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CBE 520, Safety, Installation, Operation, Maintenance

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CBE 520 Safety, Installation, Operation, Maintenance Download Page 39

 

 

39 

 

PLC (This device is not a weight controller) 

  

PLC means Programmable Logical Controller. Our PLC is programmed with specific programs 
which controls inputs and outputs to work with our equipment. Our programs are set up for Valve 
filling, O/M net weigh and Bulk Bag weighing equipment.   

 

In the PLC program, there are timers going to specific functions on the various types of equipment 
which we factory. We set them at the factory but need to be fined tuned in the field. Below we 
discuss how to adjust the timers when you doing the fine tuning to functions in the field.  

  

 

 

 

 

 

 

 

 

 

 

PLC Screen 

 

 

 

 

 

 

 

 

Summary of Contents for 520

Page 1: ...1 CBE 520 BULK BAGGER Safety Installation Operation Maintenance ...

Page 2: ...o the Supply Bin 16 Setting Conveyors 17 Installation Summary 17 Chapter 3 Load Cell Wiring 18 Load Cell Wiring to Junction Box 19 Calibration Instructions 20 Load Cell Replacement 20 Chapter 4 Component Description 23 CBE 520 Bulk Bag Filler Assemblies 24 Densifying Deck 26 Chapter 5 Operational Sequence 27 Operational Sequence 28 Auto Strap Release Optional 29 Bag Seal Cuff Optional 30 Pre Bag I...

Page 3: ...10 Troubleshooting 51 Controller Does Not Return to 0 00 52 Erratic Weights 52 Digital Readout Does Not Match the Floor Scale 53 Controller Does Not Light Up 53 Dirty Filling 54 Troubleshooting a Bad Load Cell 54 Chapter 11 Standard Parts 55 PLC Timers Adjustments 57 ...

Page 4: ... to be connected into Junction box 1 located on the filler The wires need be terminated in the J Box for the Slide gate solenoids and the reed magnet used for setting up the dribble position on the slide gate 4 See attached layout drawing for reference information For Technical Assistance call main 512 352 3694 For Parts or Service needs call main number or email Parts Service choicebagging com Fo...

Page 5: ... operating mechanisms before connecting air 8 Never start equipment without first checking for loose objects tools and trash All persons in the immediate area of the equipment should be alerted prior to starting WHEN OPERATING EQUIPMENT 1 Do not open junction boxes or control panels unless you are a qualified electrician Be sure power is off Except when electricians are performing maintenance elec...

Page 6: ... daily with the machine these points should be observed for continuous service Service parts such as belts stuffing box material bearings gears fill spouts etc are available for replacement and stock supplies through Choice Bagging Equipment GROUNDING RECOMMENDATIONS AND NOISE GROUNDING A good grounding system is a major consideration in planning any electrical system However it is essential for p...

Page 7: ...ith noise is that it is not always present Continuous or frequent periodic noises are generally easy to detect and accommodate Intermittent noise sources that produce short high energy bursts at irregular and widely spaced intervals cause the majority of problems Noise has a number of different pathways into the control equipment It can be conducted through signal or power wiring or it can be radi...

Page 8: ...result only in nuisance failures such as operation in the wrong mode machine glitches or incorrect or non existent error messages AC POWER CONSIDERATIONS Electrical devices should not be operated at the low end of their input power voltage rating for extended periods of time When input voltage is low current input is forced higher to provide the devise with the power of needs Additional current me...

Page 9: ...Pilot valve 145301 1 Quick Dump Exhaust Valve 703 014 2 Solenoid Valve 105 020 2 Solenoid valve adapter Kit 105 020A 1 Mother Board O I Board comb Assembly 104 815S 1 Vibrator Optional 503 002 1 12 feedgate optional N A 1 1 1 Slide gate optional Slide gate cylinder Magnetic reed switch 503 016 503 002 503 006 1 1 4 butterfly valve actuator 502 707 502 704 ...

Page 10: ...10 CHAPTER 1 General Information ...

Page 11: ...ified technician Be sure POWER IS OFF Except when electricians are performing maintenance electrical enclosures and junction boxes should REMAIN SECURELY CLOSED 3 STOP machine and disconnect power supply before servicing or repairing Maintenance and adjustments must be performed with all electrical power supplies disconnected unless otherwise specified in this manual 4 READ COMPLETELY any informat...

Page 12: ... PSI per fill cycle 3 Solenoids Pneumatics All pneumatic components air valves cylinders are self lubricating and additional lubricated air is not required If lubricated air is used then lubricated air must be used for the life of all the cylinders Connect high pressure airline to filter regulator located on back side of packer A suitable source of supply is a 1 2 pipe connection It is recommended...

Page 13: ... filler pipe This pipe should be connected to dust collection piping with a damper so the amount of volume of air can be adjusted to the fill head If you have too much draw material will be drawn up from the stream along with the dust during the filling cycle ...

Page 14: ...14 CHAPTER 2 INSTALLATION GUIDE ...

Page 15: ...ies and the indicator must be secured to the floor or wall and protected against crushing cutting or water damage If the site has such potential dangers a method of protection such as running the cable in conduit is recommended UNCRATING Remove the crate and inspect the Model 520 for any visible damage caused during shipment If damage is present notify your freight carrier and CBE immediately to r...

Page 16: ...ion Guide for proper connections Note Depending on the model and configuration your indicator may come pre connected to the scale CONNECTING TO SUPPLY BIN The Model 520 Bulk Bag Filler can be fed via slide gate valve butterfly valve auger rotary vane feeder or air lock feeder In a typical installation one of these feed devices will be fastened directly to the customers supply bin An 8 flex connect...

Page 17: ...r does not rock and is level Be sure to have a minimum of a maximum of clearance between the frame and the floor CAUTION If more than 1 2 clearance to floor is needed the bottom of the leveling load foot must be shimmed Be sure the leveling load foot bolt thread engagement is a minimum of 50 into each of the load cells Tighten leveling foot lock nut against load cell being careful not to over tigh...

Page 18: ...18 CHAPTER 3 LOAD CELL WIRING ...

Page 19: ...hown in Figure 1 below See Figure 2 below for junction box layout and wiring connections If equipped tighten the strain relief hubs on the junction box with a wrench to assure proper seal Figure 1 Load Cell Configuration Figure 2 Junction Box Connections Take the cable coming from the junction box of the 500 series and wire it to the controller indicator as follows ...

Page 20: ...perform this procedure Call CBE to schedule a service technician to assist you with installation of your system 4 To adjust the corner weight readings use the trim pot designated for that corner which is numbered the same as the corner you need to adjust Turning the pot clockwise increases the weight reading Refer to Figure 2 Junction Box connections for the correct location 5 After each corner ha...

Page 21: ...Figure 2 Junction Box Connections 6 Position load cells with load cell alignment arrow pointing up toward the deck With the torque wrench tighten all mounting bolts to 75 ft lbs 7 Route the load cell cables in each corner so that the cable is free from possible contact with the load cell or load foot Pull cable towards junction box not to tight and coil up extra length with cable ties and securely...

Page 22: ...22 Figure 3 500 Series Bottom View ...

Page 23: ...23 CHAPTER 4 COMPONENT DESCRIPTION ...

Page 24: ...trols to Operate Conveyor Other Motorized Functions of the Machine Including Pre Fill Bag Inflator Vibratory Bag Settler Discharge Conveyor and Powered Accumulator Conveyors Controls Wired for Either 220 or 440 Volt 3 Phase 60 Cycle 7 Live Roller Bag Discharge Conveyor 512 100 A trigger switch that is integrated underneath the filling spout that automatically initiates the bag fill upon the placem...

Page 25: ...Pre Fill Bag Inflation through the Same Filling Head The Fill Head is Bi Directional Meaning that It Allows Blower Air from the Inflator and Dust Collection to be Channeled through the Filling Head Automatically Cycled On and Off by the Controls of the Filler 14 5 Powered Bulk Bag Accumulation Conveyor 514 100 Transfer Conveyor that is used to Index the Filled Bag through Additional Steps in the P...

Page 26: ...26 CBE DENSIFYING DECK ...

Page 27: ...27 CHAPTER 5 OPERATIONAL SEQUENCE ...

Page 28: ...to dust collection and allowing the inflated air in the BB a location to escape The weighing scale will stabilize and the controller will take a tare weight zeroing out the weight of the pallet and the empty BB If the scale cannot stabilized because of vibration motion around the machine an indicator lite will appear on the display of the weight indicator and remain there until the influence cease...

Page 29: ...e loop latches while the BB is being powered off of the loading deck The operator presses the bag discharge PB The filled bag and the pallet are powered out onto the adjacent gravity accumulation or powered conveyor for staging additional powered roller conveyor sections may be added to the bag discharge conveyor for additional bag accumulation to increase the holding capacity of the system Photo ...

Page 30: ... as need to make a good seal inside the bulk bag sleeve Once the pressure is determined set the regulator by locking the regulator Installing the BB neck on to the filler head is a manual operation and will need to be performed at the beginning of each fill cycle B Regulator and Gauge The regulator gauge and quick dump exhaust valve are mounted directly to the bulk bag filler head The pressure adj...

Page 31: ...gh volume Blower LPB 2 3 way valve Exhaust system The system is designed to inflate the bulk bag to its full volume prior to being filled This is accomplished with the use of the LPB At the start of the filling cycle the 3 way valve to the blower opens allowing the bag to be inflated for the length of time on the timer set for in the PLC When the timer has expired the 3 way valve port closes posit...

Page 32: ...ngs a new empty bag on the straps o Then operator installs the neck on the sleeve o The operator presses the Bag Cuff Inflate PB located on the filler head o When cuff is fully inflated the operator presses the start fill cycle PB and the filling cycle starts over Manual When the weighment is complete the cuff will deflate after a time delay Operator presses the strap release PB on the control pan...

Page 33: ...33 CHAPTER 6 Conveyors Setup ...

Page 34: ...ou don t influence your scale weighing A Maintenance Check Live Chain Roller LRC once a year and remove slack in the chains as required Check oil levels on gear boxes once a year B Installation and Maintenance of Speed Reducers and Drives This manual provides information concerning usage lubrication and maintenance of the Speed Reducers To maximize the life and efficiency of your reducers follow t...

Page 35: ...cer from the chart below and refill with amount of oil shown in capacity chart Grease Fittings The gear reducers have grease fittings to lubricate the input shaft bearing if they are not positioned to be adequately lubricated by oil splash Periodically lubricate these bearings with a good grade of NLGI No 2 Lithium Base EP Grease applying only a very small amount each time ...

Page 36: ...en to insure that shafts are parallel and sheaves and or sprockets are in alignment This will prevent damage Sheaves and sprockets should be properly keyed and tightened to the shafts to prevent wear to the shaft and bores Extreme belt or chain tension should be avoided When assembling sheaves or sprockets on reducer shafts they should be installed as close to the reducer housing as possible Sheav...

Page 37: ... The gears nest inside the plastic coupling It is important for these gears to be properly spaced on the shafts Incorrect gear setting can result in excessive coupling noise and bearing failure Included in this manual are parts drawings with replacement parts lists Please contact our parts department at 512 352 3694 for assistance ordering parts for your system ...

Page 38: ...38 CHAPTER 7 PLC and Timers and Adjustments ...

Page 39: ...uipment Our programs are set up for Valve filling O M net weigh and Bulk Bag weighing equipment In the PLC program there are timers going to specific functions on the various types of equipment which we factory We set them at the factory but need to be fined tuned in the field Below we discuss how to adjust the timers when you doing the fine tuning to functions in the field PLC Screen ...

Page 40: ...lashes the time only Use the and keys to adjust the timer up and down in 0 1 second increments When done press the OK key again and timers will flash not as a block but more individual Press the Escape key to return to menu and using the up down arrows scroll back to the CBE screen A TIMER FUNCTION EXPLANATIONS FOUND FOR CBE Data TOUCH Pre Inflate Bulk Bag Filler Timer This timer is used to contro...

Page 41: ...N EXPLANATONS FOR 405 Pre Inflate Bulk Bag Timer This timer is used to control the duration that the bag inflation blower runs to inflate the bag at the beginning of each bag fill It is adjusted in 0 1 second increments Factory setting is 20 seconds Vibratory Densifier On Delay This is an on delay timer used to allow material to get into the bag before turning on the bag densification system It is...

Page 42: ... the bag latches open for the time the timer is set for and close again Input Output Screen The PLC screen displays which inputs and outputs are signaling on and off at any point during the bag filling process They are on when they are gray color or lite ...

Page 43: ...43 CHAPTER 8 WEIGH CONTROLLER And ADJUSTMENTS ...

Page 44: ...l go over how to calibrate and set the target weight for each controller When you go to perform these functions be sure to use the correct section matching the controller on your machine Note To Calibration a Bulk Bag Scale To calibrate scale you need a minimum of 10 of the scale capacity which for our bulk bagger would be around 1000 to 1500 NOTE THE ENTER KEY IS THE 0 ZERO LOCATED IN THE LOWER L...

Page 45: ...45 ...

Page 46: ...adings After making a change to P114 press SELECT to be sure that the setting is saved To exit out of setup and save the changes press ZERO CLR ENTER ENTER Troubleshooting If nothing is working running as expected press SELECT until Mname Test is displayed and press ENTER This is a test procedure that should fire any required set points for the bagging system s operation If the start process has b...

Page 47: ...n the desired weight and press ENTER Once the desired weight is entered press ZERO when prompted Enter Cal press ENTER and proceed through calibration Once calibrated if Cal good displays on indicator press ENTER through remaining prompts Troubleshooting Once back in weigh mode re enter setup and go back to parameter 110 Change the newly keyed in value back to original weight value and proceed to ...

Page 48: ...48 See attached Documentation For the Controller specifically Used on your machine ...

Page 49: ...49 Chapter 9 MAINTENANCE ...

Page 50: ...mage MAINTENANCE OF POWERED LIVE ROLLER BAG DISCHARGE CONVEYORS Check oil levels in gearboxes once a year Check LRC once a year and remove slack in the chains as required Grease bearings once a week or depending on usage Grease Vibrators 1 2 shots per month they are sealed so over greasing will damage the vibrators Check the chain once a year Adjust as needed GEAR BOXES OF CONVEYING SYSTEM Check o...

Page 51: ...51 CHAPTER 10 TROUBLESHOOTING ...

Page 52: ...area o Check for possible buildup of material between the filler head and the dust collector pipe o Check for possible material buildup between the floor and the main frame o Check for influences from airlines that may be too tight pulling on the scale o Check for loose bolts on the load cell Inspect and tighten as required Erratic Weights o Erratic material flows from supply bin due to not mainta...

Page 53: ...t pre act in controller o Adjust Offset compensation o Binding on load cells one to another o Recalibrate scale Controller Does Not Light Up o Check to make sure the Power switch is on Switch is located on the PLC enclosure o Check 110v fuse on transformer is good R R if bad o Check E stop make sure it is pulled out o Check round in line fuse in the GSE controller R R if bad o Check for loose wire...

Page 54: ...Very important Note Green to White is output resistance Very Important LOAD CELL CONNECTION GUIDE SHIELD CLEAR EXCITION BLACK EXCITION RED SIGNAL WHITE SIGNAL GREEN SENSE BROWN SENSE BLUE Load Cell Information Capacity Resistance Ink Ohms 2 5K Red Black 384 Red Green 296 Red White 296 Black Green 294 Black White 294 Green White 351 ...

Page 55: ...55 ...

Page 56: ...56 CHAPTER 11 STANDARD ILUSTRATED PARTS See attached documentation for Other parts Specific to Your Bagger ...

Page 57: ...57 CHAPTER 12 PLC and TIMER ADJUSTMENTS ...

Page 58: ... Our programs are set up for Valve filling O M net weigh and gross weighing equipment In the PLC there are timers going to specific functions on the various types of equipment which we factory set but need to be fined tuned in the field Below we discuss how to adjust the timers when you go to fine tuning them PLC Screen ...

Page 59: ...imers When you reach the desired timer press the OK key The timer is able to be edited when the selected time flashes with solid blocks The timer is not editable when the selected timer flashes the time only Use the and keys to adjust the timer up and down in 0 1 second increments When done press the OK key again and timers will flash not as a block but more individual Press the Escape key to retu...

Page 60: ...ory setting is 20 seconds Vibratory Densifier On Delay This is an on delay timer used to allow material to get into the bag before turning on the bag densification system It is adjusted in 0 1 second increments Factory setting is 20 seconds Input Output Screen The PLC screen displays which inputs and outputs are signaling on and off at any point during the bag filling process They are on when they...

Page 61: ...61 DRAWINGS AND SCHEMATICS See attached Schematics And Drawings specific for your machine ...

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