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43 

 

ZM 405 CONTROLLER 

Calibration

 

ZM 405 CONTROLLER 

Calibration

 

1.

 

Power On, the screen will display “boot” and then “loading.” 

 

2.

 

From start screen, press and hold the 

 key until, 

The screen will display: 

 

 

3.

 

Enter the passcode “2580”. 

 

 

4.

 

Press 

 key to enter the passcode. 

The screen will display “

busy

” 

 

and then will go into calibration mode. 

 

 

 

Содержание 510

Страница 1: ...E Guar Resources Project Q10409 Customer PO 1090 Serial 140753 Model CBE 510 BULK BAGGER Controller ZM405 Electrical Controls Electrical Motors Air Requirements 3 9 CFM 80 PSI per bag cycle Special Features POWER LIFT ...

Страница 2: ...2 Safety Installation Operation Maintenance CBE 510 BULK BAGGER ...

Страница 3: ...on Preparation Site preparation Uncrating Connecting to supply bin Installation Summary CHAPTER 3 Load Cell Wiring information 19 Wiring to Junction Box Fine adjusting each Load Cell done at factory How to replace a bad load cell Load cell information Capacity CHAPTER 4 Component Descriptions 25 CHAPTER 5 Optional Equipment 27 Butterfly slide gate valve Vibratory Deck Bag Pre inflate Exhaust Infla...

Страница 4: ...imers CHAPTER 8 Weigh Controller and Adjustments 40 CHAPTER 9 Maintenance 44 CHAPTER 10 Trouble Shooting 46 Controller doesn t return to Zero Erratic weighs Digital readout does not match the floor scale Controller does not lite up Dirty filling Illustrated Parts sheets 50 Schematics Layouts 56 ...

Страница 5: ...x 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 5 For Technical Assistance call main 512 352 3694 6 For Equipment Sales call main office or email INFO choicebagging com If any clarification is required ASK US WARNING...

Страница 6: ... power is off Except when electricians are performing maintenance electrical enclosures and junction boxes should always be securely closed 2 Stop machine and disconnect power before servicing or repairing Maintenance and adjustments must be performed with all power disconnected unless otherwise specified in this manual 3 Do not attempt to defeat any safety switches Serious injury could result 4 W...

Страница 7: ...ould 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 ELECTRICAL NOISE CONSIDERATIONS A major consideration in the installation of a successful system is the problem created by electrical noise The following paragraphs provid...

Страница 8: ...nt effect of noise on the system is to cause soft failures that is failures which do not damage the system but do cause it to function improperly Three main types of soft failures are encountered 1 Logic memory alteration 2 Register alteration 3 Momentary I O failure Logic memory alteration presents the most significant potential problem in that it may in some cases result in improper machine oper...

Страница 9: ...input is forced higher to provide the devise with the power of needs Additional current means additional heating When a system is to be installed where long brownouts are known to occur the user is advised to supply the PLC with power from a voltage regulating transformer Use of this type of transformer will provide normal voltage to the devices and keep current within normal range ...

Страница 10: ...Description Part Number 1 Load Cell 501 005 1 Summing Box 104 009B 2 Bag seal cuff 301704SP 1 Pilot valve 145301 1 Quick Dump Exhaust Valve 703 014 2 Solenoid Valve 105 020 2 Solenoid valve adapter Kit 105 020A 1 405 Controller 104 046 1 Vibrator Optional ...

Страница 11: ...11 CHAPTER 1 GENERAL INFORMATION ...

Страница 12: ... Operation may start automatically after a time delay 2 DO NOT open junction boxes or control panels unless you are a qualified 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 performe...

Страница 13: ... designed for one location hookup If the unit is equipped with a vibratory table or power conveyors three phase voltage will be required The control voltage will be maintained through a step down transformer in the control panel If the unit is only equipped with the GSE controller 110 Volt single phase is required 2 Air Requirements The system is designed for one location hookup The maximum air re...

Страница 14: ... the packer Drain trap as required Connect air hoses to cylinder of bag chair for automatic bag discharge optional equipment If the machine was ordered from the factory with options this will already be done If the machine was not originally ordered with an option the manifold should be pre plumbed for one option at a later time Connect all air hoses which were disconnected for shipment All hoses ...

Страница 15: ...15 Chapter 2 INSTALLATION ...

Страница 16: ...cator 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 packing material and inspect the 510 series for any visible damage caused during shipment If damage is present notify your freight carrier immediately to register a cl...

Страница 17: ... flex connector hose is long enough so you do not influence the scales INSTALLATION SUMMARY Place the 510 series in the selected site Align with your discharge spout and connect with flexible collar NOTE Assure that each leveling load foot is securely resting on the floor before jamming the load cell nut Be sure the equipment does not rock Be sure to have a minimum of a maximum of clearance betwee...

Страница 18: ...ble to the floor or wall Re connect the load cell cable to the weight indicator Reference the indicator User and Installation Guide for proper connections Take care not to stretch or bind cable as this will affect weight readings Note Depending on the model and configuration your indicator may come pre connected to the scale ...

Страница 19: ...19 Chapter 3 LOAD CELL WIRING ...

Страница 20: ...em shown in Figure 1 below See Figure 2 on page 14 for junction box layout and wiring connections 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 510 series and wire it to the indicator connector as follows ...

Страница 21: ... Technician should perform this procedure Call your GSE Distributor for service 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 1 Load Cell Configuration for the correct location 5 After each corner has been checked and calibrated mak...

Страница 22: ...ram in Figure 1 Load Cell Configuration 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 tight towards junction box coil up extra length with cable ties and securely stor...

Страница 23: ...23 Figure 3 510 Series Bottom View LOAD CELL CONNECTION GUIDE SHIELD CLEAREXCITION BLACK EXCITION RED SIGNAL WHITE SIGNAL GREEN SENSE BROWN SENSE BLUE ...

Страница 24: ...k is the input resistance Very important 384 ohms Note Green to White is output resistance Very Important 351 ohms Measured with no load Resistance Ink Ohms 2 5K Red Black 384 Red Green 296 Red White 296 Black Green 294 Black White 294 Green white 351 ...

Страница 25: ...25 Chapter 4 Component Description ...

Страница 26: ...ir operated functions of the machine A configuration of three to six solenoid are located in the typical solenoid control panel 3 Start Stop E Stop Push Button Control Station 115 900 Allows for Manual Start Stop Pause and Emergency Shut Down of the Machine 4 Dust Tight 12 Fill Head w Slide Gate Inlet CBE 502 NOTE App Specific 12 ID Bulk Bag Fill Head with Inflatable Bag Seal Cuff Designed to Infl...

Страница 27: ...27 Chapter5 Optional Equipment ...

Страница 28: ... to run thru the bulking cycle The program can be setup to run thru the entire filling cycle or shutoff when the weight in the bag reaches a second set point BAG Pre INFLATE BAG EXHAUST Optional Our Model 510 can be equipped with a Bag pre inflate This feature inflates the bag prior to filling to give you full volume of the bag Inflatable Bag Cuff Optional This is a rubber bladder that inflates an...

Страница 29: ...29 CHAPTER 6 SETUP OPERATING PROCEDURES ...

Страница 30: ... equipped with bulk and dribble when the bulk set point is reach the slide will closed to the mechanical selected position on the slide gate cylinder and stop When the final position is reached the slide gate will completely close During this filling process the bag densification system OPTIONAL will delay from starting either thought a time delay in some controllers or other controllers use a of ...

Страница 31: ...31 Caution DO NOT WEIGHT THE BAG FROM THE BAG STRAP SUPPORTS THE BAG STRAP SUPPORTS ARE ONLY DESIGNED TO KEEP THE UP RIGHT DURING THE FILLING CYCLE WITH THE WEIGHT SETTING ON THE PALLET ...

Страница 32: ...he blue PB to inflate and bag seal cuff Check the pressure on the regulator to make sure the pressure is between 3 5 PSI to start Adjust 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 sleeve and pressing the blue button will need to perform at the beginning of each fill cycle ...

Страница 33: ...tly to the bulk bag filler head The pressure adjustment was factory set to 3 PSI however this will need to be fine adjusted in the field using the customer s bulk bag CAUTION Caution should be exercised when inflating the cuff Over inflation could cause damage to the sleeve of the bulk bag and or burst the cuff ...

Страница 34: ...r tears and replace as necessary Replacement of the cuff is recommended if any wear tears or thinning is noticed The pressure gauge for the bag seal cuff should be kept in good working order If the gauge does not read pressure remove and replace it as soon as possible to prevent cuff damage 0 30 PSI gauge recommended D Adjusting the vibrators Remove end caps from each end of the vibratory motor Lo...

Страница 35: ...filling cycle a blower valve opens allowing the bag to be inflated for the length of time the timer is set for in the PLC When the timer has expired the 3 way valve changes position and the blower fan stops The exhaust port opens allowing the air from the bulk bag to vent to the dust collection system A Setup and Adjustment The timer for the bag inflator is found in the PLC inside the motor contro...

Страница 36: ...36 CHAPTER 7 PLC and AVERY 405 ADJUSTMENTS ...

Страница 37: ...but need to be fined tuned in the field Below we discuss how to adjust the timers when you go to fine tuning them Timer Adjustment Procedure for PLC A Button is used to scroll through the Timers B Button is used to scroll back When you get to the function you want to adjust you will push the OK key to select that function When the time is selected the numbers will flash on and off When it is not s...

Страница 38: ...nd of a cycle used to remove all the product from the filling tube into the bag after the fill is over It is adjusted in 0 1 second increments Factory Setting is 1 0 seconds Reverse For 200 Model Packers only Is the time the auger is in reverse at the end of the cycle It is adjusted in 0 1 second increments Factory Setting is 0 5 seconds Adjusting the Timers To adjust the timers you first scroll t...

Страница 39: ...s changed just like the Target o The Dribble set point is the amount of weight that will be put into the bag at the slower fill speed I E If you set it to 10 lbs the bagger will run in the slow speed for the last 10 lbs of the fill The screen will now show o This is changed just like the Target o It is used to compensate for overweight bags I E If your weight is consistently 2 lbs over you can put...

Страница 40: ...40 Chapter 8 WEIGH CONTROLLER and ADJUSTMENTS ...

Страница 41: ...play and others want a higher end controller that can provide management information The three different brands that we use are Thompson Scale Controllers Rice Lake and Avery In this section we will go over how to calibrate and set the target weight for each controller When you go to perform these functions be sure to go the correct section matching the instructions to the controller on the machin...

Страница 42: ...tart screen press and hold the key until The screen will display 3 Enter the passcode 2580 4 Press key to enter the passcode The screen will display busy and then will go into calibration mode 5 Press to go to calibration menu Scale 1 will be displayed 6 Press to go to Scale 1 menu ...

Страница 43: ...ion 1 Power On the screen will display boot and then loading 2 From start screen press and hold the key until The screen will display 3 Enter the passcode 2580 4 Press key to enter the passcode The screen will display busy and then will go into calibration mode ...

Страница 44: ...44 CHAPTER 9 MAINTENANCE ...

Страница 45: ...tears or thinning is noticed The pressure gauge should for the bag seal cuff should be kept in good working order If the gauge does not read pressure remove and replace it as soon as possible to prevent cuff damage BULK BAG INFLATOR EXHAUST SYSTEM Check plungers once a year Check and clean air filter once a month Butterfly and Actuator Check seat of butterfly once a year ...

Страница 46: ...46 CHAPTER 10 TROUBLESHOOTING ...

Страница 47: ...k load cell feet to make sure that all 4 feet are firmly touching the floor Erratic weights Erratic material flows from supply bin Not maintaining consistent head pressure above the packer causing inconsistent flow to the impeller Controller dribble setting is too close to the final cutoff setting Increase dribble setting Mechanical dribble setting on slide gate is open too far Adjust the sensors ...

Страница 48: ...ne fuse in the GSE controller R R if bad Check for loose wire Bad LED display board Dirty filling Insufficient dust collection pickup volume Bag seal not inflated enough Material bypassing the seal Operator not putting the bag neck on the fill spout far enough Bad bag seal Trouble shoot a Bad Load Cell LOAD CELL CONNECTION GUIDE SHIELD CLEAREXCITION BLACK EXCITION RED SIGNAL WHITE SIGNAL GREEN SEN...

Страница 49: ...ity Note Red to Black is the input resistance Very important Note Green to White is output resistance Very Important Resistance In K ohms 2 5K Red Black 384 Red Green 296 Red White 296 Black Green 294 Black White 294 Green White 351 ...

Страница 50: ...50 ILLUSTRATED PARTS PAGES ...

Страница 51: ...51 ...

Страница 52: ...52 ...

Страница 53: ...53 ...

Страница 54: ...54 ...

Страница 55: ...55 ...

Страница 56: ...56 SCHEMATICS AND DRAWINGS ...

Страница 57: ...57 Bulk Bagger 19 pin Yellow Cord 202 Red 204 Brown 208 Gray Pink 210 Gray Brown 234 Gray 236 Red Blue 238 Pink 240 Blue 252 Black GND Yellow Neutral White Ground Green Yellow ...

Страница 58: ...58 ...

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