1020 Check Weigher

1020 Check Weigher
1020 Check Weigher
PENKO Engineering B.V.
Your Partner for Fully Engineered Factory Solutions
Manual:
1020 Supplement Check Weigher Controller
1
1020 Check Weigher
Table of Contents
1
Introduction .............................................................................................................................. 3
2
Indication of display .................................................................................................................. 4
3
Configure and control ............................................................................................................... 6
4
5
3.1
PENKO configuration software .......................................................................................... 6
3.2
Device ................................................................................................................................ 8
3.3
Industrial protocols.......................................................................................................... 13
Parameters .............................................................................................................................. 14
4.1
Configuration parameters ............................................................................................... 14
4.2
Recipe parameters........................................................................................................... 16
4.3
Live process parameters .................................................................................................. 17
Inputs and outputs .................................................................................................................. 18
5.1
Inputs ............................................................................................................................... 18
5.2
Outputs ............................................................................................................................ 18
6
Printer Ticket ........................................................................................................................... 19
7
Program basics ........................................................................................................................ 20
8
7.1
Static check mode, Reject mode set to Time .................................................................. 20
7.2
Static check mode, Reject mode set to Photocell ........................................................... 20
7.3
Dynamic check mode, Reject mode set to Time ............................................................. 21
Default settings ....................................................................................................................... 22
2
1020 Check Weigher
1 Introduction
This manual is applicable for the following Check Weigher devices:
•
•
•
1020 CHK
1020 CAN-RS232-RS422 CHK
1020 Profibus CHK
To configure and control the Belt Weigher, the following options are available:
Full control:
•
•
•
•
•
•
PENKO Pi Mach II software
PENKO PDI Client software
Modbus protocol
Profibus protocol
EtherNet/IP protocol
ASCII protocol
Basic control:
•
•
Fins protocol*
PENKO TP protocol*
* Register functions not available
Note:
This manual does not describe the basic functionality of the device. Consult the device manual
for this.
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1020 Check Weigher
2 Indication of display
1
2
8
3
4
5
6
7
9
1
Current selected recipe
6
Total correct product weight
2
Zero active
7
Inputs 1, 2, 3
3
Tare active
8
Value
4
Weigher stable
9
Status Indications
5
Total correct product amount
Options for indication 2nd screen
Use the LEFT or RIGHT key to switch between the four main screens.
The 2nd screen shows the flow as the largest indication.
or
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1020 Check Weigher
5a
6a
5a
Currently selected low level from
recipe
5b
Currently selected high level from
recipe
Status Indications:
9
Start
Reject – reject output active
Low – last checked value was too
low
Busy – check weighing in
progress
OK – last checked value was ok
Alarm – alarm output active
High – last checked value was too
high
Transport – transport belt running
5
1020 Check Weigher
3 Configure and control
To configure and control the Check Weigher, the following options are available:
•
•
•
PENKO configuration software
Device
Industrial protocols
3.1 PENKO configuration software
PENKO Pi Mach II and PENKO PDI Client can be downloaded from www.penko.com
USB driver and user manual are included in the download
Pi Mach II supports USB and Ethernet connection. PDI Client is USB only.
Consult the manuals on how to install and connect to the device.
In the tree structure of the device, the configuration parameters are found at:
PENKO - PENKO 1020 - System Setup - Configuration
Configuration parameters
The parameters are explained in chapters 4
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1020 Check Weigher
In the tree structure of the device, the recipe parameters are found at:
PENKO - PENKO 1020 - Recipe
Recipe parameters
The parameters are explained in chapters 4
7
1020 Check Weigher
3.2 Device
Configuration
Select System Setup from the Main Menu and press Enter.
Select Configuration from the System Setup Menu and press Enter.
The following error is visible if no configuration is present.
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1020 Check Weigher
Press Enter to start with default values.
When pushing the LEFT key, the help text of the parameter is shown.
Below the example of a help text for the parameter Check Mode.
The parameters are explained in chapters 4
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1020 Check Weigher
Recipe
Select Recipe from the Main Menu and press Enter.
Select Recipe and press Enter.
Enter the recipe that you want to edit and press Enter.
A maximum of 10 recipes can be stored.
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1020 Check Weigher
If the selected recipe does not exist, the following error is visible:
To edit current selected recipe parameters, select Recipe Edit and press Enter.
The following screen is visible:
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1020 Check Weigher
When pushing the LEFT key, the help text of the parameter is accessed.
Below an example of the help text for the parameter Low Level.
The parameters are explained in chapters 4
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1020 Check Weigher
3.3 Industrial protocols
The PENKO protocols Modbus, Profibus, EtherNet/IP and ASCII have a function set called
register functions. These functions allow the user to configure and control the device.
Protocol descriptions can be downloaded from www.penko.com
Consult these on how to connect the device and use the register functions.
Modbus TCP
Modbus SERIAL
Profibus
EtherNet/IP
ASCII TCP
ASCII SERIAL
1020



1020 CAN-RS232/422





1020 Profibus




Note: the FINS and PENKO TP protocol do not support register functions, only basic read and
write operations for markers and registers.
The parameters are explained in chapters 4
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1020 Check Weigher
4 Parameters
These parameters correspond with the parameters in the tree structure of the device Recipe.
When using the industrial protocol register functions, each parameter can be reached using its
number.
Some parameters can be reached directly using ASCII, TP protocol, Modbus RTU, Modbus TCP,
Fins, Profibus or EtherNet/IP. The parameters for Profibus or EtherNet/IP are prefixed with PB
or EIP.
Note: when the device is rebooted or the recipe is manually changed, all recipe parameters are
changed back to the value that were last set manually in the recipe.
4.1 Configuration parameters
No. Name
1
Check mode
Description
Select if the check weigher is used for dynamic or static
weighing.
•
2
Stability
Dynamic => the product will move during weighing (belt is
running).
• Static => the product will be stopped during weighing (belt
is stopped when check input is high and restarted when
check is done).
Select the type of check delay. In static check mode the belt
will stop during the check delay.
•
•
•
•
3
4
H-Time
Display hold
Off => check starts directly
Stable => check starts after Stable
H-Time => check starts after H-time
H-Time+Stable => check starts after H-time and then
Stable
• H-Time/Stable => check starts after H-time or Stable
• Stable+H-Time => check starts after Stable and then HTime
Time to wait for stable weight measurement.
Δ Not used if Stability parameter is set to Off or Stable
The time to freeze the checked value on the display after the
check is done. When a check starts before the display hold
time is elapsed, the hold time will be cut off.
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1020 Check Weigher
5
6
Δ Not used if Stability parameter is set to Off or Stable
Rejector mode Select when the packages should be rejected.
Fixed speed
• Time => reject after a set time (settings are in recipe)
• Photocell => reject when passing the photocell (input 3)
Select if the belt speed is fixed or variable.
•
7
8
Min. speed
Max. speed
No => belt speed is variable between set minimum and
maximum speed and is controlled by the analog output
• Yes => belt speed is fixed (setting is in recipe)
Enter the minimum variable belt speed.
Enter the maximum variable belt speed.
9
Recipe
Select the used recipe.
10
Online ticket
11
Use alibi
memory
• Local => use the recipe selected on the device
• Remote => use the recipe from a remote device (e.g. PLC)
Select if a printer ticket must be printed for each checked
product.
Select if a result must be written to the internal alibi memory.
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1020 Check Weigher
4.2 Recipe parameters
These parameters correspond with the parameters in the tree structure of the device Recipe.
When using the industrial protocol register functions, each parameter can be reached using its
number.
Some parameters can be reached directly using ASCII, TP protocol, Modbus RTU, Modbus TCP,
Fins, Profibus or EtherNet/IP. The parameters for Profibus or EtherNet/IP are prefixed with PB
or EIP.
Note: when the device is rebooted or the recipe is manually changed, all recipe parameters are
changed back to the value that were last set manually in the recipe.
No. Name
1
Low level
2
High level
3
Preset tare
Description
If the checked value is below this value, the package will be
rejected.
If the checked value is above this value, the package will be
rejected.
The preset tare will be subtracted from the checked value.
4
Sample time
Duration of the package weight measurement.
5
Correction
6
Check delay
7
8
Belt speed
Rejector delay
9
Reject hold
10
Batch code
Correction factor to correct the fault caused by the dynamic
characteristics of the machine. Correction can be set from
0% to 200%. 100% means no correction is used.
Enter the time between detecting a product and start
checking or stopping the belt.
The speed of the transport belt in %
Delay time to activate the rejector after detecting a faulty
package.
Time to hold the rejector output active for a certain time
after activating.
Enter a Batch code for printing reports.
Location
PB-R85
EIP-R11
PB-R86
EIP-R2
PB-R87
EIP-R13
PB-R88
EIP-R14
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1020 Check Weigher
4.3 Live process parameters
When using the industrial protocol register functions, each parameter can be read using its
number.
Example: to read the value of low level, Use the function code 701 and value 1.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Name
Low level
High level
Subtotal
std.dev
Subtotal
average
Subtotal
(weight) ok
Subtotal
count ok
Subtotal
count low
Subtotal
count high
Subtotal
count total
Total
std.dev
Total
average
total
(weight) ok
Total count
ok
Total count
low
Total count
high
total count
total
Alibi no.
Description
Get the low level value.
Get the high level value.
Get the standard deviation of the
subtotal.
Get the average value of the subtotal.
Marker
M401
M402
M403
Get the weight of the accepted
products of the subtotal.
Get the number of accepted product
of the subtotal.
Get the number of too low product of
the subtotal.
Get the number of too high product of
the subtotal.
Get the number of all product of the
subtotal.
Get the standard deviation of the total
batch.
Get the average value of the total
batch.
Get the weight of the accepted
products of the total batch.
Get the number of accepted product
of the total batch.
Get the number of too low product of
the total batch.
Get the number of too high product of
the total batch.
Get the number of all product of the
total batch.
Get the number of the Alibi record.
M405
M404
M406
M407
M410
M411
M412
M414
M415
M416
M417
Marker
M401
M402
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1020 Check Weigher
5 Inputs and outputs
The following inputs and outputs are used.
5.1 Inputs
Input Name
Description
1
Start/Stop
2
Start
Sampling
Reject
Sensor
Input must be high to set the program in
run mode.
Input to start sampling the package.
3
Input to detect the package on the reject
position. Input must be placed diagonal
over the belt.
Profibus
marker
969
EtherNet/IP
marker
433
970
434
971
435
5.2 Outputs
Output Name
1
Rejector
2
Sampling Busy
3
Transport Belts
4
Alarm
Analog Belt Speed
out
Description
Output to enable the rejector after the package is detected on
the reject position.
Output to enable the busy output.
Output is high from detecting the package until sampling is done.
Output to enable the transport belts.
In dynamic mode the output is always on if no alarm is
generated.
In static mode the output is off during sampling and during an
indicator alarm.
Output to enable the indicator alarm.
This output is used to activate the indicator alarm.
This alarm can be reset by switching off input 1.
Belt Speed will be available from 0.00% to 100.00%.
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1020 Check Weigher
6 Printer Ticket
Example of the 1020 Printer recipe when ‘Ticket’ layout is selected.
Programmable header 1
Programmable header 2
Programmable header 3
Programmable header 4
-------------------------------------DATE
07-10-11
TIME
05:57.13
RECIPE
001
TICKET NUMBER
100
CHECKED NET
00000.00 kg
-------------------------------------Programmable footer 1
Programmable footer 2
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1020 Check Weigher
7 Program basics
This chapter describes a few basics of the Check Weigher program which can be used when
starting the program for the first time.
7.1 Static check mode, Reject mode set to Time
With input 1 you can Start (input high) and Stop (input low) the program. The Transport Belt
(output 3) will start. With a pulse on Start Sampling (input 2) the checking will start. During
checking the Transport Belt (output 3) will stop and Sample Busy (output 2) is on.
When the checking is complete and the weight is ok, the Transport belt (output 3) will start
again, Sample Busy (output 2) is off. With a pulse on Start Sampling (input 2) the checking will
start again.
If the weight is below Low Level or above High Level the Transport belt (output3) will start
again. After the Reject Delay time, the Rejector (output 1) will turn on, and will remain on for
the duration of the Reject Hold time. With a pulse on Start Sampling (input 2) the checking will
start again.
7.2 Static check mode, Reject mode set to Photocell
With input 1 you can Start (input high) and Stop (input low) the program. The Transport Belt
(output 3) will start. With a pulse on Start Sampling (input 2) the checking will start. During
checking the Transport Belt (output 3) will stop and Sample Busy (output 2) is on.
When the checking is complete and the weight is ok, the Transport belt (output 3) will start
again, Sample Busy (output 2) is off. With a pulse on Start Sampling (input 2) the checking will
start again.
If the weight is below Low Level or above High Level the Transport belt (output3) will start
again. When the photocell (connected to input 3) has detected the product, the Rejector
(output 1) will turn on, and will remain on as long as input 3 (photocell) in on. With a pulse on
Start Sampling (input 2) the checking will start again.
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1020 Check Weigher
7.3 Dynamic check mode, Reject mode set to Time
With input 1 you can Start (input high) and Stop (input low) the program. The Transport Belt
(output 3) will start. With a pulse on Start Sampling (input 2) the checking will start. During the
checking the Sample Busy (output 2) is on.
When the checking is complete and the weight is ok. The Transport belt (output 3) will start
again, Sample Busy (output 2) is off. With a pulse on Start Sampling (input 2) the checking will
start again.
If the weight is below Low Level or above High Level the Transport belt (output3) will start
again. After the Reject Delay time, the Rejector (output 1) will turn on, and will remain on for
the duration of the Reject Hold time. With a pulse on Start Sampling (input 2) the checking will
start again.
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1020 Check Weigher
8 Default settings
Configuration:
Configuration
Static check
mode, Reject
mode set to Time
Static check
mode, Reject
mode set to
Photocell
Dynamic check
mode, Reject
mode set to Time
Check Mode
Static
Static
Dynamic
Stability
Stable + H-Time
Stable + H-Time
Stable + H-Time
H-Time
1.00 sec
1.00 sec
1.00 sec
Display Hold
1.00 sec
1.00 sec
1.00 sec
Rejector Mode
Time
Photocell
Time
Fixed Speed
Yes
Yes
Yes
Min. Speed
0.00%
0.00%
0.00%
Max. Speed
100.00%
100.00%
100.00%
Recipe
Local
Local
Local
Online Ticket
No
No
No
Use Alibi Memory
No
No
No
(Disabled if stability
parameter is set to
off or stable)
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1020 Check Weigher
To access the DAC setup, select In/Outputs from the System Setup Menu and press Enter.
Select DAC Setup and press Enter. If you don’t have the DAC output, In/Outputs is not available.
DAC setup
Setting
Indicator
Speed
Min
0.00%
Max
100.00%
Mode
4 – 20 mA
To access the Weigher setup, select Indicator Setup from the System Setup Menu and press
Enter. Select Indicator and press Enter, enter the TAC code (the TAC code is visible in the
bottom right corner of the LCD screen) and press Enter. Select Weigher and press Enter.
Weigher
Setting
Unit Label
Kg
Step
1
Decimal point
0.00
Operation Mode
Industrial
Max Load
1000.00
To access the Stable Condition setup, select Indicator Setup from the System Setup Menu and
press Enter. Select Indicator and press Enter, enter the TAC code (the TAC code is visible in the
bottom right corner of the LCD screen) and press Enter. Select Stable Condition and press
Enter.
Stable Condition
Setting
Range
0.10 kg
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1020 Check Weigher
Time
0.50 sec
To access the Stable Condition setup, select Indicator Setup from the System Setup Menu and
press Enter. Select Indicator and press Enter, enter the TAC code (the TAC code is visible in the
bottom right corner of the LCD screen) and press Enter. Select Filter and press Enter. Select
Digital and press Enter.
Filter Digital
Setting
Digital Filter
Dynamic
App.
Cutoff Frequency
1.0 Hz
Frequency
10 Hz
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1020 Check Weigher
About PENKO
Our design expertise include systems for manufacturing plants, bulk weighing, check weighing, force measuring and process control.
For over 35 years, PENKO Engineering B.V. has been at the forefront of development and production of high-accuracy, high-speed
weighing systems and our solutions continue to help cut costs, increase ROI and drive profits for some of the largest global brands,
such as Cargill, Sara Lee, Heinz, Kraft Foods and Unilever to name but a few.
Whether you are looking for a simple stand-alone weighing system or a high-speed weighing and dosing controller for a complex
automated production line, PENKO has a comprehensive range of standard solutions you can rely on.
Certifications
PENKO Professional Services
PENKO sets high standards for its products and product
performance which are tested, certified and approved by
independent expert and government organizations to
ensure they meet – and even – exceed metrology industry
guidelines. A library of testing certificates is available for
reference on:
http://penko.com/nl/publications_certificates.html
PENKO is committed to ensuring every system is installed, tested,
programmed, commissioned and operational to client specifications.
Our engineers, at our weighing center in Ede, Netherlands, as well as
our distributors around the world, strive to solve most weighingsystem issues within the same day. On a monthly basis PENKO offers
free training classes to anyone interested in exploring modern,
high-speed weighing instruments and solutions. A schedule of training
sessions is found on: www.penko.com/training
PENKO Alliances
PENKO’s worldwide network: Australia, Belgium, Brazil, China,
Denmark, Germany, Egypt, Finland, France, India, Italy, Netherlands,
Norway, Poland, Portugal, Slovakia, Spain, Syria, Turkey, United
Kingdom, South Africa, Slovakia Sweden and Switzerland, Singapore.
A complete overview you will find on: www.penko.com/dealers
PENKO Engineering B.V. ▪ Schutterweg 35, NL 6718XC Ede ▪ Tel +31 (0) 318525630 ▪ Fax +31 (0) 318529715▪ info@penko.com
Web ▪ www.penko.com ▪ Copyright © 2014 ETC All rights reserved 7600M105-EN-R5 1020 MANUAL SUPPLEMENT CHK.
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