NW EAGLE NET WEIGH BAGGING SCALE JEM INTERNATIONAL, INC. 6873 MARTINDALE SHAWNEE, KS 66218 Phone: (913) 441‐4788 FAX: 913‐441‐1711 www.JemBaggingScales.com Email: email@example.com RECEIVING THE SCALE The scale in most instances is shipped in a wooden crate. If the scale has the following feeders, typically the parts of each shipment are as follows: Gravity Gate 2-position One scale assembly with gravity gate attached One spout assembly unattached One process controller panel Single Vibratory (2-speed feed rate) One scale assembly One vibrator assembly One control panel for vibratory feeder One spout assembly unattached One digital control panel for scale Gravity Gate/Vibratory Feeder One scale assembly with gravity gate attached One spout assembly unattached One digital control panel unattached One vibrating pan feeder and framework unattached One pant leg diverter unattached Belt 2-Position pneumatic flow gate or Variable Speed Controller (2-speed feed rate) One scale assembly with feeder attached One spout assembly unattached One digital control panel unattached One drip pan unattached Twin Auger Variable Speed Controller One scale assembly and slide gate attached One Auger feeder unattached One spout assembly unattached One digital control panel unattached Check the condition of the scale, as it arrives from the shipping company. It is extremely important that if damage is noted, a freight claim is filed by your company at this point. The shipper cannot file a freight claim on your behalf and it is imperative that before the scale system is removed from the crate that it be inspected thoroughly. DIGITAL INSTRUCTION MANUAL The scale preweighs the product prior to discharging it into the bag. The typical model is designed for handling 10-14, 50 lb. (25 kg.) bags per minute at () 2 oz. to 3 oz accuracy (55 to 85 grams) at 2 Sigma (95%). The scale can be supplied in simplex, duplex or triplex operation. The scale has 3 sections: 1) The Feeder Section is the section most associated with weight accuracy. The feeder section can be one of the following designs: Gravity Gate (2 position) Gravity Gate/Vibratory Feeder Single Vibratory (2-speed feed rate) Belt 2 Position Pneumatic Flow Gate or Variable Speed Controller (2 Speed feed rate) Twin Auger Variable Speed Controller The feeder is chosen based on product flow characteristics. All scales are designed with 2-speed feed rates, both fast and slow fill. Typically the slow or dribble fill should be set for no greater than 5 lbs. (2 ½ kg.) per second fill rate. 2) The Center Section of the scale is where the actual weighing is accomplished. The weighing is accomplished in a weigh hopper supplied with double door design. The weigh hopper is available in 2 cubic foot, 3 ½ cubic foot and 4 cubic foot as standard. The size of the weigh hopper is determined by the bulk density of your product and the target weight. The center section also includes the complete pneumatic filter regulator assembly and the weighing load cells and valves. This section also includes a transition to connect up to a bag clamp assembly or into other automated equipment. 3) The spout is designed for holding the bag in place during the discharge cycle. The spout can be supplied in either air operated dust tight design with a 21”, 25”, or 31” (52, 62, or 77 cm.) circumference spout as standard. We also have a clam shell design spout which is designed to work on bags with a larger than 28” (70 cm.) circumference. Only one clam shell size spout is available, and is typically used in non-dusty applications. The scale can be operated with either a pneumatic foot pedal or a hand switch on the spout assembly. PLANNING THE INSTALLATION The scale should be installed with the bottom of the spout typically 48” (1.2 meters) from floor level. This is typically ideal height for the operator to work at. If the scale is being supplied with an automatic bag placer, check the prints to verify dimensions for installation. The 48” (1.2 meters) is divided by a maximum bag height of 36” (.9 meters) and 12” (.3 meters) for the conveyor. If the bag is shorter than 36” (.9 meters), the height of the conveyor is typically raised to suit. If, however, the bag is taller than 36” (.9 meters), the height of the scale will have to be adjusted accordingly. The process controller needs to be positioned in an area easily accessible by the operator of the scale. The operator must be able to visually see the digital display and be capable of touching the panel to make adjustments. The scale is supplied with a filter regulator system for receiving air. A ¼” male quick connect pipe connection is supplied on the scale. The scale will require 100 PSI air pressure at 4 cubic feet per minute on a simplex and 7 to 8 cubic feet per minute on a duplex. There are two filter regulators on each scale. The upper unit is designed for handling the pneumatic needs of the feeder section and the weigh hopper. The lower unit is designed for handling the complete pneumatic needs of the bag clamp assembly. The following charts apply to typical pneumatic needs of the feeder and weigh hopper. Belt Fed Scale 60 PSI Single Vibratory (2 Speed) 60 PSI Gravity/Gravity Scale 80 PSI Gravity/Vibrator Scale 60 PSI Auger Fed Scale 60 PSI The lower regulator to supply the pneumatic needs of the bag clamp assembly has been factory set at 80 PSI. The amount of pressure here is determined by the weight of your bag and the material of your bag. The amount of pressure here should be set only with enough pressure to hold the bag in place during the discharge of the weigh hopper. Typically on 50 lb. (25 kg.) paper bags, the pressure will be set between 60 and 90 PSI. On bags of 110 lbs. (50 kg.) the setting can be 100 PSI. After the scale has been installed, it is extremely important that the scale be rigidly attached either to a support system from the floor or a support system from the bins. If the bins have vibrators attached to them, it is generally recommended that the support system be connected to the floor. Vibration to the scale will cause inaccuracies. The scale also needs to have rigid supports as the weight of the scale is as follows: Belt Fed Scale Gravity/Gravity Scale Gravity/Vibrator Scale Auger Fed Scale 1,200 Lbs. 950 Lbs. 1,100 Lbs. 1,200 Lbs. You should also account for the weight of the product in the weigh hopper, plus the weight of the product in a bag held from the spout and head pressure from your surge hopper above when designing the supports for the scale. When installing the net weigh bagging scale on your bin, head pressure is a concern. The bin must be large enough to ensure that three weighments of product are available at all times above the feeder to ensure accurate weighments. However, too much product and head pressure on the feeder can cause problems. Especially in products where the bin is large and mounted directly over the feeder. This can cause stress on the feeder and can cause inaccuracies. A baffle or some type of method of suppressing the force of your product on our feeder is recommended in many instances. The installation of such baffle is extremely important. The baffle must not cause bridging of your product in the bin, but it also must be installed in such a way that the pressure from directly above the feeder is limited. Baffles are most always used in stone, cement and other products with bulk densities of greater than 80 lbs. per cubic foot. Baffles are almost never used in industries such as soil or flour based products where bridging can easily occur. When installing the spout on the scale, check for the front and rear position. On dust tight spouts, the air cylinder will be on the operator’s right side. This spout has a bracket to hold the microswitch. The microswitch has been wired up to the scale and is generally shipped attached to the main scale section. This microswitch and bracket assembly needs to be connected to the spout on initial installation. This bracket is on the back left of the spout. Most air operated dust tight spouts are supplied with a pneumatic foot pedal. The pneumatic foot pedal assembly has been shipped in a box loose from the spout. There are three airlines connecting this spout to the foot pedal. The longest airline connects to the filter regulator attached to the lower part of the CM-780 scale. The next longest airline connects to the air cylinder on the right side of the scale; the port closest to the operator, and the shortest airline connects to the air cylinder on the right hand side of the scale; the port furthest from the operator. This arrangement will typically have the bag clamp assembly in the closed position. When the operator steps on the foot pedal, the clamps will open, thus releasing the filled bag, the operator will then insert the next bag, release the foot pedal and the clamps will close. In this arrangement, the operator does not have to stand on the foot pedal when the bag is filling. If your plant desires to have this sequence of operation reversed, reverse the A and B airlines on the foot pedal. ELECTRICAL INSTALLATION Please see included wiring schematic for installation. The main scale assembly on the scale has a terminal strip with numbers. The controller was disconnected for shipping purposes. The controller has been pre-wired with connection cables. Please follow the schematic for matching color codes for wire terminating to bagging scale. The controller (duplex or triplex scales) has a terminal strip with numbers/letters. These need to be matched to the same numbers/letters on the terminal strip at the scale housing. You will need to provide control wire for the connections. Please do not use anything less than 16 AWG stranded wire. Please see local electrical codes for length of run and AWG specifications. The load cell cable is connected within the controller and includes 15 feet to connect to the summing box on the bagging scale. Please do not run high voltage (90 VAC or higher) in the same conduit as the low voltage control wire. You can either run this in the same conduit as the load cell cable or provide its own separate conduit. A pre-punched hole is included for incoming power, control wire and load cell cable (3 total). The load cells have cable connecting into a common load cell summing box. This load cell summing box needs to connect through the bottom of the controller and terminate via the green terminal block in the Rinstrum. You will find this on the top right corner on the back side of the controller face (labeled Load Cell). It is extremely important to remember that load cell cable and wire cannot be run in the same conduit. You must run one conduit for the wire and a separate conduit for the load cell cable or else there is a possibility of line interference to the load cells causing weight inaccuracies. The programmable controller is designed to work with a clean grounded isolated 110V or 220V supply, an amp fuse is provided. If the scale is supplied with an auger or belt feeder, and with or a without variable speed drive, then the 3 phase power is connected to the terminal strip in the feeder’s control box. This terminal strip is marked L1, L2 and L3 (see attached schematic). All motors have been clearly marked with their voltage requirements. Verify prior to installing 3 phase power. On 110V/220V connections to control panel, it is extremely important that this voltage be verified before being introduced to the scale system. The incoming 110V power should be connected to L and N on the terminal strip. Verify you have a clean neutral that no voltage is present between ground and neutral. The ground wire to L should be 110V () 15%. Photo 1 Load cell cover Hopper support bracket Gap 1/4” Shipping position Bolt touching bracket NO Gap Operating position Bolt cannot touch load cell Load cell Shipping bolt Photo 2 Photo 3 SEQUENCE OF OPERATION The following is a simple sequence of operation and will be more detailed for different types of units provided. 1. Set programmable controller using final weight, free fall, and preliminary. Final weight is your target weight, Free fall is the amount of product in suspension, and Preliminary is the amount of slow fill weight. The fast feed cutoff is final weight less preliminary and slow feed cutoff is final weight less free fall. Example: Settings 50 lb. final weight, .6 lb. free fall, and 20 lb. preliminary. The feeder will run fast for 30 lb., then slow until 49.4 lb., then off. The product in suspension would fall and the weight will be 50 lb. 2. Turn scale to on. Scale will now run through fast feed, slow feed, and weigh complete. 3. Place bag on spout. When spout closes, o.k. to discharge signal will be provided. 4. Weigh hopper will be discharged. Weigh hopper doors will close and feeding cycle will repeat. OPERATIONAL TIPS The scale is designed for fast feed, slow feed, weigh complete and discharge operations. Lights on the inside of the programmable controller display each of these functions. Lights on the valve also display when the valve has been energized. It is extremely important to remember that problems can be mechanical, electrical or pneumatic. The light sequencing features allow your operators to determine if the problems are pneumatic or electrical. The valves that we supply have push button overrides on each valve and each valve has speed controls mounted directly underneath the valve between the valve and the baseplate. If the valve receives an electrical signal from the control panel, it lights. If the valve does not operate, then it probably is a pneumatic problem. If the light does not come on and you an manually override the valve by pushing in on the override push button, then you have an electrical problem. Before operating your scale, pull down on the weigh hopper 5 or 10 times fairly hard. The weight on the indicator should return to 0 or the starting point each and every time. If it fails to do so, a mechanical problem could be present. Mechanical problems are described in the troubleshooting portion of this manual. The scale is designed to provide you with optimum speed and accuracy on each and every product that you run through the scale. When setting your scale, you must set the controller for excessive slow fill. Typically setting a target weight of 50 lbs. and prelim of 30 lbs. would create a fast fill of 20 lbs. and a slow fill of 30 lbs. Remember that in slow fill, a maximum rate is 5 lbs. per second. Once you have run several bags, the weight over 50 lbs. needs to be entered into the free fall value on the 600 series programmable controller. For example, if 51.00 lbs. is obtained, 1.0 lb. is entered into free fall. This will stop the feeder at 49.00 lbs. and allow for 1.0 lb. of free fall to accomplish a 50.00 lb. weighment. First and foremost, you must make the scale accurate. DO NOT ATTEMPT EVER TO ADJUST FOR SPEED AND ACCURACY AT THE SAME TIME. By lowering the value of the prelim, will subsequently increase the fast fill and reduce the slow fill. Continue to decrease the prelim value until the accuracy is lost. Once you have obtained ideal speed and accuracy for this product, these values can be retained in the product “#” feature. See controller instructions. BAG CLAMP SAFETY Bag clamps (spouts) The most ergonomically correct height for the spout is 48 inches (1.2 meters) to the floor. Exception to this rule is that the bag closing conveyor should not be lower than 12 inches (305 mm) to the floor. If the bag is taller than 36 to 37 inches (914 to 940 mm) then height will have to be adjusted upward to ensure a gap to allow the bag to fall and clear the spout. Bags are placed on the spouts manually by operators. The clamps are operated by a foot pedal, hand wand switch or special order push buttons. Normally in plants where fertilizer, salt or other corrosive products are handled, foot pedals are not recommended. But foot pedals seem to be the most operator friendly device. Hanging the bags safely is critical to a successful operation. Bags manufactured of paper or laminated poly propylene have excellent rigidity and are the easiest to work with. Poly woven, cloth and low density poly ethylene bags have the least rigidity and are more difficult for the operator to hang. Bags with rigidity are generally placed by the operator in the following manner. 1. Grab the bag with right hand approximately 12” (304 mm) from the top. 2. Slide the bag over the right end of the spout, allowing the shape of the spout to open the bag. 3. When bag is approximately 4” (101 mm) on the spout, activate the clamping assembly. 4. Operator’s right hand will now be approximately 8” (203 mm) below the clamps. On bags with less rigidity the operator’s hand or hands will need to be closer to the top of bag. Subsequently, closer to the bag clamps and more care needs to be taken by the operator. On cloth and low density poly propylene bags two hands may be required to hang the bag. The operator needs to make sure his/her hands are clear of the spout assembly before activating the clamp switch/foot pedal. The bag clamps not only support bags during the filling but also some models are designed to control dust. To control dust the spout assembly and brackets that hold the bag must be of very close tolerance. Close tolerance also means pinch point. All dust tight spouts are designed with spring loaded brackets that hold the belting material. This minimizes the risk to the operator’s hand but the dust tight design is more cumbersome to most operators than the center grip or clam shell spout. Clam shell spouts are designed for bags with a minimum 28” (711 mm) circumference. This fits the industry standard rule that spout circumferences need to be at least 5” (127 mm) smaller than the circumference of the smallest bag being used. If the circumference of the spout and the circumference of the bag are 5” (127 mm) or less it is cumbersome for the operator to place the bag on the spout assembly. The dust tight spouts (DT) and center grip spouts (CG) are available in a variety of sizes so these are basically customized to the bags being used in normal operations. The normal shape is pecan or US football shaped. This helps in opening the bag during placement and does not misshape the bag during the filling operation. It is important that the bag not be misshaped to ensure an easier motion of the operator to close the bag after it has been filled and discharged. Not all spouts are identical in size or shape. Some products pass through round spouts more easily. Round spouts, however are generally harder for operators to use than pecan shaped spouts. A separate air regulator is provided for all bag clamps. Each pneumatic system valve cylinder includes speed control. The amount of air pressure required is trial and error. The amount of air used should only be enough to firmly hold the heaviest bag without any slippage. The speed controls are factory set and clearly marked “do not adjust” in three languages; English, Spanish and French. Do not adjust the speed controls. On gross weigh scales operators can operate the bag clamp without the possibility of the product passing through. On gross weigh digital scales, digital net weigh scales a “hold/run” switch is provided. In run mode the operation of the clamp will activate the product flow. In hold the clamps can be operated without activating product flow. Operators who want to test their skill on spouts must put the scale in “hold” first or risk discharging product unwanted. By placing the scales in “hold” will eliminate the possibility of spillage. If a finger would get caught in the spout assembly, don’t panic. We are not aware of any broken bones in 30+ years of manufacturing these products. Most damage is done by pulling out. The clamps require 50 to 80 lbs of air pressure normally to hold a standard 50 lb bag. Operators normally cannot pull out of this clamp assembly with said pressure. By pulling out the skin can be torn or a fingernail can be lost, depending on the position of the hand when clamped. Generally it is far better for the operator not to panic and wait for the release of air pressure. If the scale has an automatic release, bag clamps will automatically open in a few seconds, releasing the operator. For quicker release please refer to the following. Gross weigh mechanical scales: depress foot pedal and hold foot pedal. The clamps will automatically open. Gorss and Net weigh digital scales: F1 key turns the bag clamps off. The clamps will automatically open. Gross weigh mechanical models: turn on/off push button to “off” position. On any model scale, “quick disconnect” air has been supplied. Disconnect air and all pressure will be released. Safety is everyone’s concern. New operators should manually hang bags without product until they feel secure. Do not operate if you feel your personal skill levels do not allow you to operate this spout safely. MAINTENANCE All bearings on the scale are greaseable. These must be lubricated not less than once every 6 months. This will, however, be determined by the product and the scale usage. Gearboxes if supplied on your scale should have oil changed annually. Check gearbox oil level before starting system to ensure that oil has not leaked out in shipment. Check rubber bumpers on scale weekly. Model Belt Feeder Auger Fed Gravity/Gravity Gravity/Vibrator Single Vibratory Quantity 5 bumpers 0 bumpers Areas to be checked (2 on stream depth regulator on top of belt feeder, 2 on catch gate in closed position, and 1 on catch gate in open position. 3 bumpers (2 on catch gate closed position, 1 on catch gate open position) 3 bumpers (2 on gravity gate closed position, 1 on gravity gate opened position) 0 bumpers If a bumper is found to be excessively worn, replace immediately. If a scale is allowed to operate with a bumper omitted, structural damage will occur. GRAVITY GATE 2 POSITION The gravity gate feeder is used for free flowing products and is air operated. The gravity system works on a single radial gate controlled by two air cylinders mounted back to back. With the unit in fast feed or full open position, both cylinders are retracted. The opening of fast feed can be reduced with a mechanical stop located on the top backside of the gate housing. When the scale changes to slow feed, one cylinder will extend and the gate will become partially closed. The slow feed rate can be changed with a mechanical linkage on the air cylinders. When weigh complete is achieved, the second cylinder will extend and the gate will close completely. Note: Normal setting for slow or dribble feed is 2.0 lbs. of material per second Adjustment for slow fill should be made first. The unit should be set to run the entire cycle in slow fill. The unit should fill at approximately 2.0 lbs. per second (this is a guide and not a set value), size and density will effect filling rates. Using the handle attached to the back of the dual cylinders, screw in to decrease and out to increase the filling rate. After several bags have been run all slow fill and weights are correct, then the fast filling adjustment can be made. The fast fill adjustment is adjusted with the handle on top of the gate. Screw the handle in to decrease and out to increase. The flow should be set at a slow rate and slowly increased until there is a uniform filling. Each time the fill rate is increased, an adjustment may need to be made to the PS-1 value or time. Maintenance 1. Lube 4 bearings, 2 external and 2 internal periodically. 2. Mechanical limiting adjustments - grease lightly to prevent rusting in place. 3. Periodically check rubber gate stop bumpers. Adjust as needed and replace when rubber feels brittle. 4. Periodically check rubber gate seals both front and back. HOPPER SECTION The weigh hopper is a double door air operated hopper. This unit normally has a limit switch to give a signal that the doors are closed and the weighing can start. Also included in this section are steady rods to prevent the hopper from swinging side to side but will allow it to move up and down freely. The discharge time duration is controlled by an internal timer (refer to programmable controller instruction manual) and should be set to allow the product to clear the hopper. Any excess time is wasted and reduces the cycle rate of the scale. Maintenance 1. Lubricate 4 bearings periodically. 2. Check steady rod for tightness periodically. REPLACEMENT OF AIR CYLINDER ON WEIGH HOPPER (W.H.) DOORS 1. Remove air supply 2. Remove scale transition and bagging spout. 3. Disconnect the hopper air cylinder by first removing the cotter pins located in the mounting bolts ½” nuts. Take note of the amount of spacer washers between the air cylinder and door actuator brackets. 4. Remove the airlines from the air fittings by holding in the expansion ring while pulling on the airline. 5. Remove the male rod end and base bracket and female rod end from the old air cylinder. 6. Swap out air fittings and rod ends from old air cylinder to the new replacement weigh hopper air cylinder. 7. Drill a 1/8” hole through the female rod end and install cotter pin. 8. (Note) that both the male and female rod ends are on as tight as possible before drilling hole. 9. Re-install air cylinder facing in same direction utilizing the hardware removed earlier. When weigh hopper doors are in the closed position, the hopper door cylinder should not bottom out. There should be around ¼” clearance before the actual cylinder can bottom out. A way to check this is to manually operate the air cylinder numerous times until a small dirt ring forms on the shaft of the air cylinder r and then make sure that the ring is showing about ¼” when the doors are in the closed position. If ¼” is not present, you must remove the female rod-end from the cylinder and cut ¼” from the rod end then re-install on cylinder shaft and pin. ** M.S. = MILD STEEL S.S. = STAINLESS BRACKET, W'EIGH HOPPER DOOR <R.H.) #5448580003 M.S., #5448580013 S.S. HOPPER DOOR CYLINDER #83M17931 M.S., #83M17960 S.S. W'EIGH HOPPER DOOR <R.H.) #5448580001 M.S., #5448580002 S.S. FOR FULL ASSEMBLY, ORDER ----e HOPPER DOOR AND BRACKET ** ROD END #7061230000 # 7623130000 M.S. # 7623130001 s.s. # <R.H.) 7061590000 # <L.H.) 7061580000 BEARING (4) ----... ROD END <R.H.) HOPPER DOOR SEAL # 0544870002 ** ** FOR FULL ASSEMBLY, ORDER HOPPER DOOR AND BRACKET ROD END <L.H.) #7061590000 MATERIAL PART NUMB£R R£V. 7 PCM236 COUGHLIN 103-26-13 NW EAGLE WEIGH HOPPER (PARTS LIST) SHAJfNJ:E, KANSAS 662t8 R£V. 6 !lEV. 5 nR !lEV. 4 68'13 JlARTlNDAU RD. INNI •!lEV. 3 !lEV. 2 !lEV. I I BRACKET \o/EIGH HOPPER DOOR <L.H.) #544880004 M.S., #544880014 S.S. W'EIGH HOPPER DOOR <LH.) #5448700001 M.S., #5448700002 S.S. 6-------- I v EQUALIZING ROD # 0448836601 M.S. # 0448836602 s.s. \v'EIGH HOPPER CAPACITY 2 CU. FT. 3-1/2 CU. FT. 5 CU. FT. 6 CU. FT. 7 CU. FT. JEM INTERNATIONAL, INC. Phone: 913-441-4788 Fax: 913-441-1711 MAIN SCALE AND HOUSING PARTS LIST PART # 0001711179 DESCRIPTION 1/8 NPT Bronze Muffler REC QTY 0448836601 Equalizing rod 0544870002 Hopper Door Seal R 1 3700560112 Cord Male 16/3 8' 3770330042 Bracket modular Adapter 3770330043 Spacer T 1/4 NPT 3770330165-J Filter Regulator Series 22 Assembly R 1 3770350010 Shoulder Bolt 5448530000 Hopper 3.5 Cubic Foot MS (varies from scale to scale) 5448540000 Hopper 2.0 Cubic Foot MS (varies from scale to scale) 5448550000 Hopper 4.0 Cubic Foot MS (varies from scale to scale) 5448570000 Frame Hopper MS 5448580001 Door Hopper Right MS 5448580003 Bracket Hopper Door RH MS 5448580004 Bracket Hopper Door LH MS 5448700001 Door Hopper Left MS 7061230000 Rod End Hopper 1/2 male RH R 1 7061510000 Rod End 3/8 RH R 1 7061580000 Rod End 1/2" F LH R 1 7061590000 Rod End 1/2" RH R 1 7623130000 Bearing 5/8" Hopper R 2 7800230000 Housing Assembly MS simplex 7800230002 Housing Assembly MS duplex 7800233003 Housing Assembly MS triplex 7800390000 Transition x 14 Center-Simplex 7800390010 Transition Duplex MS (discharge of 7800550101 Load Cell 100KG Single Point 7800550604 Summing Box EL604 8953FSC-005 4 Station valve assembly (varies from scale to scale) 8953FSC-002 3 Station valve assembly (varies from scale to scale) 8953FSC-003 2 Station valve assembly (varies from scale to scale) 8953FSC-004 Valve Speed Control 9300030002 Nameplate GJ* 9400010002 Enclosure 12 x 10 x 6 Fiberglass 9500380000 Terminals 9500410000 Terminal Ground 9500440000 Terminal Fuse Holder (Simplex) 9972275700 Power Supply 24V DC 92 W 1HP 1425195A R 1 R 1 3/8 NPT Bronze Muffler R 1 1425197A 1/4 NPT Bronze Muffler R 1 31-261111-C1 Handle, Black Plastic Flush MN 7800230020-II Channel Mounting MS 78E3-57-15 Latch Vice Action Single Hole 79PCM2005 Small end door 79PCM2006 Large end door 79PCM2007 W H support BKT 4.0 79PCM2008 W H support bracket 3.5 79PCM2009 W H support bracket 2.0 R 2 79PCM2015 BF Top Plate Simplex 821J-151-01-FT 1/4" Airline 83M17931 Cylinder Hopper When ordering parts, be sure to advise if your scale is mild steel or stainless steel, and the serial number on the name plate or, on the manual cover. R = Recommended spare parts R 1 Rinstrum JEM‐BAT‐120 Digital Controller Manual For Net Weigh Scales JEM International │ 6867 Martindale │Shawnee. KS 66218 Phone: 913-441-4788 │Fax: 913-441-1711│www.jembaggingscales.com JEM BAT-120 NW OPERATION KEYS START PAUSE ABORT To begin filling press the START key. To pause the current cycle press the PAUSE key. To stop the current cycle press the ABORT key. Target value can only be changed once the ABORT key has been pressed. SETUP NEW FILL To setup a new target press the SELECT Key Press [SELECT] then key in the bag Target Weight. Press [OK] twice to save your entry Press and hold the [6-TIMER] key to edit the timers. Use OK key to scroll through parameters. o Fill.DLY timer is the delay between when the bag is clamped to when the fill begins o Dmp.TIM timer is the duration the dump gate is open. o Chk.DLY timer is the spike timer. o Bag.DLY timer is the delay after fill complete before the bag is released. Press and hold the [7-TARGETS] key to edit fast and slow fill percentages of analog drives. Entered as a percentage from 0-100. Use OK key to scroll through parameters. o FD.FST is the percentage of 100 that the analog device will run during fast fill. o FD.SLO is the percentage of 100 that the analog device will run during slow fill. Press and hold the [8-FLIGHT] to adjust FLIGHT and MEDIUM PRELIMINARY values. Use the Up/Down arrows to select the correct parameter o FLIGHT is the calculated amount of product in free fall after slow fill is complete. o M.PRE is the slow fill amount EXAMPLE: A 50 lb. target, 5 lb. M.Pre and 0.5 lb. free fall will fast feed to 45 lbs., switch to slow fill from 45 lbs. to 49.5 lbs. with the last free fall amount from 49.5 lbs. to 50.0 lbs. STORE Configuration as a new Product. o Once the above values are set press and hold and enter a product name CYCLE LIGHT – Diagnostics CYCLE LIGHT will momentarily flash when the scale is properly configured. If the light does not flash, simply make the M.PRE a slightly larger to give more time in slow fill mode. R400 SERIES ZERO/SPAN CALIBRATION PROCEDURE With the indicator powered on and in normal weighing mode, perform the following functions to calibrate the R400 series indicators. (Please note that some variation may exist between firmware versions.) 1. Press and hold the <POWER> + <F3> keys together for a few seconds until "Full Setup" is displayed and then let go. a. The display should now read "GEN.OPT" 2. Press the <ZERO> key a few times until "SCALE" is displayed. 3. Press the <TARE> key a few times until "CAL" is displayed. 4. Press the <RECIPE> key one time to display "ZERO" "CAL ?". 5. Press the <OK> key one time. The current live weight will be displayed, along with "CONT. ?" 6. Remove all weight from the scale spout, and press the <OK> key to proceed a. "Z in P" (Zero in Process) will be displayed briefly followed by the newly captured zero reference point and "DONE" 7. Press the 8. Press the <OK> key one time to return to "ZERO" "CAL ?". <RECIPE> key one time to display "SPAN" "CAL ?". 9. Press the <OK> key one time. The current live weight will be displayed, along with "CONT. ?" 10. Add your desired span calibration weight to the scale spout. 11. Press the <OK> key one time. "WEIGHT" will be displayed, along with a field to enter the span weight value. 12. Enter the desired span weight value with the keypad, and then press the <OK> key. a. "S in P" (Span in Process) will be displayed briefly followed by the newly captured span reference point and "DONE" 13. Press the "CAL ?". <OK> key one time to accept the value and return to "SPAN" 14. Press the <POWER> key one time to save the changes and exit full setup. JEM International 6873 Martindale Road • Shawnee, KS 66218 USA www.JEMBaggingScales.com Phone: 913‐441‐4788 • Fax: 913‐441‐1711 Recipe Data Base Usage ADDING A NEW RECIPE The recipe data base function saves the following information in the database for switching between products. Target weight Slow fill amount Flight Feeder fast percentage Feeder slow percentage Fill delay timer Check delay timer (spike time) Bag Delay timer The best method would be add the name of the recipe first then enter the parameters. To enter a new recipe name complete the following: 1. Press and hold the UP Arrow key. 2. NAME will appear on the top of the indicator. The current recipe will be on the bottom. 3. USE the alpha‐numeric keypad to enter the name of the product you wish to use. You may enter as long of a name as you wish. (Just write over the current recipe name that appears) 4. Press the OK key. 5. The indicator will show you the current recipe you just created as well as its recipe code. This is now the active recipe in the indicator. You can now change whatever parameter you so desire and they will be saved to that recipe when you switch to another. SWITCHING BETWEEN RECIPES To switch between recipes complete the following. 1. Press the SELECT key. 2. Code will appear on the screen. a. Each recipe when entered is assigned a user defined name, ie the name you type in, and a code. 3. You may press OK and enter the code number if you know it or press the arrow key until NAME displays on the screen. 4. When name appears on the screen press OK. 5. Use the arrow keys to cycle threw the names of the recipes until you find the one you would like to select and press OK. 6. This is now the active recipe. DELETING A RECIPE 1. 2. 3. 4. Press and hold the down arrow key with the recipe you wish to delete as the current recipe. The screen will display REMOVE CODE XX. With XX being the code number of the current recipe. Press the OK key. The recipe is now deleted. Updating the Rinstrum LUA Module Remotely To remotely update the LUA module in the Rinstrum you will need the following hardware items: 1. A windows based laptop 2. A WIFI internet connection at the scale. This can be the companies WIFI connection or a hot spot WIFI connection. Most smart phones can be used as a hot spot. 3. An Ethernet patch cable to connect from the computer to the LUA module. a. A hard wired Ethernet connection can also be made from the LUA module to the local network. If this is done we will change the DCHP setting in the indicator and will need the computer to be on the same network as the one the scale is hard wired to. To remotely update the LUA module in the Rinstrum you will need the following software items installed on the windows based laptop. 1. Team Viewer – http://www.jembaggingscales.com/contact‐us.php The following software can be downloaded and installed from the following link: https://www.dropbox.com/sh/7ifiaojvb284vjm/AAD_UJJRKXz_MwCdxHVXrKyJa?dl=0 2. LUA development environment (recommended) 3. USB‐Serial Driver (recommended) 4. View 400 (recommended) Software items 2‐4 are recommended but not required. However, if they are not installed prior us, JEM International, accessing your computer to update the LUA module we will have to install them once we are on your computer. JEM International Service or Technical Support: 913‐441‐4788 Email: firstname.lastname@example.org Application Name: JEM-423-BAT-120 Net Weigh Application Overview: This application is for a simplex net weigh controller that allows for single scale operation and 1 - 4-20mA analog reference for variable feeder control. Operation Sequence: 1. With the scale in “IDLE” the operator will select a recipe and/or edit the target and timer values accordingly. More details found in the Operator Configuration section. 2. To start weighing product the operator will press the “START” button on the indicator. The emergency stop must be pulled out to operate the scale. 3. Once started the scale will fill to its target weight. 4. Once the scale has reached its target value it will display “DUMP”… in the lower right corner, waiting for the operator to activate the dump enable switch. 5. The operator will hold a bag on the spout and activate the dump switch. a. The dump switch triggers the bag clamp to close, and commands the scale to discharge the contents of the hopper into the bag. b. After the first filling cycle the dump switch can be activated at any time to clamp a new bag, and does not have to wait for the scale to be done filling. 6. After the product has discharged into the bag, the scale will automatically refill and be ready for the next discharge cycle. a. After discharging, the cycle counter will increase, and the data for that bag will be stored in the indicator. See DataStore section for details on data collection. i. The bag clamp will then open to drop the bag after the BAG.DLY timer has expired. Operator Configuration: (The functionality below highlights what is required to operate this system as it is designed to operate. For additional info on additional key operation please see the indicator operator and reference manuals) Data Entry: (Data is entered with the alpha-numerical keypad on the right side of the unit. Remember, after making changes to data you must press the OK key to accept it and again to return to weighing mode.) Up / Down Arrow keys: • Short Press: These keys are used to scroll through options in the operator menus. • Long Press: Perform secondary function to ADD and new recipe or DELETE the currently active recipe. Rinstrum Inc. 1343 Piedmont Drive, Telephone: 248 680 0320 Troy, Michigan 48083-1918 USA Facsimile: 248 499 1331 Toll Free 1 877 829 9152 Web: www.rinstrum.com Cancel (C) and OK keys: These keys are used respectively to clear data from and entry field and to accept changes to the data. Numpad keys: • Short Press: to enter alphanumeric data in the current field. • Long Press: Allows access to the menus outlined in Operator Configuration. SELECT key: • Short Press: Allows the operator to view and change the currently active recipe. • Long Press: Allows access to Operator Configuration menu containing all TARGETS, FLIGHT, and TIMERS. CLOCK key: Press and hold the CLOCK (1) key to view and edit the current time and date settings for the indicator. HOLD key: Press and hold the HOLD (2) key to toggle HOLD MODE operation on or off. • DISABLED: This is the normal operation mode, and allows the dump gate to automatically operate after the operator presses the foot switch. • ENABLED: When hold mode is enable the operator may press the foot switch to clamp a bag, but the dump gate will not automatically activate to dispense product into the bag. COUNT key: Press and hold the COUNT (3) key to view, edit, and clear the available bag and cycle counters. • BAG.CNT: is the number of bags that have been run for the currently selected recipe. • CLEAR: allows the operator to clear the selected counter and return it to 0 by pressing the (OK) key. Press the CANCEL (C) key to not clear the counter. TOTAL key: Press and hold the TOTAL (4) key to view and clear the totals for the currently selected recipe, and grand totals for all recipes. • CLEAR TOTALS: While in the totals menu, press and hold the DEL (DOWN ARROW) key to be prompted to clear all totals. Clear totals by pressing the (OK) key. Press the CANCEL (C) key to not clear the totals. TIMER key: Press and hold the TIMER (6) key to view and edit the available timers. • FILL.DLY: is the amount of time after the bag clamp is released, that the unit waits before refilling the hopper. • • • CHK.DLY: is a timer that prevents the scale from looking at the current weight after the fast fill or slow fill outputs change from on to off. This is used to prevent ending the fill cycle prematurely if there is a spike in the weight from product rushing into the bag or hopper. DMP.TIM: is the amount of time that the dump gate will stay open during the discharge cycle. Set this to the minimum amount of time required to fully evacuate the hopper. BAG.DLY: is the amount of time after the discharge is complete, that the unit waits to turn off the bag clamp output. TARGET key: Press and hold the TARGET (7) key to view and edit the available targets and variable feeder speeds. Variable feeders may include a vibratory feeder, auger feeder, belt feeder, or etc… • TARGET: This is the final fill target. • SLO.FIL: This is the amount of product filled in slow fill. • FD.FST: This value is entered as a percentage (%) from 0% to 100% and determines how fast the variable speed feeder will operate during fast fill. • FD.SLO: This value is entered as a percentage (%) from 0% to 100% and determines how fast the variable speed feeder will operate during slow fill. FLIGHT key: Pressing and holding the FLIGHT (8) key allows the operator to view and edit the current FLIGHT value. Flight is the amount of material in the air after both fast and slow fill feeders have cut off. (eg: 50.00lb final target with SLO.FIL set to 10.00lb and Flight set to 0.50lb. The unit will fast fill to 40.00lb, then slow fill to 49.50lb and turn off, then reach its target of 50.00lb when the remaining product in the air falls into the bag.) DUMP key: Press and hold the DUMP (9) key to manually dump the weigh hopper. • The manual dump sequence will close the bag clamp, discharge the hopper, and then open the bag clamp automatically. INFO key: Press and hold the INFO (+/-) key to view the application name and version information. ACC key: Press and hold the ACC (0) key to view the accessories menu. • This menu holds diagnostic information for the indicator and all installed accessory modules. H.WARE key: Press and hold the H.WARE ( . ) key to view the hardware menu. • MVV: select this option to view the millivolt per volt (mV/V) value sensed by the indicator. Function keys: F1 – Start Batch F2 – Pause Batch F3 – Abort Batc Cycle Light: The cycle light illuminates to identify the portion of the slow fill that is outside of the DLY.CHK(Spike Time). This is used as a troubleshooting tool to insure that the unit is in slow fill long enough for accurate bag weights. On – Off Switch: The On – Off switch is used to turn the scale controller on or off. Emergency Stop: (This switch has 2 positions, pulled out is the normal operating position, and pushed in, in case of emergencies. The functionality is defined as follows.) a. When the Emergency Stop is pulled out the scale will operate normally. b. When the Emergency Stop is pushed in the, power is removed from the relay rack, solenoid valves, and feeders. This will also retract the bag clamp to its open position. a. The scale controller will be placed in a pause condition. Once the Emergency Stop has been returned to the pulled out position the operator may resume normal operation by triggering a start with the F1 key. Supervisor Configuration Press and hold the POWER and START (F1) keys together to enter the Supervisor Configuration menu. (This menu is protected with a passcode to be supplied upon request to JEM International.) • • SCALE menu: This menu has options that will affect the scale operation. o FILTER: Used to adjust the amount of filtering applied to the load signal. Filtering should be set to the minimum amount required. The default value is 0.20s and is recommended for most applications. o COR.TYP: Allows the supervisor to alter the fill correction type. Available options are AUT.FLT, MAN.FLT, AUT.JOG, and JOG. These are defined in the Correction Type section. The default is AUT.FLT and is recommended for most applications. CALIBRATE menu: Allows the supervisor to scroll through the options to calibrate the scale. o ZERO: When “CAL ZERO” is displayed, remove all weight from the scale and press the (OK) key to calibrate the scale zero point. “Z in P” (Zero in Process) will be displayed while the unit is calibrating, followed by “ZERO OK” when complete. o SPAN: When “CAL SPAN” is displayed, add test weigh to the scale and press the (OK) key. “SPAN” will be shown on the top display and a weight on the lower display. Used the keypad to enter the value of the applied test weight, and press the (OK) key to calibrate the scale span point. • “S in P” (Span in Process) will be displayed while the unit is calibrating, followed by “SPAN OK” when complete. Correction Type: • AUTO FLIGHT (AUT.FLT) o The unit will attempt to calculate and optimize the Flight value automatically as it is being used. This allows the unit to maintain accuracy and consistency throughout the filling process. • MANUAL FLIGHT (MAN.FLT) o The unit will use the operator entered Flight value for every fill cycle, no automatic correction is performed • AUTO JOG (AUT.JOG) o The unit will utilize automatic flight correction, add a jog sequence to the end of the fill cycle. Additional settings will be added to the FLIGHT menu to control the jogging sequence. • MANUAL JOG (JOG) o The unit will utilize manual flight correction, add a jog sequence to the end of the fill cycle. Additional settings will be added to the FLIGHT menu to control the jogging sequence. • Jog settings: o These settings are added to the FLIGHT menu if AUT.JOG or JOG correction type is chosen. JOG.ON: is the amount of time the slow fill output will be activated during the jog sequence JOG.OFF: is the amount of time to delay between JOG.ON pulses. JOG.NUM: is the maximum number of times the unit will attempt to jog before the target value is reached. Setting JOG.NUM to 0 will force the unit to continue jogging until the target value is reached. The default value is 0. Recipe Database: • Select a recipe from the database: o Enter the recipe menu with a short press of the “SELECT” key. o The currently selected recipe name and code number will display for a few seconds followed by the recipe select menu. Use the ARROW KEYS to scroll through the options and press “OK” to select it. o Recipe menu options: CODE: allows the operator to select a recipe from the database by entering the recipe code. NAME: allows the operator to select a recipe by scrolling through a list of all recipe names. LOT.NUM: allows the operator to assign a lot number to the product currently being run. This lot number gets stored with each weighment in DataStore. QUIT: exit menu and return to normal weighing mode. • Add a new recipe to the database: o From weighing mode “IDLE”, press and hold the up arrow “ADD” key for 2 seconds. o The operator will be prompted to enter a new recipe name. The field will be pre-populated with the currently selected recipe name. Use the arrow keys to change the cursor position and or the “C” clear key to delete any unwanted characters. Enter the new recipe name using the keypad and then press “OK” to accept it. The operator will be prompted that the new recipe has been created and the code number that was assigned to it. o The new recipe is created with the same settings as the previously selected recipe. These settings can be altered and stored at any time by entering new values in any of the TARGETS, FLIGHT, or TIMERS. • Remove a recipe from the database: o From weighing mode “IDLE”, press and hold the down arrow “DEL” key for 2 seconds. o The operator will be prompted to remove the currently selected recipe code. Press the “OK” key to remove the recipe. Press the “C” key to exit without removing the recipe. DataStore: To collect the data from the scale indicator the operator may perform the following procedure. 1. Stop the filling / batching sequence by pressing the “ABORT” key. The indicator will display “IDLE” on the lower portion of the display. 2. Insert a BLANK USB flash drive into the USB port found on the M4223 module that is located on the back of the indicator. a. The Indicator will analyse the flash drive, and then open the USB menu automatically. 3. The indicator will display “USB” on the upper portion of the display, and a prompt in the lower right corner to “USE ARROWS OR REMOVE USB” 4. The operator may choose from the following 3 options by using the arrow keys to scroll through the options and then pressing the “OK” key to accept the option. a. “TO USB” – is used to download the data files from the indicator. • The data files that are downloaded will contain the Datastore_xxxxxxx.csv file, where xxxxxxx is the serial number of the indicator. This Datastore_xxxxxxx.csv file can be opened in a pc software like Excel to view the captured data from each filling cycle. b. “FROM USB” – is used to upload new data files to the indicator if an update to the indicator software is required. • This option should not be chosen unless asked to do so by JEM International personnel. c. “EJECT USB” – This option can be chosen to safely remove the USB flash drive from the indicator. • “USB REMOVE” will be displayed when it is safe to remove the usb drive. • Once removed the indicator will return to “IDLE” and be ready for use. If a software update was loaded the indicator will automatically reboot to apply the update.
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