use the ENTER key to select the logical input and the UP DOWN ARROW
17. 79 25 n x 3 53 o See pages 18 amp 82 Machine Overview 3 COTSWOLD MECHANICAL LTD Machine Overview 4 Description A duel lane automatic linear weighing machine which utilises the highest quality components and materials and combines a precision loadcell weighing mechanism with the latest electronic technology Weight Range 5 0kg upto 50 0kg although versions may vary Applications are also dependent on the product bulk density Capacity 30 70 litres per weighment depending on application versions may vary Function The machine utilises a hopper system that is filled with the product to be weighed By means of a series of vibrating trays product is fed in a controlled manner to the weigh pan assembly A series of pneumatically actuated gates ensure that the weigh pan is filled to their correct target weight with no excess product overspill The product weights are continuously monitored by the electronic controls and once the target weight has been achieved the weigh pan pneumatically discharges the weighed product upon receipt of an electronic volt free signal This is usually done via an operator footswitch or is given by an ancillary piece of equipment such as a vertical form fill and seal bag maker Alternatively the CMW8000 machine can give an output volt free signal to indicate that a weight is complete and ready for discharge As the weigh
18. CHINE USER 36 5 4 7 5 MACHINE PASSWORD 5 TESTING THE MACHINE emeret 51 INPUT TEST 5 2 OUTPUTTEST teretes 53 VIBRATOR TEST seems 54 STATIC WEIGHING INFO 5 5 DYNAMIC WEIGHING TRACE 1 0 INTRODUCTION This manual has been compiled to assist the machinery manufacturer in the basic operation of the CMW Control System The controller utilises a backlit high contrast LCD display and operator keypad to enable the display and modification of all areas of the linear weigher operation The weighing characteristics of up to 100 different products can be pre set into the product library and then products may be called up for use by either their name or optional product code The unit is easily cleaned being housed with a stainless steel enclosure sealed to the IP65 standard The controller can be configured to control one or two weighers and up to four vibrators Depending upon the configuration of your machine not all options shown in this manual may be accessible or appear on the screen layouts 2 0 OPERATION In this part you will be guided through the operation of the basic functions of the controller This manual assumes that the machine is correctly installed and powered on Bel
19. COTSWOLD MECHANICAL LTD The Cotswold Weigh MW 8000 USER MANUAL Cotswold Mechanical CMVV8000 User Manual COTSWOLD MECHANICAL LTD Page Number 98 101 103 105 111 Appendix Appendix li Contents Title amp Description Front Cover Contents Basic Overview Hints on Successful Operation Machine Overview Product Feed Hopper Vibratory Feed System Gating System Hopper Probe Assembly Optional Extra Loadcell Mechanism Weighpan Assembly Outlet Chute Assembly CMW Controls Variable Frequency Vibrator Option Optional Data Recorder Cleaning Schedule Maintenance Schedule Pneumatics Electrical Drawings Electronics Drawings Other Equipment COTSWOLD MECHANICAL LTD Basic Overview The entire range of Cotswold Mechanical weighing machines have the same basic mode of operation and whilst the format style size and specification may differ to suit different products weights and speed requirements basic principles are valid throughout 1 Product is placed into a holding hopper and is then fed automatically at a fast speed into a pan that is attached to a weighing mechanism until the target weight is almost reached at which point the feed rate slows to a trickle On achieving the required weight feed stops altogether and after checking that the weight is correct the weighed product is released into a waiting container The product infeed hopper normally has adjustable gates to regulate the depth
20. Empey Si COTSWOLD MECHANICAL LTD 2 11 DIAGNOSTICS Current Diagnostics vibratore Disabled Warning Demo Operation 2 WHeigher Disabled When any machine faults exist the red lamp in the key HELP flashes Pressing the will list the current diagnostic faults press again to return to previous screen The diagnostic types are either general or weigher specific Weigher specific diagnostic include the weigher number as an icon within the message The possible diagnostics are listed below together with a brief explanation of their meaning GENERAL 1 Memory Loss The program memory has been corrupted Either the battery is switched off or exhausted or there is a program fault 2 Reset DIL On The reset DIL switch has been left on and should be switched off This is DIL switch 4 With this switch on the program memory is cleared to all zeros at power on 3 Invalid System Parameters There are inconsistencies within the machine configuration settings a Incorrect Checksum of Data b Maximum In Flight Adjustment 7596 4 Invalid System Shift Times There are inconsistencies within the shift times settings a Endof Shift Times must be in ascending order 58 DIAGNOSTICS CONTINUED di 10 11 12 Invalid System Refill Control There are inconsistencies within the refill control settings a If infeed output is selected then full hopper input must be sele
21. RE ACTIVE DL oog aut Eus pu X Em c o NN iB e e CONS IC11 028 xx E 2 og LK12 09 RIS Rom lt LK13 ARa olo olan R36 8351 Slo RS485 PR i G e VI 52422 gt 0 x gt 2 255 23 1 0 gt 9 gt 9 gt gt a PTX x Todo EFR 0 o lt 0 lt 0 lt 0 1 1 1 1 1 5 Mo 2 2 5 2 9 8 8 9 CONS 5 ELECTRICAL DRAWINGS 4 CORE SCN 5 d al RX 1 elle 2 Exc 2 e 3 Sen S 3 ng ee 9 2 4 TX 4 TY 5 ac Log0 5 5 e 6 Sen E 10900 6 2 7 5 1091 7 5 e 8 L 41 8 a4 PWR 9 O 10 Gnd 10 FM 5 5 NO v a lt gt anon 92 1 MINI AVE NS NO 5 5 RE m
22. Rated output tolerance ____ 059020 Zero balance ee Zero Simi 990 _ fot Eror per MIL Reo 99 _ 2 of applied load Beene dng COGI coso stain Temperature range compensated c Temperature range safe O 559002020607 essi Ultimate central overload Excialion recommended _ 001 VdeerVaeme 2 635 10 1500kg capacities platform size 600 x 600mm Wiring Schematic Diagram mE ve Output Rad S Output White Weigh pan Spindle 2 Weigh pan Cylinder 2 Rose end Bearing 2 Weigh pan Lid x2 Weigh pan Lid Mounting Brackets x4 The Weigh pan Assembly This 15 a pneumatically operated storage container it 15 attached to a precision load cell weighing system via two weighpan mounts These facilitate quick release of the weighpan for cleaning purposes Removal of the pan should only commence once appropriately qualified personnel have isolated the air supply to the machine Before removal of the Weighpans the air supply pipes must also be removed from the weighpan hanger bars This is achieved by sliding the release collar on the quick release fitting upwards in the direction of the arrow see illustration on the left To re assemble simply push both halves of the fitting together An audible click denotes corre
23. SWOLD MECHANICAL LTD 2 3 HOME SCREEN Last Discharged Weight for Weigher 6 ha eg RICCO Bulk Feed Fine Feed Weight Complete Live Weights Main operating screen shows status for one or two weighers 45 COTSWOLD MECHANICAL LTD 2 4 SETTLED WEIGHTS SCREEN press EX to ENABLE DISABLE the weighing stations Shows the live weight against the settled weight for each weigher such that when weighing is complete this will provide an indication of how accurate the weighing settle parameters are 46 COTSWOLD MECHANICAL LTD 2 5 STATISTICS SCREENS Last Drop vere ght Target Height Underweight Total Accepted Total Rejected shlft Average ab Shows weights occurrences and standard deviation for batch and shift statistics Use batch shift button to move between the two statistics sets See section O SHIFT BATCH CONFIGURATION to set up batch statistics over time or number of weighings and shift statistics for one to three shifts Shift Tl Histogram Shows weight histogram for batch shift Use batch shift button to move between the two statistic sets Use T1 T2 button to select histogram spread displayed 47 COTSWOLD MECHANICAL LTD 2 6 MAIN MENU Main Menu at Lont iguration Menu Test Henu Static Calibration Manual ero Empt Machine service Into Password Ta m me 1 E 3 4 2 Main menu allows entry
24. ace This will offer a greater measure of protection from liquid ingress into the controls box Exact cleaning schedules however are usually determined by the end user and are largely dependent on the characteristics of the product to be weighed and the end user s operational procedures Maintenance Schedule There 15 very little routine maintenance required on The machines other than routine adjustments and occasional calibration The equipment is extremely reliable and breakdowns are rare Even after the warranty period has expired our fully trained and experienced engineers are at your service giving both telephone and on site support backed up by our comprehensive spare parts inventory if necessary It 15 recommended that the Machine is serviced by an Qualified Engineer once annually based on a single shift working pattern Weighpan Maintenance 1 Check Rose End Bearing for Monthly wear damage 2 Check Pneumatic fittings for leaks Weekly amp air flow 3 Check Cylinder for wear damage Monthly 4 Check Headed Oilite Bushes for Monthly wear damage 1 Check Fine Gate for wear Monthly damage 2 Check Bulk Gate for wear Monthly damage 3 Check Speed Controllers for leaks Weekly amp flow adjustment 4 Check Rotary Actuator Stops for Monthly adjustment amp for air leaks VOL V2 Vibrator Maintenance Check Vibrator Springs for wear 3 Monthl
25. ator option allows the vibrator control frequency to be adjusted to maximize the vibrator performance This reduces the need to manually tune vibrators by replacing springs There is also an increase in usable life of the springs by adjusting the control frequency to compensate for spring wear When variable frequency control boards are fitted The Machine Configuration Screen 1 will appear as below Hachine Configuration 1 Inputs Outputs Humber of Hei ghers 1 Loadcell Digitiser LOU External vibsz Beltz 5455 Count Option Disable Lai External Vibs Belts will be set to RS485 91 COTSWOLD MECHANICAL LTD VARIABLE FREQUENCY VIBRATOR OPTION Setting up Vibrators using frequency control Go Test Menu Main Menu Option 2 Vibrator Test Option 3 Vibrator Test Screen 1 Yibrator Test Vibrator 1 4 Vibrator 2 oU x 3 2 Vibrator 3 gt 4 2 Vibrator 4 x 1 Set the Vibrator 1 amplitude to 80 0 2 Set the Vibrator 2 amplitude to 00 0 3 Use to go to Vibrator Test Screen 2 92 COTSWOLD MECHANICAL LTD VARIABLE FREQUENCY VIBRATOR OPTION Setting up Vibrators using frequency control Continued Vibrator Test Screen 2 Vibrator Test 1 b Vibrator 1 hz 4 2 Vibrator 2 46 5 hz 5 Wibrator 3 hz d vibrator 4 0 0 hz LS baed 4 Set Vibrator Frequency to 50 0 hz 5 Use enable Vibrator T
26. cate the function of each key See Button Table for meanings COTSWOLD MECHANICAL LTD BUTTON TABLE Go to main menu Go to configuration menu Go to test menu Return to home screen Main operating screen Return to previous screen from home screen Show statistics screens Show batch statistics Show shift statistics Show histogram to T1 limits Show histogram to _ T2 limits Show settled weights screen Shows weighing status Go to monitor screen 41 BUTTON TABLE Go to previous screen Go to next screen Select product to run change product Edit current product Accept Cancel Copy item to another location Delete selected product Change entry font to lower case Change entry font to upper case Run Enable Stop Disable BUTTON TABLE Start next calibration stage Run To empty Empty Reset data Test output on off Cycle selected test output 2 2 SECURITY Access Security Please Enter Security Code Code E Data within the controller is protected from unauthorised access by means of three levels of password 1 Supervisor lowest 2 Engineer 3 Manufacturer highest When access code is required the screen above will pop up At this point the user should enter their 4 digit code followed by ENTER COT
27. ct connection The weigh pan is filled with product to the correct weight via the vibratory feed trays and gating system The product 15 held in the weigh pan until an external discharge input 15 received at this point the pneumatic cylinder opens the two weigh pan lids discharging the weighed product The Weigh pan is factory set and normally requires no further adjustment Outlet Chute Assembly Mounting Key Hole Slots Outlet Chute Outlet Chute Assembly The Outlet Chute 15 located on the front of the machine beneath the weighpan assembly It attaches to the machine by means of two keyhole slots Removal of the chute 1s simply achieved by lifting the chute clear of the two studs located in the machine frame The design and manufacture of the chute 15 such that it meets the handling requirements of the product to be weighed chutes may vary to that shown above Some chutes may be fitted with sound deadening panels as an optional extra in order to reduce product noise These panels are permanently adhered to the outside of the chute and are sealed in place Under no circumstances should any attempt be made to remove them COTSWOLD MECHANICAL LTD CMW CONTROLS USER MANUAL CONTENT O 1 2 OPERATION 24 USERINTERFACE ens 22 SECURITY 23 HOMESCREEN
28. ct into the container to be filled These outlet chutes are designed to suit the application and may be fitted with different size and style of extensions to adapt them to various sizes and styles of packaging 10 All aspects of the machine operation including target bulk and fine weights the speed amplitude of the vibratory feeders the frequency of the auto tare facility etc are all set and held in the Product Code Memory of the control System along with all other information necessary for the correct operation of the machine Once the correct settings for a particular product and weight combination have been determined they can be retained in the control system memory and simply recalled the next time they are required to be used COTSWOLD MECHANICAL LTD Hints on successful operation THE SECRET OF ACCURATE AUTOMATIC WEIGHING IS IN OBTAINING A CORRECT AND RELIABLE PRODUCT FEED INTO THE BOX OR CONTAINER 1 The amount of product on the bulk primary tray is determined by The position of the adjustable sliding gate on the front of the hopper The correct position of this gate is determined by a The type of product being handled b The throughput and depth of product deemed necessary 2 The level of product on the fine secondary tray is determined by The position of the adjustable sliding gate on the front of the hopper The correct position of this gate is determined by a The type of product being handl
29. cted b andif Refill is controlled by Low Hopper condition then a low hopper input must be selected Invalid Product Parameters The current product code settings are incorrect a Incorrect Checksum of Data b Invalid Product Weights Invalid Product Weight s The current product code weights settings are incorrect a Target Weight Underweight b Target Weight Overweight Printer Busy The printer buffer is full up and further printouts cannot be done until it has emptied Emptying Machine emptying is in progress Refilling Hopper Hopper refilling is in progress Hopper Low in Product The hopper low level input indicates low product and the vibrators are disabled Re Sample Required No Piece Weight Sample information exists for the current product Perform a Piece Weight Sample procedure or enter a new Item Weight within the product code 13 14 16 17 18 19 DIAGNOSTICS CONTINUED Vibrators Disabled There is no Mains Power supplied to the vibrator drive card or it is disconnected Warm Up Period The machine has just been switched on and is warming up Weighing may be slightly inaccurate during this period Emergency Stop Input The emergency stop input is ON Line Stop Input The line stop input is ON Warning Low Air Pressure The low air pressure input is ON Low Air Pressure Timed Out The low air pressure i
30. ed b The throughput and depth of product deemed necessary IT ISESSENTIAL TO HAVE A SMALL BUT SUFFICIENT FINE FEED 3 If there is none or it is too little invariably over weights will be produced If itis too long product may build up behind the bulk gate resulting in erratic weights correct weight followed by an overweight etc FINE FEED TOO SHORT DECREASE the BULK WEIGHT SETPOINT FINE FEED TOO LONG INCREASE the BULK WEIGHT SETPOINT 4 It is important that the depth and speed of movement of the product are in keeping with the weight being made and the accuracy required In general the higher the target weight and the smaller the product piece size the greater the depth of product and the faster the movement can be It is impossible to give exact advice on actual settings they will only be determined by running the actual product through the machine and by using trial and error along with experience gained in the best method of operation for your own particular products and requirements COTSWOLD MECHANICAL LTD Hints on successful operation continued Before starting the machine Set the desired Target weight Example 10 0 kg Set the Fine set point to equal the Target Weight Example 10 0 kg Set the Bulk set point to Target Weight minus 10 Example 9 0 kg Set the Fine vibrator fast speed to 50 and the slow speed to 40 Set the Bulk vibrator fast speed to 40 Switch the machine in to run mode Place a small a
31. electing the correct combination of fiberglass springs to replace those already on the unit The springs are supplied in three varying thicknesses 7 9 and 11 ply The object of successful tuning is twofold 1 To obtain approximately 4 5mm 5 0mm of displacement movement the top plate of the vibrator unit WHEN A TRAY IS LATCHED IN POSITION and the unit is running at 100 2 To obtain good linear vibration range This is determined by reducing the vibrator speed in the machine controls in intervals of 10 from the full load speed of 100 If the speed of the vibrator experiences a larger than 10 decrease in speed when 10 speed reduction 15 inputted via the machine controls the vibration range is deemed as bad However often there is little vibration below 40 and these low end values are largely ignored The procedure for tuning the vibrator units are as follows M8 PLAIN WASHER Fig 6 otep 1 STAINLESS STEEL Assemble the vibrator springs as a separate assembly as shown Fig 6 using three 11 ply springs in each ie position Make sure that all the bolts V1 VIB SPRING 11PLY 9PLY OR 7PLY are tightened wherever possible with a torque wrench set at 40N m 29 5 lof ft as shown in fig 7 Bolts GASKET 17 COTSWOLD MECHANICAL LTD Getting Started Vibrator Tuning continued Fig 7 13mm A F socket 3 8 square drive torque wrench set at 40N m 29 5lbf ft Step 2 Set the co
32. er often there is little vibration below 40 and these low end values are largely ignored The procedure for tuning the vibrator units are as follows Air Gap between armature amp coil Electromagnetic Coils wr p Spring Assemblie 5 4 Base Plate Fig 10 Typical V2 Vibrator Assembly V2 Vibrator Vibrator Tuning Continued M10 Hd Bolt Gasket Spacer 11 Ply Spring M10 Plain Washer 3 S S gt Clamp Plate E001G Fig 11 Typical Exploded Spring Assembly 4 off complete assemblies per V2 Fig 12 Typical V2 Vibrator Unit with Spring Assemblies bolted in Step 1 Assemble the vibrator springs in four separate assemblies as shown in Fig 11 using three 11 ply springs in each position Make sure that all the bolts are tight Bolts that are not properly tightened will result in false linear vibration range readings later Step 2 Set the correct gap between the armatures and the coils in two places This gap is 6mm typically the thickness of an 11 amp 9 ply spring combined Air gap adjustment is achieved by slackening the two bolts per coil on the underside of the base plate Once loose the coils can be moved backwards or forwards until a snug fit is achieved with the 11 amp 9 ply spring wedged between the coil and the armature see Fig 13 17mm A F Ring Step 2 Continued Once the correct air gap has been set up the retaining bol
33. est Test on 6 Adjust the frequency by 0 1 hz increments decrements until the required vibrator amplitude is achieved 7 Use to go back to Vibrator Screen 1 93 COTSWOLD MECHANICAL LTD VARIABLE FREQUENCY VIBRATOR OPTION Setting up Vibrators using frequency control Continued Vibrator Test Screen 1 Vibrator Test k 1 gt Vibrator 1 4 2 vibrator 2 x 2 vibrator 3 x 4 2 vibrator 4 x 5 Ensure that the vibrator 1 dose not hammer Noisy when the amplitude 1s set to 100 0 96 9 If hammering occurs then re adjust the frequency until hammering Stops 10 When desired settings have been achieved and then note the Frequency values ie 48 6 hz 11 Repeat the process from step 1 substituting vibrator with the Next vibrator until all Vibrators have been set and their frequency values recorded Now go to Configuration Menu Weighing Configuration Screen 6 94 COTSWOLD MECHANICAL LTD VARIABLE FREQUENCY VIBRATOR OPTION Saving the frequency Values Engineer s level of password is required to enable changes The following Weighing Configuration screen 6 shows the option for two Vibrators Heighing Configuration a hz 100 0 46 5 hz 100 0 Bet SS Enter the recorded frequency values from the previous section The Frequency values are now saved 95 Optional Data Recorder A Active LED should be w
34. f the user to exercise good lifting techniques The complete unit weighs approximately 30 0kg The V2 Vibrator Unit as illustrated on page one has been designed amp built to accurately perform for many years When handling the unit it is the responsibility of the user to exercise good lifting techniques The complete unit weighs approximately 60 0kg The unit requires 230v A C at 50Hz 1 5 amp supply IT IS ESSENTIAL THAT THE ELECTRICAL SUPPLY TO THIS EQUIPMENT BE ISOLATED BEFORE ANY WORK IS CARRIED OUT BY APPROPRIATLEY QUALIFIED PERSONNEL Only suitably trained personnel should operate this equipment This machinery has been designed and manufactured where possible in accordance with the following transposed harmonised European standards BS EN ISO 12100 2010 safety of machinery basic concepts general principles for design EN ISO 13857 2008 safety of machinery safety distances to prevent danger zones being reached by the upper limbs EN349 1993 A1 2008 safety of machinery minimum gaps to avoid crushing of parts of the body EN13850 2005 BS EN 60947 5 5 safety of machinery emergency stop equipment functional aspects principles for design BS 60204 1 2006 A1 2009 safety of machinery electrical equipment of machines specification for general requirements NEN EC IEC 61000 6 4 2007 Generic Emissions standard and Generic Immunity standard Industrial environments In addition this machinery has bee
35. ger bars This 1s achieved by sliding the release collar on the quick release fitting upwards in the direction of the arrow see Fig 4 To re assemble simply push both halves of the fitting together An audible click denotes correct connection Once the air supply pipes are disconnected the weighpan assembly can simply be lifted clear of the hook style hanger plates If the pan 1s to be cleaned in a wet environment ensure that the ends of the pipes do not get exposed to moisture as this could get into the weighpan cylinders and cause failure Cleaning Schedule 6 Remove any Ancillary Equipment If fitted This usually comprises Rise and Fall Funnels or Product Diverting Chutes Release over centre latches where fitted and remove each assembly If latches are not fitted the chute or funnel is usually cleaned in its normal working position but can be un bolted for complete removal Fig 1 shows a typical over centre latch where fitted that is used to fasten ancillary sub assemblies and hoppers Fig 5 shows a typical example of a rise amp fall funnel Obviously there are a great number of funnel variations as these are designed and built to match specific applications Mounting Key Hole Slots Latch Keepers x2 Typical Rise amp Fall Chute As a precautionary measure it 1s also a good idea to cover the Pulse Controls with a waterproof hood ensuring that the opening is tied securely once the hood is in pl
36. gth Settle Average 1 Tolerance 20 bits Loadcell Filter Type Bessel Loadcell Filter Cutoff 3 hz La loco M Delay Before Settle range 0 00 5 00 seconds This time is the delay after the feed has stopped before the program looks for a settled weight Settle Length range 1 126 Enter the number of values which determine the length of the settle buffer Settle Average Enter the frequency at which values are placed in the settle buffer The frequency is defined in multiples of 20 milliseconds Weighing Tolerance range 0 1000 Enter the weighing tolerance in a d bits used in determining when the weighing is settled and stable Loadcell Filter Type range Off 7 3 1 1 Typical Bessel Select the digital filter Type Bessel Butterworth Fast Bessel or gaussian Loadcell Filter Cutoff range 1 14 Typical 1 Enter the required filter setting for the loadcell Digitiser a higher filter equals less damping and a lower frequency equals heavier damping 73 COTSWOLD MECHANICAL LTD WEIGHING OPTIONS Heighing Configuratio Delay Berore are Maximum Tare Limit Bulk Hysteresis In Flight Batch In Flight Deadzone In Flight Correction Maximum In Flight Adjust Topup 16 Delay La SS Sze Delay Before Tare range 0 00 5 00 seconds This is the time between starting a tare and checking for a settled weight within the calibration tolerance Maximum Tare Limit range 0 100 96 Enter maxi
37. hen power applied Insert Compact Flash Card Press Stop Record Button R LED Will Light During Recording LED Will Flash To Stop Recoding Press Stop Record Button LED Will Go Out Press Card Eject Button To Remove Card Insert Compact Flash Card into the Card Reader amp Connect the Card Reader to a file Type is DAT use Notepad to Open COTSWOLD MECHANICAL LTD Cleaning Schedule The weighing system 15 designed such that most of the component parts that come into contact with the product can easily be removed for cleaning purposes This includes Hopper Feed Trays Weighpan Rise amp Fall Chutes amp Outlet Chute BEFORE REMOVAL OF THESE COMPONENT PARTS CAN COMMENCE IT IS ESSENTIAL THAT BOTH THE AIR SUPPLY amp THE ELECTRICAL SUPPLY TO THE MACHINE BE ISOLATED BY AN APPROPRIATLEY QUALIFIED PERSON the contact parts are manufactured from grade 304 or 316 stainless steel and will easily withstand cleaning with most food industry approved sanitary cleaning fluid It 1s recommended that the machine 15 stripped down and cleaned at least once per eight hour shift It 15 also essential that cleaning take place when there is a change of product to be run through the machine During any clean down procedure it 15 vital to ensure the cleansing of the entire machine and not just the removable contact parts The entire range of weighing machines have the same basic
38. icate B port is pressurized Angle adiustment 2 5 Rotation ranae 90 ELECTRICAL DRAWINGS 203 red RESET
39. ieved Step 8 Once the correct amplitude has been achieved reduce the vibrator load speed in increments of 10 in the machine controls If the speed of the vibrator experiences a larger than 10 decrease in speed when a 10 speed reduction 15 inputted via the machine controls the vibration range needs altering This is achieved by altering the combination of springs used to that of a slightly thinner combination i e remove one 11 ply spring and add two 7 ply or one 7 and one 9 ply Essentially having previously achieved good amplitude of vibration the vibrator is now being restricted or de tuned in its overall performance in order to gain good linear range of control Overall tray speed is therefore a trade off over good linear range of control Be aware that below 4046 load speed on the controls usually results in little or no vibration so generally these low end results are largely ignored The extent to which a vibrator unit is tuned is largely dependent on the flow characteristics of the product For instance an awkward product such as diced lettuce requires a high fast amplitude In such a case it is not so important that the vibrator exhibits good vibration range However a free flowing granular product such as grass seed requires little vibration to start it moving along the tray We would therefore suggest that a high fast amplitude is not that important Good range of control however is It is important that these characteristic
40. in the CMW controls parameters and 1s dependent on product flow characteristics COTSWOLD MECHANICAL LTD Vibratory Feed System Continued Method Of Adjustment See CMW Controls Instruction Manual Product Feed Section 3 4 Each Vibrator has two speed settings fast and Slow speeds Each speed 1s digitally set within the Product Code Menu values 0 100 Fast Speed This speed settings is used to when feeding the majority Bulk of the product through the feed system and in to the Weighing system Normally the Primary Rear Vibrator speeds are set slightly lower than the Secondary Front Vibrator this will allow thinning of the level of product as it progresses through the system Example Primary Rear fast speed 50 Secondary Front fast speed 55 The Fast Speeds continue to be used until the Bulk set point is achieved Slow Speed This speed settings is used to when feeding the final Fine or top up of the product to achieve the desired target weight Again normally the Primary Rear Vibrator speeds are set slightly lower than the Secondary Front Vibrator this will maintain the correct level of product during slow fill part of the cycle Example Primary Rear fast speed 40 Secondary Front fast speed 45 The Slow Speeds continue to be used until the Fine set point 15 achieved The Fine set point is normally set to slightly below the desired target weight this allows for product in f
41. into the main control topics Configuration Menu access set up overall machine operation Test Menu access test functions of the machine Static Calibration calibration section Manual Zero manual zero Empty Machine to run the machine until empty Service Info Service contact details program monitoring Password enable disable current password Data within the controller is protected from unauthorised access by means of three levels of password 48 COTSWOLD MECHANICAL LTD 2 7 PRODUCT LIBRARY Select Existing Product LICHT 1 002 SALAT OOS test 004 CHEESE OOS EIRSCHEH Popcorn 509 Wy EIESCHEH Lal uu machine allows the details for up to 100 different products to be held volatile memory Use UP DOWN ARROWS to select current product to run or edit Confirm selection with OK button Use COPY button to copy selected product to a new location This is also used to create a new product Use DELETE button to delete the currently selected product 49 COTSWOLD MECHANICAL LTD 2 8 STATIC CALIBRATION Static Calibration gher Calibration Counter Pressa button to begin Calibration 1 Before commencing for multi weigher machines select the weigher to calibrate with the ENTER key The Calibration Counter displayed on this first screen is a non resettable counter that increments after each successful calibration It is a
42. light If the Fine set point value 15 set low the system will stop early and the target weight will not be achieved The feed system will then begin to top up again using the slow speed settings 13 COTSWOLD MECHANICAL LTD VI amp V2 VIBRATOR UNITS VI Vibrator Unit 2 Vibrator Unit The V1 and V2 Vibrator Units are high precision quality engineered products treated and maintained correctly should give many years of trouble free operation It is therefore essential that these instructions are understood completely prior to installation and operation Any electrical work maintenance or service should be carried out by suitably qualified personnel The information contained herein is based on our present knowledge and experience and is given in good faith As the product detailed herein may be used for a wide variety of purposes and as the Cotswold Mechanical Ltd has no control over its use Before proceeding further it is strongly advised that the operator qualified personnel familiarise themselves with the essential parts of the unit as outlined below Doing so will make crucial parts of the unit s setup considerably more straightforward 14 COTSWOLD MECHANICAL LTD Overview TOP PLATE TRAY RETAINING V1 VIB ARMATUR BRACKET V1 VIB COIL SPRINGMOUNTING BLOCK TAPPED SPRING CLAMP Fig 1 MOUNTING RUBBERS 15 COTSWOLD MECHANICAL LTD Overview continued M8 PLAIN WASHER V1 SPRING
43. lution is invalid for the calibration Unable to Settle During the weighing operation settling period the a d output was not stable within the set parameters Check weighing parameters in machine configuration 61 COTSWOLD MECHANICAL LTD WEIGHER DIAGNOSTICS CONTINUED 12 13 14 15 16 17 18 19 20 21 Unable to Tare During the weighing cycle tare the weigher was unable to achieve a settled zero level within the time allocated Tare Weight too Low During the weighing cycle tare the tare weight level was below the zero calibration level Check weigher with test weights to ensure it is operating correctly Tare Weight too High During the weighing cycle tare weight was so high that the target weight is not achievable within the range of the machine Check weigher with test weights to ensure it is operating correctly Zero Span Exceeded For an Approved machine only during a manual zero operation the zero level has drifted more than 496 of the range since the last static calibration Weigher Disabled The weigher has been disabled from the front panel Feed Disabled The feed enable input is OFF Weigher Not Feeding The feed fault input was detected during a weighing cycle Weighpan Open The weighpan open input is ON and the weighing cycle is aborted Weight Not Removed A new discharge call input is received before the last weight has been removed This
44. mount of product in to the Fine vibrator tray check the product is transferred along the vibrator with a smooth and consistent flow rate If the transfer of product is too slow or too fast adjust the Fine vibrator fast and slow speeds accordingly Place a small amount of product in to the Bulk vibrator tray check the product is transferred along the vibrator with a smooth and consistent flow rate If the transfer of product is too slow or too fast adjust the Bulk vibrator fast speed accordingly Stop the machine Close the hopper slide gate and then fill the hopper with product Now open the hopper slide gate only a sufficient amount to allow the product to flow from the gate Re start the machine 26 50 26 504 15 00 Bulk Cut off Weight range Q target weight Enter the weight at which the vibrators will switch from fast to slow feeding Fine Cut off Weight range Q target weight Enter the weight at which the vibrators will stop feeding and the weigher start to settle Machine Overview 1 Vibratory Feed System See pages 12 13 amp 75 77 Product Feed Hopper See pages 11 amp 74 Gating Assembly CMW Controls See pages 14 amp 78 See pages 19 73 Machine Overview 2 Weighpan Assembly See pages 17 amp 81 Loadcell Plate Assembly beneath cover See pages 16 amp 80 LIL Hopper Probe Assembly Optional Extra See pages 15 amp
45. mum tare level as a percentage of the Target Weight Bulk Hysteresis range 0 100 96 Enter the bulk hysteresis as a percentage of the bulk weight If during the fine feed of a weighing cycle the weight falls below this percentage of the bulk weight the machine will revert to bulk feeding Maximum In flight Adjust Enter the maximum in flight adjustment as a percentage of the target weight When performing in flight correction this is the maximum amount the cut off points will be adjusted by for any one correction 74 COTSWOLD MECHANICAL LTD WEIGHING BAGMAKER Heighing Configuration 1 Fitted Weighpan Discharged Check Ho Elindfold Time a 40 Hen Cyclic Full Bag Energise ime LI 210 il hoc Weighpan Fitted Select whether a weighpan is fitted or not If no weighpan selected the machine will assume it is feeding directly onto a weigh platform Bagmaker Type Type of bagmaker fitted to the weigher CYCLIC NON CYCLIC Delay Before Full Bag range 0 00 5 00 seconds Enter the time between discharging the weighpan and issuing the full bag signal Full Bag Energise Time range 0 00 5 00 seconds Pulse time to the bagmaker 75 COTSWOLD MECHANICAL LTD WEIGHING VIBRATOR FACTORS Heighing Configuration speed Factors mmm 100 0 X a Vibrator Speed Factors This percentage scales the vibrator amplitudes as set in the product code
46. n designed and manufactured in accordance with British Standard PD 5304 2005 Safety of Machinery The Plastics Materials and Articles in contact with Food Regulations 201 1 The equipment is supplied with a suitable mains lead and must be properly connected to a mains supply which is adequate for the unit s requirements and correctly protected by fuses or circuit breakers Provision must be made by the end user for quick safe disconnection of the supply The equipment must be connected to a good reliable low impedance noise free earth to ensure correct safe operation and compliance with EMC regulations 24 COTSWOLD MECHANICAL LTD The Gating Assembly Pneumatic Bulk Gate Rotary Actuator 2 Air Supply in out The Gating Assembly This Consists of pneumatically operated Bulk and Fine gates They are located beneath the Loadcell Plate Assembly and at the end of the product feed trays The gates open at the start of the weighing cycle The Bulk gate closes when the Bulk set point is reached the product continues to feed at slow speed until the fine set point 15 reached at which point the Fine gate closes If the weight of product in the weigh pan 15 less than the target minimum weight system or less than the under weight tolerance Average weight system then the fine gate will re open and the product feed will resume at slow speed until the target weight is achieved The Gating system is Factory set and will no
47. nit running at 100 steel rule used to measure tray displacement left by ghost image of tray when 18 COTSWOLD MECHANICAL LTD Getting Started Vibrator Tuning continued Step 4 If the amplitude of the tray measures approximately 4 5mm to 5 0mm then proceed to step 8 to ensure good linear vibration range Step 5 If the amplitude of the tray measures less than 4 5mm to 5 0mm loosen one of the lower vibrator spring 8 bolts It is important to loosen the bolt as the vibrator unit is running As the bolt is loosened a change in amplitude should be easily detected If no change is discernable gradually loosen a second bolt Step 6 If the tray amplitude increased when the bolts were slackened then the vibrator springs are too stiff The overall spring thickness needs to be decreased by either removing changing the spring thickness combinations If the tray amplitude decreased when the bolts were slackened then the vibrator springs are too weak and the overall spring thickness needs to be increased again by adding changing the spring combinations Step 7 Vibrator springs are available in three thicknesses 7 9 amp 11 ply Adding or replacing springs should take place one at a time When a spring combination has been altered check that the M8 retaining bolts are correctly tightened and repeat the amplitude measurement test again return to step 3 as many times as necessary until the correct amplitude is ach
48. nput has been ON for a maximum time and the machine is stopped Warning Demo Mode Operation The demonstration mode has been selected The machine cannot run in this mode COTSWOLD MECHANICAL LTD WEIGHER DIAGNOSTICS 1 10 11 Loadcell Not Communicating The loadcell amplifier is not working or disconnected Re Calibration Required The operator has changed important weighing parameter s or the weighing information is corrupt Weigher At Lower Limit The weighing analogue to digital converter is giving its minimum output Weigher At Upper Limit The weighing analogue to digital converter is giving its maximum output Zero Weight too Low During the zero phase of the static calibration routine the analogue to digital converter output is below a sensible minimum value Check loadcell and LDU connections Zero Weight too High During the zero phase of the static calibration routine the analogue to digital converter output is above a sensible maximum value Check loadcell and LDU connections Calibration Span too Low For an Approved machine the span of the calibration weight must be above a certain percentage of the loadcell output Calibration Weight too Low The chosen calibration weight is too small for the size of loadcell Calibration Weight too High The chosen calibration weight is too large for the size of loadcell Invalid Weight Resolution For an Approved machine the selected reso
49. ntify weighing machine Language Select language for display and printouts 53 COTSWOLD MECHANICAL LTD 4 7 4 MACHINE PASSWORD SETUP Security Configuration ewel 2 Supervisor 2222 evel 3 Engineer evel 4 Manufacturer This screen can only be selected by the current level 4 password holder Enter or reassign the password level codes 84 COTSWOLD MECHANICAL LTD 5 0 TESTING THE MACHINE Test Menu Input Test Output Test Vibrator Test Gate Test Heiahpan Test static Weighing Into Dynamic Weighing race Settled Weights fat _ g 1 5 4 e From the test menu select test area of interest 5 1 INPUT TEST Input Test E 8 Lane 1 Discharge Call Lane 1 Vib Probe 1 n a in of E A po DODDO Circle indicators show state of inputs ON OFF 85 COTSWOLD MECHANICAL LTD 5 2 OUTPUT TEST m m L m Bulk Door Fine Door Ready Fine Door Bulk Door 19 an UP DOWN ARROWS to select output Select to turn on off selected output 14 c CH it PJ PJ Fi pi e e Duo 1 3 4 4 Select to cycle the selected output Press to RUN STOP the test 96 COTSWOLD MECHANICAL LTD 5 3 VIBRATOR TEST vlbrator Vibrator Vibrator Vibrator
50. of product allowed out on to the feed system The feed system normally comprises a series of vibratory feeders sometimes referred to as feed trays There are normally two vibratory feeders one to take the bulk product out of the hopper bulk or primary tray and one to feed the product under strict control into the weighpan fine or secondary tray At the outfeed end of the feed system there are normally some gates These are designed to assist in the precise feed of the product In the case of the bulk gate this closes to shut off the bulk feed tray when fine feed is taking place Similarly the fine feed gate closes when the correct weight is in the weighpan making sure that no further product is allowed in thus minimizing the possibility of over weights being produced The type and design of feed system is determined by the characteristics of the product to be handled A suitable receptacle is placed beneath the Outlet Chute of the machine usually specified by the machine operator When the correct signal is given usually via an operator footswitch or ancillary piece of equipment such as a vertical form fill and seal bagmaker weighed product is discharged down the Outlet Chute and into the waiting container 8 9 Basic Overview continued The weighing function of the machine is performed by a precision weighing mechanism normally a loadcell The gating system is located above a chute that transfers the produ
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52. ow is a summary of the following sections in this part Section 0 is a guide to the user interface Section 0 shows the security features for protecting data entry Section 0 shows the layout of the normal operating home display screen Section 0 explains the settled weights screen Section 0 explains the statistics screens Section 0 shows the main menu screen Section 0 is a detailed guide to the product library Section 0 explains how to statically calibrate the weigher Section 0 explains how to manually zero the weigher Section 0 explains how to empty the weigher Section 0 explains the diagnostic fault reporting 2 1 USER INTERFACE The user interface is designed to allow simple set up of the linear weigher and display clear weighing and statistical information during operation Numerical data is entered via the 0 9 and keys with the data being accepted with the ENTER key These same keys can also be use to enter alphanumeric characters in a similar fashion to that of a mobile phone The four ARROW keys are used to select specific screen entries and to move around the screens quickly The four keys at the bottom right hand side of the keypad are used for the machine operation Each of these keys contains a red LED lamp to indicate when they are active Directly below the LCD screen are six keys whose functions depend upon the screen displayed The bottom of the screen contains a row of display icons that indi
53. pan discharges the product falls down a chute that is usually custom made to suit individual application This ensures that the weighed product falls into a suitable receptacle placed or positioned beneath the outlet chute Machine Overview The 8000 System comprises of the following sub assemblies Product Feed Hopper Vibratory Feed System Gating Assembly Hopper Probe optional extra Load cell Mechanism Weighpan Assembly Outlet Chute Assembly CMW Controls gt 10 COTSWOLD MECHANICAL LTD Product Feed Hopper Product Feed Hopper x1 Hopper Feed Control Gate Bulk Hopper Feed Control Gate Fine Hopper Gate gt Adjusting Hand wheel 2 Note Some Hoppers are fitted with various sound deadening panels as an optional extra to dampen product noise when product enters the hopper These panels are permanently adhered and sealed to the Hopper Hopper Locating Under no Catches x4 circumstances should they be removed The Product Hopper is usually custom designed to suit the individual product requirements It is normally bolted to the main machine frame As an optional extra they can be mounted by means of quick release over centre catches The hopper sits on the top face of the machine frame and 15 then firmly latched into position This enables fast removal of the Hopper for cleaning Product feed from the hopper 1s controlled by t
54. plitude of the tray measures less than 4 5mm to 5 0mm loosen one of the lower vibrator spring M10 bolts It is important to loosen the bolt as the vibrator unit is running As the bolt is loosened a change in amplitude should be easily detected If no change 15 discernable gradually loosen a second bolt 22 COTSWOLD MECHANICAL LTD V2 Vibrator Vibrator Tuning Continued Step 6 If the tray amplitude increased when the bolts were slackened then the vibrator springs are too stiff The overall spring thickness needs to be decreased by either removing changing the spring thickness combinations If the tray amplitude decreased when the bolts were slackened then the vibrator springs are too weak and the overall spring thickness needs to be increased again by adding changing the spring combinations Step 7 Vibrator springs are available in three thicknesses 7 9 amp 11 ply Adding or replacing springs should take place one at a time When a spring combination has been altered check that the M10 retaining bolts are tight and repeat the amplitude measurement test again return to step 3 as many times as necessary until the correct amplitude 18 achieved Step 8 Once the correct amplitude has been achieved reduce the vibrator load speed in increments of 10 the machine controls If the speed of the vibrator experiences a larger than 10 decrease in speed when 10 speed reduction is inputted via the machine controls the
55. rator Control 115 COTSWOLD MECHANICAL LTD PAC 015 Key Pad amp Connector Board sss2 l y 41414111111444444 ii M lil nn 116 COTSWOLD MECHANICAL LTD Back Light LCD Board 117 a rms 2 20 24 Two Channel Relay Board Optional 80 24 Eight Channel Relay Board Optional
56. rget Weight then the Bulk and Fine Cut off weights are moved up by the error correction weight If the minimum weight is below then the Bulk and Fine Cut off weights are moved down This operation attempts to correct for any product falling In Flight from the vibrator feeders after the feed has stopped Sample Size range 1 100 Number of discharges over which the in flight correction calculations are performed 65 3 3 PRODUCT OPTIONS 2 Product 001 Drops Per Bag Open Time 0 50 sec Close Time 0 40 sec e Drops Per Bag range 1 100 Enter the number of discharges required to fill bag Weighpan Open Time range 0 00 5 00 seconds Time for which weighpan remains open during product discharge upon completion of a weighing Weighpan Close Time range 0 00 5 00 seconds Time after starting to close the weighpan when the next feed cycle commences Time is to allow the weighpan doors to completely close before restarting feed COTSWOLD MECHANICAL LTD Product 01071 Fear Probe Enabled During Fee HoPPER Low STOP DELAY 1 sec Low START DELAY 0 70 sec FUNCTION LENGTH D ser Rear Probe Enabled Use the ENTER key to select when the rear probe is enabled Hopper Low Start amp Stop delays only if LOW LEVEL PROBE FITTED Timer Function Length Duration of Function Output Example Use Product Settling Duration Time 6
57. rn topup operation ON OFF When topup is turned ON In Average Weight Mode if during the time that the weight is settling after feed the settled weight falls below the Underweight then the feed is restarted in an attempt to achieve the minimum target weight In Minimum Weight Mode if during the time that the weight is settling after feed the settled weight falls below the Target weight then the feed is restarted in an attempt to achieve the minimum target weight Feed will run up to the Maximum Topup Time see next page 64 COTSWOLD MECHANICAL LTD 3 2 1 PRODUCT OPTIONS 1 CONTINUED Maximum Topup Time range 0 00 5 00 seconds The maximum time allowed for an individual topup A time of zero limits topup only to the threshold weight In Flight Correction Turn In Flight Correction operation ON OFF If the In Flight Correction is turned ON In Average Weight Mode an error correction weight is calculated as 50 of the difference of the average weight collected over the Sample Size batch and the Target Weight If the average weight is below the Target Weight then the Bulk and Fine Cut off weights are moved up by the error correction weight If the average weight is below then the Bulk and Fine Cut off weights are moved down In Minimum Weight Mode an error correction weight is calculated as 50 of the difference of the minimum weight collected over the Sample Size batch and the Target Weight If the minimum weight is below the Ta
58. rrect gap between the armature and the coil This gap 15 6mm typically the thickness of an 11 amp 9 ply spring combined Air gap adjustment is achieved by slackening the two bolts per coll see fig 4 on the underside of the base plate Once loose the coil can be moved Step 2 Continued er P Once correct air gap has been ba Jy ft _ up the retaining bolts on the underside of the ol base plate should be fully tightened Step 3 1 Make sure that the product feed tray 15 Tr latched bolted into position on the vibrator unit Set the vibrator speed in the machine control parameters to 100 and switch the system into test mode Make a note of the current vibrator amplitude This 15 best achieved by holding a steel rule as close to the feed tray as possible and measuring the ghost profile created by the movement of the tray see Fig 9 a Fig Vibrator Unit with 11 amp 9 ply springs wedged between coil amp armature to create 6mm air gap Note Some vibrating trays are fitted with a vibration motion label see below which will indicate clearly how much tray displacement occurs It completely negates the need to use a rule to measure the tray movement As the label vibrates with the tray the two diagonal lines will appear to converge The point of convergence can be read off the scale indicating precise tray displacement Fig 9 V1 Vibrator U
59. s are duly taken into consideration when tuning 19 4 ae nu red a gg a gt A N T ur e 4 b _ JN d Di i 7 I B 4 7 y AA b E 4 ne Vibratory Feed System Vibrator Tunin Over a period of time the performance of the Vibratory V2 feed unit may diminish This is usually after a period of eight months or more and 18 more noticeable on weighing applications requiring high vibration speed and amplitude to move the product Leaving the vibrators running at full load speed when the machine is empty or during a wash down can also exacerbate the condition Tuning is a relatively simple process and basically involves selecting the correct combination of fiberglass springs to replace those already on the unit The springs are supplied in three varying thicknesses 7 9 and 11 ply The object of successful tuning 15 twofold 1 To obtain approximately 4 5mm 5 0mm of displacement movement on the top plate of the vibrator unit WHEN A TRAY IS LATCHED IN POSITION and the unit is running at 100 2 To obtain good linear vibration range This is determined by reducing the vibrator speed in the machine controls in intervals of 10 from the full load speed of 100 If the speed of the vibrator experiences a larger than 10 decrease in speed when a 10 speed reduction is inputted via the machine controls the vibration range is deemed as bad Howev
60. struction e Single point 800 x 800mm platform e OIML R60 and NTEP approved e 65 protection e Available with metric and UNC threads OPTIONAL FEATURES e EEx ia IIC T4 hazardous area approval FM approval available P67 option available APPLICATIONS Large platform scales Hanging scales Check weighing ia IIC T4 and are FM approved to class I Il III Division A special humidity resistant protective coating assures longterm stability over the entire compensated temperature range The two additional sense wires sample the bridge supply voltage at the load cell Complete compensation of change on the in the lead wires resistance due to temperature change and or cable extension is achieved by feeding this voltage into the appropriate electronics 191 85 40 5 Overlap Stop 2 1 Not Preset Adjust As Required For Each Specific Application 125 Dia 11 5 or 10 2 metric 8 Mounting Holes M8 OR 5 16 18UNC x 15 Deep 1250 Aluminum High Capacity Single Point Load Cell _ _ __ O O Rated capacity R C Emax 50 75 100 150 200 250 300 500 635 750 1000 150 2 NTEP OIML Accuracy class Maximum of intervals n 5000single 09 71 2 YsEmaVmw 1000 140 1000 available 10000 Rated output R 0 2011 ___
61. t normally require any adjustments The entire Gating Assembly is not intended for removal from the machine IMPORTANT Before any work can commence on the gating mechanism the air supply must first be switched off and the air supply pipes to the pneumatic rotary actuators disconnected by a suitably qualified person The illustration immediately left shows a typical speed controller as found on the underside of the rotary actuators By winding the adjustment screw in or out ADJUSTING SCREW will accelerate or decelerate the speed at which the LOCKING SCREW gates open and close It 18 important to tighten the locking screw once the correct position of the adjusting screw has been ascertained To remove the air pipe from the speed controller first depress the quick release 0 collar and then pull the pipe free disconnect air supply first AIR IN 2 The Hopper Probe Assembl Hopper Probe Post x1 Hopper Probe Adjustable Mountings x1 Hopper Probe x1 The Hopper Probe Assembly Optional Extra The Hopper Probe Assembly is located towards the rear of the machine frame The actual Hopper Probe itself is sited such that it looks downwards into the Hopper Its purpose 15 to control the level of product within the machine Hopper The Hopper Probe monitors the high and low level of product in the hopper If the product level exceeds the levels to which it has been set the in feed equipment Elevator
62. to abort Calibration and return to Main Menu 53 STATIC CALIBRATION CONTINUED Static Calibration 251 Calibration Completed Height 0 05 9 6 Check successful calibration by displayed weight agreeing with actual weight on weigher COTSWOLD MECHANICAL LTD 2 9 MANUAL ZERO Before commencing for multi weigher machines select the weigher to manually zero with the ENTER key Ensure the weigher is empty and clean of product Follow screen instructions her 551 Pressa 7 C button to begin Manual zero anual Press oor Dio an External Discharges to Empty Heighparn L Press button to abort Hanual zero and return to Main Menu 55 COTSWOLD MECHANICAL LTD MANUAL ZERO CONTINUED Zero Progress Please Hait L Press button to abort Manual ero Completed Manual Zero Manual Zero Completed Height 00 q Return to main menu 56 COTSWOLD MECHANICAL LTD 2 10 EMPTY MACHINE To empty the machine of residual product Before commencing for multi weigher machines select the weigher to empty with the ENTER key Press to run normally until no product left in the machine Low product probe is ignored uu Press to empty the machine Runs vibrators at fast speed with all the doors open Emptu Hachine Press oh button to Eun Empty button to
63. ts on the underside of the base plate should be fully tightened Fig 13 V2 Vibrator Unit with 11 amp 9 ply springs wedged between coil amp armature to create 6mm air gap COTSWOLD MECHANICAL LTD V2 Vibrator Vibrator Tuning Continued Step 3 Make sure that the product feed tray 15 latched bolted into position on the vibrator unit Set the vibrator speed in the machine control parameters to 100 and switch the system into test mode Make a note of the current vibrator amplitude This is best achieved by holding a steel rule as close to the feed tray as possible and measuring the ghost profile created by the movement of the tray see Fig 14 Note Some vibrating trays are fitted with a vibration motion label see below which will indicate clearly how much tray displacement occurs gt gt It completely negates the need to use pe nt a rule to measure the tray lon movement EI As the label y Tu vibrates with the LI tray two T diagonal lines will V appear to converge The point of convergence can be read off the scale indicating precise tray displacement Fig 14 V2 Vibrator Unit running at 100 steel rule used to measure tray displacement left by shost image of tray when vibrating Step 4 If the amplitude of the tray measures approximately 4 5mm to 5 0mm then proceed to step 8 to ensure good linear vibration range Step 5 If the am
64. unce directly off the tray and straight back again causing problems on set up later on 3 Move Timing range switch to position 1 4 Adjust the sensitivity sens to suit product depth when an optimal level of product is present in the machine Hopper This 15 largely dependent on the flow characteristics of the product to be weighed and some trial and error experimentation may be required As a general rule dense less free flowing products require a low filling level within the Hopper whilst lighter easily free flowing granular product can be filled to a much higher level To achieve this fill the Hopper manually by hand to the desired level as would be experienced under normal running conditions Turn the sens adjuster until the red LED stays permanently on NOTE The green LED denotes healthy probe status 2 Hopper Probe Assembly optional extra Adjusting The Probe Sensitivity continued 5 Adjust the 1 on delay so that the red LED illuminates approximately two seconds after product has been placed in front of the probe For ease of set up the operator s hand can be placed in front of the probe and remain in position whilst a period of two seconds elapses rather than trying to achieve the same effect with product The purpose of the two second delay is to protect the integrity of any ancillary equipment such as a product elevator feeds product to the machine hopper Without the two second delay any ancillary equipment would
65. weights and measures requirement to ensure no unauthorised calibrations can be performed 2 Ensure weigher is warmed up allow at least 15 minutes for this 3 Ensure the weigher is empty and clean of product 4 Press to begin calibration Next screen is displayed Follow screen instructions until successful calibration 50 COTSWOLD MECHANICAL LTD STATIC CALIBRATION CONTINUED Static Calibration Press oF Dio an External Discharge to Empty Heighpar L Press button to abort Calibration and return to Main Menu Static Calibration Ensure Helgher is Empty umm 7 button to Perform cero Calibration Press L Press button to abort Calibration and return to Main Menu SI COTSWOLD MECHANICAL LTD STATIC CALIBRATION CONTINUED Static Calibration Zero Calibration in Progress Please Hait aaa Static Calibration Zero Lalibration Successful Flace 100 Calibration Weight on the Heigher and L Press gus button when Stable L Press button to abort Calibration and return to Main Menu 5 Place calibration weight value as shown on the weigher and follow screen instructions 32 COTSWOLD MECHANICAL LTD STATIC CALIBRATION CONTINUED Static Calibration Range Calibration in Progress Please Halt Static Calibration Range Calibration Successful Remove Calibration Height LI L button to complete Press L Fress button
66. wo hopper feed control gates One of the gates controls the bulk or majority of product exiting the hopper whilst the other controls the fine amount The volume and depth of product that exits the hopper can be adjusted by loosening the hand wheels then raising or lowering the appropriate hopper slide gate and re tightening the hand wheel once the correct level has been achieved Normally this 15 set to the minimum gap that will allow the product to flow freely from the hopper 11 a B CEU Ww 7 gt 4 A MW B O A C BE N j D E 7 mr E Vibratory Feed System Bulk Primary Feed Tray Fine Secondary Feed Tray ElectroMagnetic Vibratorv Feed Unit V2 Electro Magnetic Vibratory Feed Unit The Vibratory Feed system The CMW8000 system comprises of two vibratory feed trays mounted on electromagnetic vibratory feed units The Primary Bulk Vibrator Tray feeds product from the hopper in to the Gating System Similarly the Secondary Fine Vibrator Tray feeds product in much the same way to the Gating System as well When the weighpan is being filled both trays feed product simultaneously to achieve maximum product throughput As the weighpan approaches target weight the Bulk Tray switches off and the Fine Tray dribble feeds the last few pieces of remaining product The exact point of shut off can be adjusted and set with
67. y damage 2 Check Vibrator Spring retaining Monthly bolts for wear damage 3 Check Vibrator Armature for 3 Monthly wear damage 4 Check Armature air gap 3 Monthly adjustment should be approx 6mm 5 Check Vibrator Coil for wear 3 Monthly damage PNEUMATICS Solenoid Value Fitting Round head combination screw M1 7 x 17 Matt nickel plated Applicable manifold base Manifold base Valve model Type of actuation EMI PES A B b Cv b E um 36 So 37 41 047 036 039 010 97 1804 164104 SECC ANTA pos Pressure 0 5 MPa j Series 06 010 016 020 025 032 040 800 700 E Um E upward actuation neri EI LLL rizontal actuation 1 5 3140 5 si re 100 m Cylinder is extending Speed controller meter out which ts Pei connected with cylinder and its needle is fully opened Average speed of cylinder is obtained by dividing the full stroke time by the stroke Load factor Load weigh x 9 8 Theoretical force x 100 5 Rotary Actuator me Stop Position Adjustment Air Flow Speed Adjustment Rotation range When pressurized from the Port A the shaft will rotate clockwise Flat face and parallel key position ind

CMW 8000 USER MANUAL - Cotswold Mechanical Handling

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