Home

Thompson 4693_"Gross"_Weigh Manual

1. CHOOSE ONE 1 TURN LISTING ON 2 TURN LISTING OFF 3 PRINT INTERIM REPORT 4 PRINT FINAL REPORT 5 CLEAR STATISTICAL MEMORY 6 DISPLAY FLOW RATES X RETURN TO PREVIOUS MENU Statistics Data Menu Selecting item 1 will turn the listing feature on choosing item 2 will turn it off This will change the main heading to reflect the current condition Listing can also be toggled via the main Filler display and the optional remote report switch The listing feature prints all bag weights from all connected spouts for as long as the feature is on See 8 2 2 1 below for more detail 3 and 4 allow reports to be called from within this menu The can also be invoked via the main Filler display and optional remote report switch See 8 2 2 2 below Sub menu item 5 allows for any statistical data held in memory to be cleared This is useful when first starting up the filler controller removing any random or unwanted data from memory Selecting 6 will display the flow rate information described in 8 2 1 above The primary function of the STPR STatistical Production Report option is to produce a Summary Report which is a statistical analysis of all units produced for a particular product recipe There are three basic report types available with STPR These are Unit Weight Listings Interim Reports and Final Reports Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com
2. Serial Port Information The Model 4693 controller offers several types of serial ports for connection to printers remote displays etc The 470 CPU card contained in every system provides two 2 serial ports One labeled REMOTES is dedicated to transmitting each unit weight as it occurs The second port labeled PRINTER is for use with the optional STPR statistical reporting package offered by Thompson Scale An optional 477 card may be added to the controller to provide full duplex communications and is provided in either RS 232 or RS 422 configurations Additionally we offer an optional Ethernet TCP IP port for communications with PLC s or system networks A 1 470 CPU Card REMOTE Port The 470 CPU card which resides in the far left slot of the 4693 controller contains an eight 8 pin connector labeled REMOTES This 8 pin connector contains two 2 serial ports both operating on the same protocol and delivering identical data The port can be hard wire configured as either a 20mA current loop Active or Passive port 20mA current loop is a digital signal not to be confused with a 4 20mA analog signal The drawing below and those at the back of this manual shows the proper wiring for this port 20mA ACTIVE CURRENT LOOP CONNECTIONS Two Ports Available As Shown 20mA PASSIVE CURRENT LOOP CONNECTIONS Two Ports Available As Shown Thompson Scale Company 4693 Gross Filler Controller User s
3. T Select OK Depending upon your operating system and configuration the PC may require a Restart 8 Connect a Crossover Ethernet cable between the PC and the Ethernet converter s Ethernet port 9 On the PC Open Internet Explorer or other web browser and type in the IP Address setup in step 6 above Connection to the Ethernet converter should be made and a menu provided by the converter will appear displaying setup options for the converter A 4 3 Ethernet Port Redirector Option l Load the CD provided with the Ethernet converter into your PC Select the option for the Comm Port Redirector software package 2s Start the Comm Port Redirector program 3 Click on the Com Setup button and select Com 3 or some other comm port not currently used by the PC Com 1 amp 2 are normally already assigned 4 Click on the Add IP button and enter the IP address of the Ethernet converter as setup in step 6 of Section A 4 2 above 5 Enter 10001 as the TCPPort Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com 10 11 Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 93 Click on the Port settings button and make sure that Raw Mode is selected Click on Save button then close the Comm Port Redirector program Start Hyper Terminal in your PC using the Com port number that was setup in steps 3 7 of this section Set the following p
4. 7 CONNECTIONS 8 L2 POWER L1 CONNECTIONS As the 4693 filler controller completes its fill cycle on the current fill the weight value is transmitted out of the serial port on the 477 card This weight value is constructed of a start character STX data characters weight data and or commands or error codes a Carriage Return CR and Line Feed LF Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 90 Protocol which includes data transmission rates and hardware hand shaking are fixed per the configuration shown below 1 Start Bit Eight 8 Data Bits No Parity 1 Stop Bit 9600 BPS The 477 card can be provided with either RS 232 or RS 422 serial ports This must be specified at the time or order and is noted on the face plate of the card Connections for both are shown below RS 232 Connection 477 card pin 2 Receive 477 card pin 3 Transmit 477 card pin 5 Signal Ground RS 422 Connection 477 card pin 1 Receive 477 card pin 2 Receive 477 card pin 3 Transmit 477 card pin 4 Transmit 477 card pin 5 Signal Ground For further information on connection of this card to your computer network or closed loop system contact the Technical Service Department at Thompson Scale Co A 4 Ethernet Port Option As a purchase option the 4693 filler co
5. Flow Rates amp Reporting 0 0 cece eens 58 6 2 1 Using Flow Rates Peatine 3 ose E Ss te oes ee Se eee ede tad 58 8 2 2 Production Reporting Package 0 0 cee en ene 60 92201 Unit Werght EASES era ita seve wed A iaa 61 8 2 2 2 Interim REPO AS AA hy hy a ES eo EES A eS 61 902203 Final REPOT y Reese trad oi a tad yrs teen ol gs gadis eee ae A mag ie ee E 62 8 2 2 4 52394 Serial Converter for Optional STPR Package 4 66 8 2 2 5 Printer COMmeuraliOn 222345 8ees A eee 67 Spare Parts EA Oe PESTER RARA S 69 Controller Configuration A A OOP ARS 71 TO CONE Sra Ment eyes Le Gi a Ow ania CoN ea Sa eRe eS AS oan dt 71 AA ets Sample Rae A ce tw aia ng Owe es ew A A 72 10 1 2 Setting Filter Frequency 2 25 i424 bastidores blas feasts 12 10 1 3 Setting Max Product Number AA AA AA A 72 10 14 Set AID Gain Nude os oS io 14 ee dd ds a 72 10 1 5 Set 2 A D Gain Number 24 cleo E E 72 10 1 6 Set Decimal Point 4 54 45 ts a A eee ey WAS Wa ee ta 12 10 1 7 Initialize A D Serial BEPROMS ostra A So Mae ee eee 73 10s 8 GetNext Ment aora Bom ig vio at ot tii AS as 73 10 2 Secondary Configuration Menu spa a A Pee eB AA ee eae ee AAC 73 10 21 Setting TIMO cuota ba Derek daub leah ei dee naaa 74 10 22 Select Valve PE A rd e do 74 10 2 3 Seb Oliset Compensation estaria ii As 74 10 24 Set Piller Pe sn id rad sa eo MU o al LE DO e oi 75 10 2 3 Set Languages vips pd le a A ceed Sides 75 10 2 6 4693 Test ROUDE
6. Manual This mode is intended for robotic bag placing and retrieval systems and provides a signal and sequence to allow the end effector of the robot to remove the broken bag and place in a reject location B 4 Broken Bag Sequence Of Operation A bag is placed onto the fill spout Manual bag clamp if used is actuated Operator presses Start or bag actuates automatic start limit switch when bag is placed Bag clamp actuates for pneumatically controlled bag clamps Settling time initiated and run followed by 1 2 second of weight sampling to establish TARE of the empty bag Bulk fill is initiated Timer begins tracking fill time Fill weight verses time is calculated throughout the fill in both bulk and dribble if used If fill time is exceeded fill is aborted and bag handling method activated broken bag error displayed on screen If rate of change does not meet minimum requirement fill is aborted and bag handling method activated broken bag error displayed on screen Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 100 Fill weight cut off is achieved and bulk or dribble is closed stopped Final fill time is calculated Settling time is initiated and run followed by 2 second of weight sampling to determine final bag weight Final bag weight updated statistics fill time are displayed on
7. 12 pin removable connector RS 232 Connection 477 card pin 2 Receive 477 card pin 3 Transmit 477 card pin 5 Signal Ground RS 422 Connection 477 card pin 1 Receive 477 card pin 2 Receive 477 card pin 3 Transmit 477 card pin 4 Transmit 477 card pin 5 Signal Ground For further information on connection of this card to your computer network or closed loop system contact the Technical Service Department at Thompson Scale Co C 3 Product Load Commands The remote product load option allows for remote operation and product loading of the filler controller As with manual entry of data into this controller the remote product load must execute specific steps in order to load a new or modify an existing product set up The filler controller can store 75 unique product recipes in memory Remote product load must specify a product number to enter or edit between 01 and 75 Any value outside of this range will invoke an error response from the controller Any product between 1 and 75 can be loaded in any order desired If it is desirable to load product 24 before loading 1 through 23 then the controller will automatically create products 1 through 23 to allow access to 24 Since data fields for each product recipe are stored sequentially it is necessary to open these other product recipes If no data is entered into these vacant recipes they will contain no valid data Each time a command
8. 2 C is assigned to spout 2 and D is affixed to spout 4 Eight unit weights print across the page followed by a running total of units produced on this reporting cycle and an elapsed time since the beginning of the production run The following page contains a sample of this report The filler controller automatically tracks paper position in the printer and generates a skip over the perforation between pages The controller also prints the current weight settings and product number as a heading at the top of each page for reference Unit Weights will continue to print until the List function is toggled off These listings are useful since they provide a real time printout of weights crossing the Filler A50 00 B49 98 A49 97 B50 03 A49 98 B50 00 A49 96 B50 06 108 00 05 A49 98 B50 04 A49 98 A50 00 B49 97 A49 98 B50 02 A50 00 116 00 05 B50 04 A49 99 B50 00 A50 06 B50 02 B50 08 A49 96 B49 96 124 00 06 A50 06 B50 00 A50 08 B50 00 A49 98 B50 03 A50 00 B50 02 132 00 06 8 2 2 2 Interim Report As with the Unit Weight Listing a prompt is displayed within the Statistics Main Menu or the main Filler display for calling an Interim Report By calling this report the display will temporarily display a message that an Interim Report has been called This report can be called throughout production without interrupting production Multiple Interim reports can be called during production without the loss of data All data contained in this
9. F4 3AG Fuse 250 Volt rated 1 Amp Fast Acting Glass Fuse Spare fuse on right side of 472 card F8 Other cards used in the 4693 controller are described in detail in Chapter 2 section 2 4 and on the electrical drawings found at the back of this manual 1 2 System Battery for Time Date Clock The 4693 controller contains a time date clock for use with the system s calibration audit trail and for calculating production rates and time date stamps used on production reports The time date clock I C chip located on the system s 470 CPU card is maintained by a self charging battery which is also located on the 470 CPU card This battery will continue to properly operate the time date clock chip for a period up to 6 months if AC power is lost to the controller The self charging battery is designed to last for the life of the CPU card and will never require field replacement The battery is permanently affixed to the printed circuit card and under no circumstances should it be removed for testing repair or replacement Contact Thompson Scale Co for instructions on return of the 470 CPU card in case of battery failure CAUTION Danger of Explosion if battery is incorrectly replaced Replace only with the same or equivalent type recommended by the manufacturer Dispose of used batteries according to the manufacturer s instructions 1 3 Environmental Rating of Equipment The 4693 controller is housed in a NEMA 4X IP67 rated
10. HOWEVER working on or around pneumatic or mechanical clamps or cut off assemblies is potential dangerous and it is strongly recommended that power to the controller is removed prior to this work Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 4 Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Chapter 2 Introduction 2 1 Controller Overview The 4693 Filler Controller is designed to control all phases of the filling operation of a single or dual spout valve or Gross packer The 4693 controller operates all associated Input and Output devices solenoids load cells weight displays etc and can generate detailed production and diagnostic reports The 4693 controller provides the operator with a means to input Net Target Weights Product Name Lot Number and Customer Name for 75 individual product types It automatically fills each bag quickly and accurately Product flow rates are automatically calculated and Bulk and Dribble cut offs are anticipated and set internally by the controller TO functions are provided to allow interface of peripheral equipment such as printers and automatic bag placing equipment Default configuration for the 4693 controller is for an Air packer but can be configured for use as an impeller or auger packer controll
11. In this step the controller can be in any menu including Calibrate Scale or Calibrate Check The controller must be in the Run Filler screen to begin filling bags After a fill cycle begins the controller can be changed to any other menu without interrupting the fill in progress but will not allow another fill to begin until it is returned to the Run Filler screen 2 A bag is placed on the spout actuating the bag sensor or the Start push button is pressed The bag clamp is actuated immediately whether or not the refill timer has timed out The controller also looks for any interface signal that indicates that a bag is not actually on the spout for optional bag in place sensor This sensor would drive the Input to the controller high indicating there is no bag on the spout 3 A timer is loaded with the Bag Placer Dwell Time set in Main Menu 4 Set Time Date and Placer Dwell Time This timer must time out before any other operation takes place Dwell time may be set to zero for manual placement applications in which case no time is required for this step NOTE This should be the first item checked if the filler has a long delay at the beginning of each fill cycle 4 Some vibration is introduced by placing the bag onto the spout and actuating the bag clamp Before reading TARE the controller sits idle for the period of time entered into Settling Time see Chapter 10 to allow the vibrations to diminish to a point where a
12. Weight values can be entered in either conversion and changed without affecting the accuracy 4 6 2 Editing an Old Product Once products have been entered into the controller you may wish to change a setting weight limit or product LD value To do this select item 2 from the Enter Edit Product Main Menu This menu allows for the input of a product number to be edited Once entered the Customer Name Product Name and Product number will be displayed The display also contains data structured similar to the Enter New Product display as well as two prompts labeled N for Next Product and P for Previous Product By entering either of these two letters you can scroll through all products in memory As with the Enter New Product Menu you must enter a password if enabled to edit the weight values You must also select L to load the new product values to run as the current product or select X to simply save the changes and exit from this sub menu Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 37 4 6 3 Edit Password The 4693 Filler Controller contains password protection for the entry of product weights such as Target Weight and Refill Timers This password also protects execution of calibration Each system is shipped from the factory with a null string space entered as the password This
13. x and to enter a new number then hit the Enter key This will automatically load all the set up information for the new product and you re ready to start filling that product Let s say you are running a 50 Lbs bag of flour which is product 1 and you need to set up to run a 40 Lbs bag of cake mix which is product number 34 Hit the P key hit the keys 3 then 4 and then hit the Enter key Now everything is loaded and ready to run If your system has a printer package you might see a screen that says it is waiting until the production data is sent to the printer Once the data is sent the screen will automatically change over to the new product settings and you ll be ready to fill 6 3 Running The Filler Once products are set in memory and you have a product ready to run you need to know how to start the filler and more importantly how to stop it if something goes wrong The filler controller can be configured to work in a couple of different ways The controller may operate a single spout or up to four adjacent spouts at the same time and may be interfaced to an automatic bag placer The 4693 Filler controller fills in two different modes The first is Automatic Set Point Mode and the second is Manual Set Point Mode If you are running Automatic Set Points the filler will automatically call a 1 Cycle whenever the following events occur Select a new product set up Hit the STOP ABORT switch twice Get an Overweight Error or No
14. 10 3 below for information on testing the serial converter included with the optional STPR printer package Once you have verification that hardware hand shaking is established and properly functioning you can invoke test 2 and transmit a test string to the printer When this test is enabled the string The Quick Brown Fox This string will print continuously until the test is turned off or the printer is turned Off Line The remote test will transmit a string of weight data to a remote display or computer port The remote port does not use hardware hand shaking so there is no means of testing the integrity of the serial link other than by transmission of data This signal is a 20mA current loop serial port not analog and therefore generates differing voltages when transmitting To electrically test this port to confirm transmission first confirm that a jumper between terminals 4 and 7 is in place the plus signal is wired to terminal 1 and the minus signal is wired to terminal 3 Now place a digital volt meter on mA milliAmps and place the plus lead on terminal 1 of the REMOTE port Place the common lead on terminal 3 of the REMOTE port When the line is idle the mA reading should be 19 to 20mA nominal When data is transmitted the mA reading will drop to 15mA The line should pulsate between these two readings as data is transmitted Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web S
15. 2 Duration Timer Settings The duration timer is responsible for inhibiting the discharge of a bag unless a clear space is available below the spout For example A filled bag is discharged from spout 1 its Delay timer starts This timer times out once the bag reaches a point where it would interfere with a bag from spout 2 The time required for the bag from spout 1 to cross under spout 2 and reach a point far enough away so that spout 2 can discharge is the Duration Time As with the Delay Time there is a set of six 6 timers responsible for maintaining proper bag drop distances This is also described in the Traffic Control Drawing at the back of this manual 8 2 Main Menu Item 6 Flow Rates amp Reporting The default configuration for the 4693 filler controller provides detailed information on product flow rates in pounds per second for Bulk and or Dribble fills for the last 5 fills As an option the 4693 controller can be upgraded to collect and print production weight data and provide flow rate information First we will describe the flow rate screens and usage and then offer information on the optional reporting package 8 2 1 Using Flow Rates Feature This information can be invaluable for diagnosing a number of problems with erratic fill weights or to help improve the efficiency of the filler First conduct a number of fills on each fill spout as you would during normal production then look at these values for consi
16. ALTERNATE y 2 RX 3 20mA 7 SN EN SOURCE i r GND E a BS ea DATA OUT A DTR i oo rt Ym O ES H PL 3 H DB 25 CONNECTOR TO PRINTER PRINTER TO NX 7777 i READY INPUT a DTR A A eee 1 Jumper Information pertaining to the configuration and set up of the Okidata printer can be found at the end of this Chapter Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 86 A 2 1 Serial Converter The STPR package is provided with a 20mA to RS 232 converter part number 52394 This converter is housed in a NEMA 1 style painted metal enclosure and is provided with a pre wired 110VAC line cord and a communications cable with a DB 25 pin connector for connection to the Okidata printer s serial port Terminals are provided on the 52394 converter board for connection of wires from the 470 CPU s PRINTER port The 52394 enclosure is intended for use in an Office Type Environment and is not suitable for use in a dusty wet or corrosive environment The 52394 enclosure should be placed within five to six feet of the printer and either mounted to a wall or other structure Wires from the 4693 filler controller s PRINTER port should be connected the DB 25 connector plugged into the Okidata printer port and the Line cord plugged into a GROUNDED receptacle Two of the four
17. B_ Blast Air Enable Disable Blast Air enabled This setting is not displayed nor adjustable unless the program for the filler controller is specifically for the Model 150 packer upgrade This feature will initiate an output to turn on a very short blast of high pressure air directly into the fill nozzle of the packer This blast of air breaks up any blockage or plug that may exist 10 2 C_ Chair Discharge Mode The 4693 is configured to a default that operates the bag chair saddle to automatically remove the bag from the fill spout at the end of the fill sequence This method of discharge is considered a powered chair Several other methods of removing a bag from the fill spout are offered in the following screen Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 81 SET CHAIR DISCHARGE METHOD CHAIR DISCHARGE METHOD IS POWERED 1 SET DISCHARGE METHOD TO POWERED 2 SET DISCHARGE METHOD TO GRAVITY 3 SET TO DISCHARGE INTERLOCK 4 SET TO 2 STAGE CHAIR Esc RETURN TO MAIN MENU Bag Chair Discharge Gravity discharge method is used for applications with either no powered bag chair no chair at all or a spring loaded and counter weighted chair that allows the bag to fall away once the bag clamp is released The discharge interlock method requires an interface between two adjacent fill spouts to
18. Cycle routine since cut off points are established by the operator Adjustments for under over weight fills are manually entered by the operator If your filler controller is set for Manual Set Points disregard the following references to the 1 Cycle routines Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 41 During each fill cycle the controller makes several measurements which are stored and used to predict cut off points in the next fill cycle All measured variables must be initialized and this is done in our 1 Cycle The description of 1 Cycle is intermixed with the normal fill cycle since that is how it actually works A complete Input Output list is included at the end of this sequence Special Inputs and Outputs used for bag placers and traffic control have been programmed to allow the basic manual filler bags placed by hand to operate without the need for special configuration of the controller or jumpers across inputs or outputs 1 With no bag on the spout the chair is in the fill position the bag clamp is open and the refill valve is opened allowing product to flow into the upper chamber Impeller Packers should have the Refill timer set to 0 0 sec When the refill timer times out the refill valve is ready to close and the controller display changes status from REFILL to READY
19. DB 9 Female connector 1 With Power OFF to the Ethernet Converter connect the serial cable between the unit and a PC The DB 25 connects to the converter unit and the DB 9 connects to the PC 2 Start Hyper Terminal Communications program supplied with Windows on the PC This is typically found under Start Programs Accessories Communications Hyper Terminal 3 A New Connection dialog box is presented Type Ethernet Converter as the description 4 A Connect To dialog box will appear Set the bottom selection Connect Using to COM 1 or com port of the PC used to connect to the Ethernet converter 5 A new dialog box COM1 Properties will appear Set to the following 9600 baud 8 data bits 1 stop bit and no hand shaking Parity none 1 Stop Bit Flow Control none 6 Now click OK and this profile will be saved 7 Apply power to the Ethernet converter unit and press the x key on the PC several times as soon as the converter is powered up This will place you into the Setup mode 8 Press Enter to display available options 9 Press 0 to enter IP Address Server setup 10 Enter an IP address that is authorized and compatible with your company s local network or use the following fixed address IP Address 192 168 1 139 Gateway 192 168 1 1 Select default for all other options 11 Press 9 to Save and Exit Setup mode Thompson Scale Company Houston TX Phone 713 932 90
20. Dribble value will always be 0 0 This screen will display the last five 5 fills completed for the spout chosen Flow rates should be consistent within a few tenths of one another Variations in either Bulk or Dribble flow rates is an indication of material flow problems such as clumps bridging or inconsistent low pressure air pressure It can also be an indication of mechanical problems such as binding or inconsistent actuation of the pinch tube air cylinder interference during the fill from machinery or personnel touching the flexures load cell or bag post or slow reacting solenoid valves used to operate the pinch tube cylinder Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 60 Although these rates are updated on a bag to bag basis it is not necessary to view or clear this screen during normal production 8 2 2 Production Reporting Package The Filler controller offers an optional statistical analysis and production reporting package for extracting production data from your system When this upgrade is installed See Appendix A for information on hardware included Main Menu item 6 will change from Flow Rates to Statistical and Diagnostics Reports This menu and its sub menu selections are listed below Selecting Main Menu item 6 will produce the following menu LISTING IS OFF
21. ESC RETURN TO PREVIOUS MENU Bulk Dribble Settings The filler controller has a very high sample rate and does an outstanding job of tracking and calculating final cutoff weight With this in mind an option is presented to operate the filler in a Bulk Only mode instead of the standard Bulk and Dribble mode Typically the Bulk Only mode produces final fill weights only slightly less accurate than with both Bulk and Dribble but greatly reduces each fill cycle time thus increasing overall production rates Bulk and Dribble produce the most consistent and accurate fills and rely on a pre set Dribble time of 3 0 seconds The filler controller will automatically calculate a Bulk Cut off point that will deliver three 3 seconds of Dribble Dribble only fill is available for applications filling both large and small containers on the same packaging machinery Bulk flow rates may be too high to accurately fill a small container and so these particular products can be set to fill in a Dribble Only mode A word of caution Some filling systems use a two stage Bulk Dribble air cylinder to operate the pinch tube These cylinder arrangements require going to Bulk before changing to Dribble in other words you cannot go directly to Dribble from a closed position Running in Dribble Only will cause the pinch tube cylinder to actuate to Bulk for a split second before changing to Dribble fill The final variable Fills TARE allows the filler control
22. Page 111 For example let s say that the filler controller has a Target weight of 50 00 lb 10 bags are filled and run across the checkweigher The weights as seen by the checkweigher are 50 00 49 85 49 90 50 00 49 95 49 95 49 90 49 90 49 90 49 85 Adding all these values together the sum 499 20 This value is then divided by the number of units in the sample 10 and a result of 49 92 is derived This is then subtracted from the actual Target Weight of 50 00 resulting in an error of 0 08 Using the Correction Factor variable described below the filler controller would induce a correction in the next fill weight of either 0 02 lb 25 0 04 lb 50 0 06 lb 75 or 0 08 lb 100 as preset by the customer A 3 1 Sample Count This value can be set from 1 to 10 and is the number of weighments that will be averaged to generate the next weight correction in the filler controller Normally this value would be set to 5 but can be set lower to provide faster response to changes or higher to dampen response to variations in weights CURRENT FEEDBACK SAMPLE COUNT IS 05 SAMPLES ENTER NEW FEEDBACK SAMPLE COUNT MAXIMUM OF 10 AND ZERO IS NOT ALLOWED X RETURN TO PREVIOUS MENU Feedback Sample Count Parameters A 3 2 Sample Frequency This value can be set from 1 to 100 and is the number of bags between the filler spout and the checkweigher The best way to gauge this is to run bags in normal production mode a
23. Serial EEPROM the calibration procedure requires writing and reading to the serial EEPROM that resides on the 474 Scale Digitizer card If data cannot be written and stored the calibration procedure cannot be completed Although not typical it is possible that some corrosion has occurred between the busboard s card edge connector and that of the 474 scale card and data is either not properly transmitted or not transmitted at all Usually removing the 474 card and cleaning the edge connector will solve this problem If it does not it may be that components on either the 474 card or 470 card are inoperable and either card may require replacement Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 16 Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Chapter 4 Setting Operating Parameters The 4693 Filler Controller allows the operator to input variables and other operating parameters via the front panel keyboard The operator is prompted through each setting by the controller s menu driven display Each menu is described below along with default settings for each variable The filler controller offers two distinctly different modes for determining cut off points for Bulk and or Dribble fill weights The default is the Automatic Set Point Mode
24. The optional mode is the Manual Set Point Mode Manual set points can be selected in the configuration menu which is discussed in Chapter 10 of this manual Each of the modes are described below 4 1 Configuration for Single or Dual Spout Controller Upon applying power to the Filler controller the 470 CPU card within the controller addresses each card within the card rack and determines the system s configuration If one 1 474 Scale Digitizer card responds then the system configures itself as a single spout filler If two 2 474 cards are located then the main fill display and several other variables are set up for operation as a dual spout controller Each 474 Scale Digitizer card contains terminals for connection of a load cell as well as three terminals dedicated to addressing the card The Leading 474 card is considered to have the address of 00 A second 474 card added to the system must contain a jumper at the address terminals to configure the card with the address of 01 This same holds true for the addition of a 473 I O card In a single filler system there is one 1 473 I O card A second must be added to accept inputs and drive outputs for an additional filler Terminals are also provided on the face of the 473 to address the card via a jumper The first display screen at power up will show the initialization of one or two 474 Scale Digitizer cards An example of this screen is shown on the following page This screen rema
25. Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 61 8 2 2 1 Unit Weight Listings The Filler Controller s Main Menu item 6 Statistical and Diagnostics Reports and the main filler display offer a choice to turn on or off the unit weight listing The printer used with STPR transmits a ready signal back to the filler controller if it is connected loaded with paper and On Line If the List feature has been turned on each unit weight is transmitted to the printer Upon the eighth 8th weight transmission a carriage return and line feed command is also transmitted which prints all eight weight values and advances the paper If the filler controller is being used in a multi spout application 2 3 or 4 spouts weight data from all spouts are combined on the listing report If a separate controller is used with a third and or fourth fill spouts a n in conjunction with the 477 Traffic Sequencer card weight data from the Trailing 3rd 4th spout controller is transferred to the Leading controller 1st amp 2nd spouts and weight values from all are combined on the listing report That is to say if you have more than one filler controller on a common production line the two controllers can be interconnected to generate a single listing and production report A prefix letter of A B C and D are affixed to each unit weight Prefix of A is generated by spout 1 B is assigned to spout
26. at the beginning of each fill cycle This value can be set to a maximum of 99 fills between TARE s If the TARE value is set to a number greater than one 1 the filler controller will always perform a TARE on the Ist Cycle fill perform a TARE on the next fill which is a normal fill and will then fill the third thru x number of bags without taking a TARE The TARE values taken on the Ist Cycle and next fill are used to determine an average TARE for all successive fills If your packaging machinery experiences fluctuations in the amount of product left in the fill tube at the end of each fill or if your machinery spills an excessive amount of product during each fill cycle it is recommended that the TARE to fill ratio be kept very low However if your packaging machinery runs cleanly and with a minimum amount of left over product in the spout this number can be increased up to 99 fills between TARE s Now back to entering Manual Set Points If Bulk Only fills have been selected entering into item 1 Target Weight will present the following screen Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 34 1 SET TARGET WEIGHT 2 SET 1 PREACT PLUS 3 SET 2 PREACT PLUS ESC RETURN TO PREVIOUS MENU Manual Bulk Only Settings Entering item 1 allows the NET Target Weight to be entered Items
27. bag is 50 10 but the checked weight of that bag is 50 50 You would want to invoke a Minus compensation of 0 8 This would make the displayed weight value increase to 50 50 lbs thus matching the checked weight Keep in mind that even though we call the air and auger packers Gross Weight fillers they are in fact filling to a NET weight since they zero out the bag s weight at the beginning of the fill cycle When making a comparison between the filler s weight and a check scale always place 10 empty bags onto the check scale determine the weight and divide by 10 to get the average container weight Either enter that value into the check scale as a TARE value or simply subtract it from the check scale s displayed weight when you put the bag onto the scale Offset compensation should only be used if the difference between displayed weight and actual weight are consistent If displayed weights vary randomly from checkweighed weights there are most likely other problems such as varying flow rates mechanical interferences or electronic stability problems Do not use Offset Compensation to try and correct these other hardware problems 10 2 4 Set Filler Type The 4693 controller can operate two distinctly different types of valve baggers These are Air Impeller baggers and Auger baggers The main difference between these two types of machines are found at the end of each fill cycle An Air Impeller bagger has an adjustable timer for setting Sp
28. been purchased If this port is active two tests are enabled to allow confirmation of operation of the port and the printer The remote port is always active and transmits weight data in one of two formats See 10 2 7 below In either case data is transmitted with a leading letter character of either A B C or D which corresponds to the spouts on the filler system A single spout filler will transmit the letter A before the weight Three tests are provided to exercise the optional printer port optional printer and remote port These tests are 1 Printer On Off Line Test 2 Print Test String 3 Remote Test The printer On Off line test allows for visual verification of the printer s status The four 4 conductor printer cable between the filler controller s PRINTER port and the 52394 serial converter enclosure included with the STPR printer package performs two functions First it establishes hardware hand shaking between the printer and the 4693 controller If the 4693 controller does not see the printer then it will not transmit data For the printer to be On Line it must drive the interface on the 4693 s PRINTER port low If the printer is On Line the 4693 controller s display will indicate that the printer is On Line If the printer is turned off or is turned Off Line or if serial communications with the printer are not properly established the 4693 controller s display will indicate that the printer is Off Line See section
29. da oe ea PB ORR Ae 7 Remote Product Recipe Loading a2 ii dy hens SNe tee Ieee ee eee 8 Production Reporting 2226 iccresandeeiigesithiiveuhesiiievckes taken be bb 8 Calibration DARIA ER BERRI OS RAS BERS So TOPE LEIS TORSO OE 9 O21 x DOU Cal OraLlOns Yin a Bese ds ad Btls e ANE eA De Ne DO Oe ee 9 2 Calibration CHECK aacr se o A A EA A ie a Ae aE 2 Oia ha Pee a es 9 3 3 Calibration Procedure i sscani cand oan a ad a DERE EA Saw Rowe SS 10 SA Calibraion Errors st ae Sears Shee eased el BERR ee E 14 Cannot Zero scale e sorpsstanira rar orde toria par 14 No Test Were Onscale stoke eo E e a A O oe eae Lette 15 Span At Either Max Or Min caso weed eee head A Ea apa a 15 Cannot Write To Serial EEPROM 00d rererere errr rrer 15 Setting Operating Parameters lt a A A A A AR 17 4 1 Configuration for Single or Dual Spout Controller 2 0 0 eee ee eee 17 Ae any MES A AA A A th hae a eet ea Baten E Cae 18 4 3 Minimum System Set UPS dp 19 4 4 Menu Item 1 Ru Biller Asay dd a ed bu de bee a do O 19 44 1 Weight Display i2 aise ied wigs da i vie alee bo Bisa ied ae a 20 AAD SPAWNS Display a a aad Sa a Sean Rie Ode ee an ete wd do AREAN ENT 20 SA3 Product tall ps ele yess Bey oe pee te eee end a 20 AAA Production Data logra Gee y tors aoe Ahn dese de a whe Rca dhe 4 eh AE Seg 20 AAS Quick Keys once dyhwathy ca A ASS Rew Ay ee EOS OAS 21 Setting Operating Parameters Continued 4 5 Main Menu Item 4 Set Time Date a
30. equipment One benefit of Standard Deviation calculations as opposed to just the Mean Unit Weight is that the squaring and square root functions have a tendency to filter out the extreme high and low errors from the overall population This provides a more realistic picture of the majority of your production Since this filtering function takes place the final number usually contains only about 95 to 97 of the total population Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 65 Between the summary of production boxes and the distribution graph is the statement 3 Sigma Distribution for X Units Produced Sigma is another mathematical term that means several Standard Deviations So 3 Sigma equals the Standard Deviation times 3 In the STPR statistics report we calculate the 3 Sigma value and generate a plus and minus weight value on each side of the Target weight In this way the report bar graph contains the majority of weight values occurring during production Since Standard Deviation does qualify weight values within the report some values at the high or low range may not always fall within the 3 Sigma distribution and may not be included in the bar graph at the bottom of the page So the graph may not contain exactly the same number of unit weights as Total Units Produced in the Summary of Produ
31. fill cycle by lowering the bag clamp turning on associated devices such as butterfly valves low pressure blowers etc and then actuating Bulk fill In this test routine the filler controller DOES NOT read the load cell output but displays an incremental weight increase in 0 1 Ibs The dry cycle fill will continue until the display reaches Target weight or until the associated Stop switch is actuated When the dry cycle completes normal functions including actuation of the bag chair will take place Dry cycle fills can be done indefinitely as long as each cycle is initiated by actuation of the Start input This test is always set to a default of OFF whenever power is cycled on the controller That is to say if you are running this test and turn the controller off the test will have to be enabled in the EXIT menu again before it becomes activated This test can also be turned off by entering into the EXIT menu and choosing Test Fill Routine OFF Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 78 10 2 6 4 Test Printer Remote Port Each 4693 filler controller is provided with two serial ports located on the face of the 470 CPU card One port is labeled PRINTER and the other is labeled REMOTE The printer port is disabled unless the optional STPR statistical production reporting packaged has
32. going to the Filler controller This switch consists of a three position selector switch labeled LIST OFF REPORT The List position allows for the unit weight listing to print The OFF position suppresses the listing and the Report position is used to call for Interim and Final reports Calling Interim reports is done by holding the switch to the Report position for less than three 3 seconds Calling a Final Report is accomplished by actuating the switch in the Report position for more than three 3 seconds Reports and listings can also be controlled from the Filler controller front panel What s Included with STPR The STPR option can be purchased as part of your new Filler system or added at any time after installation The package consists of Program EPROM Program Read Only Memory chip for the 470 CPU card 52394 Serial Converter within a 10 x 8 NEMA 1 enclosure with pre wired connector to printer Okidata Dot Matrix Printer that accepts standard 9 1 2 x 11 tractor feed paper The software for STPR is added as a sub routine to the standard Filler program and is only available through the factory PROM s are programmed depending upon options purchased and can be easily changed if the STPR or other option is purchased after the initial installation By removing the 470 card from the controller s card rack you will see a 32 pin I C chip slightly to the left of center on the card This I C chip is covered with a label containing informa
33. is transmitted to the filler controller a response is issued to either acknowledge acceptance of the data or an error in delivery or receipt of the data Error codes are shown below Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com E00 E01 E02 E03 E04 Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 105 transmitted as STXEOOCRLF issued as a data acknowledge command STXEO1CRLF issued as a Not Valid Command error STXE02CRLF Report Called No Data In Buffer error STXE0O3CRLEF Printer Off Line error STXE04CRLF New Product Load Requested But Data In Statistical Buffer error Product Load Commands are to be in an ASCII format and are as follows 001 002 003 004 005 006 007 008 009 Load Customer Name into Temporary RAM Load Product Type into Temporary RAM Load Target Weight net into Temporary RAM Load Bulk Dribble bulk only or bulk amp dribble into Temporary RAM Load Refill Valve Timer into Temporary RAM Load Chair Return Time 0 0 is default into Temporary RAM Load Operating Units Ib kg into Temporary RAM Load Broken Bag Timer 1 30 sec into Temporary RAM Load Temporary RAM into EEPROM and Load Product To Run CAUTION DO NOT ISSUE COMMANDS BETWEEN 10 amp 22 023 024 025 026 027 028 029 032 Turn Unit Weight Listing ON Turn Unit Weight Listing OFF P
34. method of controlling exactly when a new TARE is taken When Manual TARE is enabled prompts will be displayed in the Run Filler screen that allow for a manual TARE to be taken This requires the operator to empty the fill auger and spout completely zero the scale and place a bag onto the fill spout At this point the operator hits the Enter key setting TARE This TARE will be used throughout production or until anew TARE is taken by the operator 10 2 S Set Auto Manual Setpoints The 4693 controller is set to the Automatic Set Point Mode as a default Manual set point mode allows the operator to manually enter cut off points for Bulk Dribble and Pre act values and presents the operator with features to auto track weight variations and change Preact settings See Chapter 5 for more information on the use of Automatic verses Manual set points 10 2 A Broken Bag Detector Applications using automatic bag placers or robots typically do not have an operator in constant attendance of the filler or fill station For this reason if a problem or error occurs such as a broken or mis placed bag onto the fill spout it is possible to dump a significant amount of product onto the floor or reclaim screw The broken bag feature is enabled and visible on this screen when the 477 card configured for broken bag operation is installed into the 4693 controller card rack For information on the use of this feature please refer to Appendix B 10 2
35. or bulky product into the bag during the fill Timing of the vibrator is handled internally by the 4693 controller The fill begins and at the earliest possible moment the vibrator is turned on and run to within one 1 second of either cut off or change over to Dribble fill If this feature is not enabled in the configuration menu this recipe menu item will not be displayed Item 7 Of Filter Samples sets the number of past fills to use when calculating error correction for the next fill This value is adjustable from 02 to 10 As the final weight of each filled bag is determined the error from Target weight as compared to this final value is stored in memory These errors are then averaged together and 1 2 of their value is applied to the correction of the next fill For packers with very good flow rates and accuracies a setting of 2 3 or 4 samples would provide a quick response to any changes detected in the flow rate of your product keeping the final weights on target For packers running products that perform poorly higher settings of 8 9 or 10 would slow the response to change effectively reducing the possibility of over correction It is always wise to start with a median value of 5 and then analyze production and adjust this value accordingly You are also presented with the option to choose either Lb or Kg conversions Although Ounces and Grams are shown on the display they are not available with this model of filler
36. outputs and a device for reading the load cell The embedded program within the CPU cannot change so if the machine appears to act erratically there is most likely a mechanical reason for it 7 1 Typical Problems and Solutions Listed below are some typical problems and suggested solutions Power must be OFF before removing or inserting a printed circuit card into the controller 7 1 1 Front Panel Keyboard does not respond The membrane keyboard is tied directly to the 476 Interface board mounted inside the controller s door Check the cable to insure it is properly seated There are two 2 Red LED s in the lower left corner of the 476 card One LED blinks with a steady heart beat This indicates that the microprocessor on the 476 card is functioning properly The second LED will light for one 1 second whenever a key is pressed on the keyboard Press a key and see if the LED comes on It may be that a string of keys on a common circuit may have failed or that the circuitry on the 476 card that reads the key presses has failed Messages from the keyboard are buffered through the 476 Interface board but are ultimately controlled by the 470 CPU card located in the rack Check the cable running between the 476 and 470 cards and replace either card 7 1 2 Fill Does Not Start When Bag Placed On Spout Check the bag sensor switch It is possible that the bag sensor limit switch is not being actuated due to a bent or mis a
37. requirements to maintain the NEMA 4X rating of the control enclosure Recommended conduit sizes and wire sizes are noted on controller layout drawing found in back of this manual Voltage supply wiring must be routed per instructions found on the controller layout drawing in the back of this manual The 472 Power supply card located within the 4693 controller provides a termination point for supply 110 VAC power and Ground The Hot side of the supply voltage L1 is terminated on the L1 IN terminal on the face of the 472 card Voltage is internally routed through a fuse located on the 472 card F4 and the card s front panel Power On Off switch Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 2 A front panel voltage output terminal L1 OUT should be used for powering internal I O cards within the controller Fuses for 5 VDC F1 and 24 VDC F2 and 24 VDC F3 which are voltages used internally on the card rack are also found on this card Fuse sizes and ratings for the 472 Power Supply card can be found below and on the schematic drawings found at the back of this manual Replace each fuse with the same or equal type of fuse as noted below Fl 5 x 20 mm Fuse 250 Volt rated 2 Amp Fast Acting Glass Fuse Spare fuse in upper left corner of 472 card F7 F2 amp F3 TES Sub miniature Fuse 125 Volt rated 0 315 Amp Fast Acting Spare fuse on left side of 472 card F5 amp F6
38. that this version software allows for the input of American Standard Date Format which is MM DD YY month day amp year Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 24 01 ENTER MONTH AND PRESS ENTER PRESS N NEXT IF MONTH IS OK PRESS X TO RETURN TO MAIN MENU Date Menu As with setting time you can advance from Month to Day to Year by pressing N for next menu after entering the current information 4 5 3 Bag Placer Dwell Time Your bagging operation may contain an automatic bag placing machine which automatically detects the need for and places a new bag onto the spout of the filler Interfaces are provided as part of the 4693 controller s standard programming A dwell timer is required for systems using automatic bag placers to allow the placer time to retract from the fill spout before the controller zeros the scale at the beginning of the fill cycle This timer is set to 0 0 second as a default and should remain at this value for equipment not using bag placers A dwell timer setting other than 0 0 will initiate a delay in fill time The screen used for entering this time is accessed through the Set Time Date amp Dwell Time Main Menu 5 A sample of this screen is shown below 203 PRESENT BAG PLACER DWELL TIME 0 0 ENTER NEW BAG PLACER DWELL TIME MAXIM
39. the display The intensity of the back light is adjustable via a small multi turn potentiometer located on the 476 Interface Board mounted inside the enclosure door Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 6 2 4 Controller Internal Components Internally the filler controller is comprised of a main card rack keyboard and interface display connector board back light power supply and LCD display module The card rack contains all necessary printed circuit cards for operation of the filler and all peripheral devices These cards include 471 Passive Bus Board contains all connectors for cards listed below Resides inside card rack mounted directly to the controller back panel Although this board does contain a small amount of data line filtering components it is for the most part totally passive 470 CPU card containing all processing logic battery backed and EEPROM memory Printer and remote digital display ports are also located on this card 472 Power Supply card provides connection points for 110 220 VAC power supply switched power supply for 473 I O card and filtered and regulated power supply for all other cards and display within the controller This card also contains fuse protection and power on off switch for controller 473 110 VAC I O card This card provides connection points for eight 8 solid state output signals corresponding to inputs and processor commands of the
40. to 25 Hz The factory default setting is 5 In mechanically noisy environments it may be necessary to adjust this value higher to filter out vibration induced into the scale mechanism Increasing this value will slow the systems responsiveness as a result of heavier filtering The lower this value the faster the response to the load cell output AND the more ambient noise is allowed in The factory default of 5 should always be the place to start Adjustment of this value should only be done by a trained technician with the change qualified by filling several bags and noting both the increase decrease in response of the system and change to variation seen in final weight 10 1 3 Setting Max Product Number The 4693 is capable of retaining 75 unique product set up s in non volatile memory If for some reason it is determined that invalid data is stored in these memory locations or if you decide to wipe the slate clean you can change the value displayed in Setting Max Product Number to a value of 02 This will give you two initial set up s to start with This is typically done at the factory and never requires modification As new set up s are added the number in this variable will automatically increase to show the number of set up s held in memory 10 1 4 Set 1 A D Gain Number The A D setting is a value set internally by the filler controller It is not an adjustable value and is only shown for reference 10 1 5 Set 2 A D Gain
41. to return to the main menu and save the data without loading it to run as the current product Once all new set up s have been entered return to the main filling screen and use the Quick load feature P key to enter the next product to load A third choice allows for exit to the main menu without saving any of the data just entered This is done by pressing the Esc button 4 6 1 2 Editing Target Weight in Manual Set Point Mode The Filler Controller can be configured to run in a Manual Set Point Mode See Chapter 10 for more information on activating this mode Manual Set Points require the entry of the Target Weight Bulk Cut off if dribble is used and a Pre Act value Accommodations are made for automatic and manual tracking of variations of bag weights as is the standard with Automatic Set Point Mode and adjustment of Pre act values are readily available from the main fill screen The Manual Set Point Mode is designed for either very high production rates such as small packages placed on a packer with high flow rates or for non free flowing and unpredictable product such as sticky or floody powders masonry mixes or portland cements and aggregate mixes Once a password if any has been entered the next screen will appear as shown on the following page Data is entered into this menu by selecting the proper parameter to adjust and entering numerical data only Decimal points are fixed and cannot be adjusted in these menus Thompso
42. type of filler product package and flow rates the complete successful fill of a bag may take from just a few seconds to nearly one minute However each specific product and package type are normally consistent in their fill rate The broken bag timeout detection method relies upon consistent fill times from bag to bag for each specific product Based upon this a short time study can be done to determine the average fill time for the specific product and bag To assist the operator and only with the broken bag detection card in place the Run Filler screen will display the current target weight and actual fill time for the bag Use this value to help determine the proper amount of time to enter for broken bag detection If for example a fill of your particular product takes 5 seconds from the instant the fill starts to the instant the fill mechanism stops pinch tube cut off cylinder or auger motor the timeout value should be set to 6 or possibly 7 seconds This allows for some margin of error and fluctuations in fill rates without creating false alarms on the occasional fill that may take 5 3 4 seconds The broken bag timeout feature is displayed in each product recipe below Refill Valve Time From the Main Menu select item 5 Select Edit Product Now select either creation of a new product recipe or edit of an old recipe Follow the prompts until you reach the Change Product Weights prompt Upon entering this menu you w
43. will remain open until a new bag is placed onto the spout and the next fill cycle is initiated High density free flowing products may refill the chamber in less than 2 seconds while lighter or difficult products may take as much as 6 seconds or more to refill It is important to experiment with this refill time and adjust for the minimum time required to completely refill the upper chamber Impeller packers should set this timer to 0 0 second If your filler is configured for use with an Auger Packer this timer is disabled Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 36 As a purchased option item 5 Broken Bag Timeout detects that the current fill has exceeded the maximum allowable fill time and is aborted This is a feature commonly used in conjunction with unmanned automatic bag placers or robots See Appendix B for more information on this feature If this feature has not been purchased or configured this menu item will not be displayed Item 6 Vibrator On Off is enabled through the configuration menu 2 item 8 Enabling this feature in the configuration menu will make item 6 appear in the product recipe Certain applications and fillers are equipped with either a pneumatic or electrically controlled vibratory settler on the bag chair or saddle This vibrator assists with settling a fluffy
44. 0 Bag Chair Timer 0 0 value between 0 0 and 5 0 Broken Bag Timer 24 6 value between 0 0 and 30 0 Weight Conversion 00001 Ibs Number Fills TARE 00001 equals Tare every fill All data fields are first loaded with information then Command 09 Load Product is issued to place this collection of data into product 1 This would be executed as STX001 Acme Brick CR LF response back of E00 STX002 Dry Mix 50 CR LF response back of E00 STX003 050 00 CR LF response back of E00 STX004 00001 CR LF response back of E00 STX005 00060 CR LF response back of E00 STX006 00000 CR LF response back of E00 STX031 00246 CR LF response back of E00 STX007 00001 CR LF response back of E00 STX009 00001 CR LF response back of E00 STX032 00001 CR LF response back of E00 It is important to remember that the Statistical package must be cleared before attempting to upload a new product This can be done in two ways 1 Issue command to transmit Final production report before loading new product data and command to load new product Za Issue command to clear statistical data buffer This of course will result in a loss of any data within the buffer If the buffer is not cleared before transmission of a new product load the controller will issue an error code and await a proper response from the remote terminal Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Com
45. 01 PELLETS UNITS MIN TOTAL UNITS TOTAL WEIGHT 0 0 0 L LIST OFF I INTERIM REPORT C CLEAR TOTALS F FINAL REPORT X MAIN MENU P PRODUCT LOAD Main Filler Display The main filler display contains a wealth of information about current fill weight and status as well as information on the current production run Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 20 4 4 1 Weight Display The displayed Net weight at the top of the screen is either a bold 1 2 high centered display for single filler controllers or two weight values separated by a divider for dual filler controllers This display also shows whether the displayed weight is in LB or KG which is selected as part of the product selection entered in Main Menu item 5 Displayed weight for either single or dual fillers will always set to 0 00 as the bag weight is zeroed at the beginning of the fill cycle and will show increased weight as the fill proceeds To avoid refreshing the LCD continuously during the fill weight values are updated every 0 8 second Upon completion of the fill the weight display will hold the final Net weight until the next unit is placed on to the spout and another fill cycle initiated 4 4 2 Status Display Directly below the box containing the current fill weight are three 3 status lines The first of these li
46. 2 and 3 are for setting the Preact value or the value at which the filler turns off Bulk before or after the Target Weight is reached For example if Target Weight is equal to 50 00 Ib and a Preact value of PLUS 0 50 lb is entered the filler will turn off bulk at 49 50 lb This anticipates that Ya 1b of product will fall into the bag after the Bulk has been turned off Inversely the Preact value can be set to a MINUS 0 50 lb causing the filler to turn off Bulk at 50 50 lb This anticipates that pressure from the product or air induced during the fill causes the bag weight to be over Target Weight and will settle back 1 2 lb when the Bulk is turned off If the optional Broken Bag Detection card is installed into the 4693 controller a configuration feature becomes available to allow for selection of upper and lower checkweigh limits When this feature is enabled entering into the Target Weight setting of the product recipe will present the following screen Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 35 BROKEN BAG CARD INSTALLED SELECT DESIRED FUNCTION 1 TARGET WEIGHT 50 00 LB 2 SET 1 PREACT PLUS 3 SET 2 PREACT PLUS 7 SET UPPER WEIGHT LIMIT 50 25 LB 8 SET LOWER WEIGHT LIMIT 49 80 LB X RETURN L LB K KG Set Check Wt Limits If a fill results in a bag weight that i
47. 5 Select Edit Product The Filler Controller is capable of storing up to 75 unique product settings in memory Each of these settings include important data such as Net Target Weight Fill Mode Information Refill Timers and Product I D information A sample of Main Menu Item 5 is shown below The default operating mode for the 4693 Filler controller is the Automatic Set Point Mode An optional Manual Set Point Mode can be selected through the configuration menu Instructions for activating this feature can be found in Chapter 10 PRESENTLY RUNNING PRODUCT NO 01 CHOOSE ONE 1 ENTER NEW PRODUCT 2 SELECT EDIT OLD PRODUCT 3 EDIT PASSWORD 4 TAKE PRODUCT SAMPLE 5 PRINT PRODUCT REPORT X RETURN TO MAIN MENU Select Edit Main Menu Each of the menu items are described below in detail 4 6 1 Entering a New Product The filler controller has enough memory to hold 75 unique product settings Each of these set up s can be used to input production data such as Net Target Weight whether the product is to run in Bulk Only mode or with both Bulk and Dribble and time required to refill the upper product chamber for each type of product New products or product types should be entered as a unique product set up in the controller Selecting 1 from the Select Edit Product Main Menu allows for the input of this data Data fields are provided for each entry in this menu Items such as Customer Name Product Type or Product I D c
48. 71 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 23 4 5 1 Setting Current Time To set the time select sub menu item number The following screen will appear 19 ENTER HOURS AND PRESS ENTER PRESS N NEXT IF HOURS ARE OK PRESS X TO RETURN TO MAIN MENU Setting Hours Hours are entered in the 24 hour format For example 8 O clock in the morning would be input as 08 hours 8 O clock in the evening would be input as 20 hours Simply add 12 to the time from 1 p m until midnight The next menu screen is for input of minutes This screen is exactly the same in appearance as the Hour input screen shown above Simply input the number of minutes with minutes O through 9 entered as 00 01 02 etc After the entry of minutes another screen will appear for the input of seconds This is typically not a critical setting and the default 00 can be selected by choosing Return to Main Menu Upon returning to the Time Date Bag Placer menu you have the opportunity to set the current date It is important to enter both time and date for use in the calibration audit trail Calibration cannot be completed until a current time and date have been entered into the controller 4 5 2 Setting Current Date Date is entered essentially the same way as the time The first sub menu offers the input of the current Month followed by Day and Year Please keep in mind
49. 71 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 92 The Ethernet converter is now setup to respond to the IP Address you entered on step 6 If the Ethernet connection is made through a hub on the factory floor then no further action is required and the static IP address assigned to this device will be visible through any computer connected to the same network as the hub If the Ethernet converter is connected via a straight run cable to a PC or PLC it will be necessary to use a cross over cable to establish communications See A 4 3 below for instructions Depending upon the program used in the PLC or PC it may be necessary to emulate this incoming data through a virtual serial Com port To accommodate this need the Ethernet converter device includes a CD with a Port Redirector option See A 4 4 below for instructions on use A 4 2 Ethernet Connection to PC 1 At the PC click on Start then Control Panel and open the Network Connections icon 2 Right click on LAN or High Speed Internet and select Properties 3 Right click on Internet Protocol TCP IP and select Properties 4 Under the General Tab select Use the following IP Address and type in an address in the same range as that setup in step 6 above use 192 168 1 140 for example S Type in 255 255 255 0 as the Subnet Mask 6 Type in the Gateway address setup in step 6 above
50. 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 19 4 3 Minimum System Set Up The Filler Controller requires a minimal system set up to begin using the system These minimum requirements are l System Calibration Ze At Least One Product Set Up 3 Time Date and Placer Dwell Timer set System Calibration is covered in detail in Chapter 3 and should be executed before attempting to use your Filler system Product set up s are found under Main Menu 5 with detailed information on entering or editing set up s found later in this chapter Time Date and Placer Dwell are found under Main menu 4 with set up information also discussed in this chapter 4 4 Menu Item 1 Run Filler Selecting Main Menu item 1 will place you within the main filler display This is the most used display for the controller and shows all necessary information for the operator With the exception of changing product types and occasionally executing calibration the main filler display is where the controller will reside the majority of the time The operator receives all information about current status of the filler fill weight and production data from this screen An example of a dual filler display is shown below Single filler display shows only one weight value 4 4 1 0 00 15 0 00 15 READY READY FIRST CYCLE FIRST CYCLE TARGET 50 00 LB PRODUCT
51. A et oe ees eal 12 Configuration Men A eed ele lee fb Ge be wl ee bw eels Re 71 Editing Cal Test Weight si ior A See OGLE Rel Leer oR Res Dh le tees 11 Feedback Para Met vota A emiaee ahaa teed Ss eee Peed Saag ea 110 Peedback Sampl Count 2 9 0 4 hoes A A Re Le Re Re ewe ee 111 Feedback Sample Frequency sisi e she So ba dow dee Sbincd a fea baal oleh Ge La dn eagtibbed eel a 112 Feedback Weight Correction mers gentrana poneti E pede WE oh Se Dae ara a Late a Se 112 Setting Discard M S carita tore Sen dient sides a ae e ew Sty h te a Wi Le OA aKa Ni 60 Final Calibration Settings AS Ste ee ROR AA Ce Re eA Be ee rh AS 13 Flow Rate Diapnostic Menu ole ied ti ata 59 Flow Rat Soren tao pee Ase Be Red See MG ect WE bene Aa Ae as Ra ee the et eo 59 Interim Production Report visir tai da a tes 63 Main Filler Displayen taa E AS NS AT E A EIA 19 Marmn Me u Display sios ir asad has waa iia A A a Whe wae ea on ed 18 Marni Time amp Date Med 2 A lees et Bee edad eae ae al 22 Manual Setpoint Bulk Only so eeror inr erener nii oainnt kme tee erence rete teen en eben eeneneee 34 New Product Ment 2 55 144 vs ee ees Se ne AA ee ie ee a A 27 Password Entry Menu Vii A bibs os vie DE hive he diy sage eee 37 Placer Interface Menu socis pirar a Soa oP ae ea Sees pia SP era ees ees 79 Power p Screen A A A a E dis 18 Printer SCHEm ate a a SB DGS hey 85 Product Listing Report scce ie manra eee hd A Sk whee ets bared 38 Product Listing Rep
52. Automatic Set Point Mode The Filler Controller is set to the Automatic Set Point Mode as a default This mode allows for the simple entry of Net Target Weight only as well as a few other pertinent parameters The following screens and settings are for Automatic Set Point Mode only For information on Manual Set Point Mode see Section 4 6 1 1 below The Automatic Set Point Mode is very well suited for applications with free flowing and predictable product such as most granular and pelletized products seed feeds and free flowing powders Once a password if any has been entered the next screen will appear as shown on the following page Data is entered into this menu by selecting the proper parameter to adjust and entering numerical data only Decimal points are fixed and cannot be adjusted in these menus Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 28 CHOOSE ONE 1 TARGET WEIGHT 50 00 LB 2 BULK AND OR DRIBBLE B amp D 3 CHAIR RETURN DELAY 0 70 SEC 4 REFILL VALVE TIME 2 3 SEC 5 BROKEN BAG TIMEOUT 7 OF FILTER SAMPLES X RETURN L LB K KG Fill Values Target weight is input as a NET weight value That is to say it does not include the weight of the package your product is in The filler controller automatically tares out the bag weight at the beginning of each
53. E RO ERS 45 6 1 Finding Your Way Around iaa ida aia 45 O27 Changing toa New Product sssi kta oh EB E Bale dd o ea a E N 46 6 2 Running The Filler 00 A hed aes gp Oe ea eh eg We ease Sa ed ee pT 46 63 Star and Stop SWItehesS sr ade il are el out Gavi A a a zeae ee ewe 47 6 3 2 Topping Off a Partially Filled Bag 0 ce eee ene ee 48 6 3 2 Fill Stats OW Screen 38 bein bys Gees aw aia whey AS Ie eae peewee ae 48 6 4 Fill Errors and Error Corrections 0 0 cece cc cence eect teen arcano 48 6 0 Other Important A Set Biot setae A eee et ee Ae ts a Rane Aenea Sts otk 49 Trouble SHOOUNE AA AAA TREE ER ERE AER EEE RON ee 51 7 1 Typical Problems and Solutions v 42 2 e e sie eee dev ees ieee ceded eee bee e ee da 51 7 1 1 Front Panel Keyboard does not respond 0 0 cece eee eee eee 51 7 1 2 Fill Does Not Start When Bag Placed On Spout 0 0 e eee eee eee 51 7 1 3 Final Bag Weights Not Consistent oi no02o os de neunana 52 7 1 4 Unable to Calibrate Filler cuco nic ade aa 53 7 1 5 Display Goes Blank or Resets 426 2032 eee yee ricino REST SS li 54 Options ACCESOS AAA AA FNS AAA E RO OR AA 55 8 1 Traffic Control Sequencer ici bade pee es bey ns Sed ews si ene aed Pie AS 55 8 3 1 ate CONTO LINES ls ioe ae eee eee wie ewe Bee es Beds ae eed 57 e lal Delay Timer Settings AAA a A aes Weim Bete ar a hate aa ee 57 8 3 1 2 Duration Timer Setting foc A za 58 Options amp Accessories Continued 8 2 Main Menu Item 6
54. ENTLY SET TO 50 CORRECTION 1 SELECT 100 CORRECTION 2 SELECT 75 CORRECTION 3 SELECT 50 CORRECTION 4 SELECT 25 CORRECTION X RETURN TO PREVIOUS MENU Weight Correction Parameters Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 113 A 4 Other Contributing Factors to Feedback Feedback correction only occurs during the normal fill cycle 1 Cycle fills only done if in the Auto Set Point Mode are not included in the feedback correction routine That is to say if Target weight is changed or a new product is loaded the first fill is always a 1 Cycle fill and that bag s weight will not be included in the Que for making corrections Feedback correction is only engaged in the Manual Set Point Mode when autotrack is on If autotrack is off no corrections will be made Turning autotrack off does not clear any previous fill weights that may already be in the Que so it is safe to turn autotrack off and on as required Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 114 Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Typical System Drawings
55. Guide Version 11 0 Page 84 Protocol for the REMOTE port is as follows 1 Start Bit 1200 Baud 8 Data Bits No Parity 1 Stop Bit Protocol is fixed and cannot be changed Data String in either the Ticket or Stream Mode lt STX gt lt XXX XX gt lt CR gt Leading Zeros Suppressed The REMOTES port offers no hardware or software hand shaking and transmits data as it becomes available The receiving device is responsible for queuing data The REMOTES port can be configured to transmit data in either the Ticket or Stream modes Ticket mode transmits each unit weight value one 1 time only and is intended for delivery of data to a line printer or a database or spreadsheet program The Stream mode transmits the unit weight value continuously until a new weight value is registered by the 4693 filler controller The Stream mode is the most common mode used when connecting to a remote digital display The default setting for the 4693 controller is the Stream mode To change this mode refer to Chapter 10 System Configuration for further information A 2 STPR Statistical Reporting Package PRINTER Port The 470 CPU card which resides in the far left slot of the 4693 controller contains an eight 8 pin connector labeled PRINTER This 8 pin connector contains a single transmitting port with two 20mA current sources only one is used and is dedicated to transmission of data from the optional STPR statistical analysis packag
56. Line has paper and appears to be operating properly but there is a problem calling reports check the following items with a digital volt meter and confirm proper operation of the converter Please note a plus or minus sign in brackets indicates placement of the positive or negative lead of your meter Set meter to Volts DC Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 87 WARNING THIS EQUIPMENT IS TO BE INSTALLED AND SERVICED BY QUALIFIED SERVICE PERSONNEL ONLY Instructions within this manual and attached drawings are to be strictly followed to insure both personnel safety and proper operation of the equipment Please read carefully before attempting to install or operate this equipment On 52394 converter board PL1 terminal strip Place meter leads as indicated and note voltages 6 amp 7 Should produce a 0 7 to 0 8 VDC with printer On Should produce a 23 to 24 VDC with printer OFF 2 amp 3 Should produce a 0 7 VDC signal with the 4693 controller On Should produce a 1 2 to 1 3 VDC signal with controller OFF 8 amp Pin 4 of Ul Should produce 0 VDC with 4693 controller On Should produce 4 9 VDC with 4693 controller OFF NOTE terminal location 8 does not contain a terminal block Place meter lead into hole above the location marked 8 on PL1 Locate IC chip la
57. NG ZERO CLEAR FILLER SPOUT amp CHAIR PRESS ENTER WHEN READY X RETURN TO MAIN MENU Zero Screen Again the operator is presented with the option to exit from this procedure and return to the main menu without affecting the existing calibration If the operator presses Enter the screen advances to the next menu Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 12 SETTING ZERO PLEASE STAND BY Setting Zero In setting Zero for this system the controller displays two values The top value is a variable adjusted by the digital instrumentation amplifier This value references a zero operating point and should change during this step as the second value self adjusts The second value is an internally generated variable corresponding to a digital reference within the 474 Scale Digitizer card and is used as the Zero reference throughout the rest of the controller s program If these values do not adjust or an error is displayed refer to the Trouble Shooting guide in Chapter 7 of this manual A D OFFSET NUMBER IS 1130 OFFSET DAC SETTING IS 138 PRESS ENTER TO CONTINUE Zero Setting Data Once the Filler controller has automatically adjusted zero it will display information on the zero setting This data will vary only slightly calibration to calibration but will show drastically
58. Number This variable is for the 2 spout of a dual spout controller configuration As with Set 1 this value is set internally by the filler controller 10 1 6 Set Decimal Point The default setting is 02 for the decimal point This value can be changed from 0 to 3 depending upon the full load capacity of the load cell and the package being filled This value should remain at 02 for systems with a load cell up to 500 Lbs Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 73 10 1 7 Initialize A D Serial EEPROMS Each 474 Scale Digitizer card contains a serial EEPROM that records each calibration This information is used by the 470 CPU card during normal operation and as a record of calibrations for the system Initializing the A D EEPROM provides a means to confirm that the EEPROM is functioning properly Selecting this setting within the configuration menu will display a secondary screen offering either scale 1 or 2 In systems with only one scale there will be no displayed value if scale 2 is selected Once a scale is selected the controller will automatically query and read information from the serial EEPROM on the 474 card If an error is detected or if the EEPROM cannot be read a message will appear stating that the card should be replaced 10 1 8 Get Next Menu Since there are more variables t
59. O Test This test operates similar to the 473 rotating test described above Each of the four 4 outputs on the 477 card will be turned on for 1 second turned off and then the next output will turn on for 1 second Each output can be tested with a volt meter to confirm proper operation As with the 473 s test the 477 also displays 0 s for each of the four 4 inputs Driving each input high will turn the displayed 0 to a 1 10 2 6 2 2 Local Loop Back Test This test checks the operation of both the transmit and receive ports on the 477 card This test is for a single 477 card Testing for two 477 cards in separate controllers 3 or 4 spout filler configurations is described below in 10 2 6 2 3 If the card is configured for RS 232 communications typically for interface to a computer or remote PLC device connect pin 2 to pin 3 to perform the loop back test Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 77 If the card is configured for RS 422 communications typically used between two 4693 controllers for traffic control connect Pin to Pin 3 and Pin 2 to Pin 4 When the test is started the display will show transmission of a character starting with A and incrementing thru Z Next to this display it will provide a visual indication that the character has been received by displaying th
60. OT MANUAL DISCHARGE BY ROBOT ESC RETURN TO PREVIOUS MENU Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 99 Broken Bag Dump Mode Descriptions Different applications require different methods for managing bags at the filler The 4693 filler controller offers four 4 distinctly different methods to accommodate your specific bag handling needs B 3 1 Dump Broken Bags Automatic This mode is the default mode and upon abortion of the current fill due to a broken bag being detected it will cause the powered bag chair to discharge the defective bag from the filler In this mode there is no difference between discharge of a good bag or a broken bag B 3 2 Hold For Operator Automatic This mode will cause a broken bag to remain on the fill spout and the powered bag chair to not kick until the operator acknowledges the broken bag by pressing Enter on the 4693 controller front panel Upon pressing Enter the filler will execute the normal bag chair discharge routine kicking the bag from the filler B 3 3 Hold For Operator Manual This mode also holds the broken bag on the fill spout and requires the operator to press Enter to acknowledge the aborted fill However this mode will not actuate the bag chair and requires the operator to physically remove the offending bag B 3 4 Hold For Robot
61. Product Flow Error Get a TARE Fault Error Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 47 The 1 Cycle fill will run Bulk for a few seconds stop for a moment then run Dribble for a few seconds During this time the controller is figuring out how fast the product is flowing into the bag and calculating the times to cut off Bulk and go to Dribble and time to cut off Dribble to reach Target weight The second mode is called the Normal cycle This is where we run production filling Bulk is turned on till it reaches its calculated cut off point and then Dribble is turned on The controller completes the fill and then waits for about 1 2 to 1 second to take a final reading on the weight in the bag The bag clamp is then released and the bag is ready to be discharged In a Normal cycle the controller stores each final weight in memory and then determines if the weight was under or over Target Weight If it is the controller automatically adjusts for the next fill In this way the controller can track and compensate for changes in the product bulk density and flow rates The Manual Set Point Mode requires the operator to enter cut off points for Bulk and Dribble if used Another setting called Preact is set for the amount of product that falls into the bag when the fill is finished In some cases it i
62. S 00 irrita al ae 75 10 26 T47 NVO Fad Bote ee mPa Re BR mm e a E AE 76 10 26 247T VOTES rssi pend Aia peat eee ee 76 AA VOTES erorita Ae cated SNM A ef TN oe R 76 10 2 6 2 2 Local Loop Back Test 2 2 2 sie 8ebeseiedaiwasieiee be eek dias 76 10 2 6 2 3 Remote Loop Back Test envite at Tt 10 2 6 3 Test FIL ROGUE nia e tt 77 10 2 6 4 Test Printer Remote Port na shay tars aS few ee ATA RED a A 78 10 2 7 Set Remote Port Mode of Operation 0 0 0 ee eee nee 79 10 28 Vibrator Enable Disable cas tt A A A A ia 79 10 2 9 Set Bag Placer Interface Mode ninia iii A 79 10 20 Set Au to Manual TARE Si e O a al A a N A 80 10 2 S Set Auto Manual Setpoints 6 eee ete ees 80 10 24 Broken Bas Detector acs dus oven oe ee e Bee aye ww RAV A A ee enw 80 10 2 B Blast Air Enable Disable 4 oo 35s bese oe Sete woe ae cao ee eee ees 80 10 2C Chair Discharge Mode A hes AS Ie Ree see ee se 80 10 2 W Weight Limits Enable Disable 0 0 00 ee eee ee eee 81 10 2 D Enable Disable Top Off Function 0 0 0 0 ee eee eee eee 81 Serial Port Information 555655 hse ek denn A AA OR A 83 A 470 CPU Cand REMOTE Potts cis A A A AS AS AS 83 A 2 STPR Statistical Reporting Package PRINTER Port oooooococococorocooo ns 84 AZ 1 Serial Convert our dr da ad a ta DOME CA bs ta 86 A 2 2 Okidata Printer ss vey ae ae Sak oats UE ERAS RSE Oe BEERS eae Sete eee Rees 88 Bes HAN Traffic Controle ato tots rs a ti ps eae e 89 A 4 Ethern
63. Scale Model 4693 Checkweigher 000000000 109 ALS Theory ol Operation unos tka nanie cob e nares AA ood ea ae eee es 109 ABI Sample COURSE See POS Rae ew ee aoe 111 Ac ore Sample PreQueney pais hae or eee TS Leas ped SOS He A AA AS 111 A 3 3 Correction Factor Verna eee la heed dA ade OMOTAG ED EMP da sew a Ue 112 A 4 Other Contributing Factors to Feedback 0 0 2 eee cc nee eens 113 Typical System Drawn S sock ERA RANA 115 Figures FATT Card Layouts ita si is cheb sed caer bedne bout iee thu obde tn Lette aah 89 Bag Chair Discharge Method a c2nc02 0i ce drys A A Bea ee Be 81 Broken Bag Configuration s oie se a e sh ee ba ate 97 98 Broken Bag Fill Rates cutis trae AS bee ER Re ee Ppa cad Mh baw sat ed 97 Broken Bag Handling Methods vecinita Sateen ets eee pate a sade eee ete 98 Broken Basan Recipe Setting ti A ee OT eee eee id 96 Bulk Dribble Settings court A A Ba a als Bay ae Sage 32 Calculatins Calibration PM 00 das A eda tee totes So A SOA 13 Calculatins Calibration Zeros r e n A A bed Fee teak wo ota ae Be eee 12 Calibrate Check Sereen ir tddi Gone A aes Rae Dh ea AG baa A oe ibaia 10 Calibrate Zero Settne 7 6 vise secs 54te A poke Osea sh ae bee alae anata Ge sealants DS 11 Calibrating Scale Span a A goed ing E ies ein toes eto sek kee a E 13 Calibration Test W e1ght o 2 2x cca pace ted aaa in tela eat oe esha eee ase ie EWE aha ae eee 10 Calibration Zero Settings Sterne s ane ee obs gee Ee Bee Ee ea
64. Thompson Scale Company 4693 Universal Filler Controller For Air Impeller Auger Operation amp Maintenance Manual Version 11 0 Issued April 2007 Table Of Contents Important Installation Information 0 ccc ccc cece ccc cere ee ee eee eee cece cece sence 1 1 1 Electrical Requirements amp Wiring Methods 0 0 cece cece teens 1 1 2 System Battery for Time Date Clock cs ait aie A A A A a a ae 2 1 3 Environmental Rating of Equipment 0 0 eee eee tenes 2 14 Warning amp Caution Statements e A E A a A E 3 Introducci lt td e A Et a 3 ZAC ORTO LEONES lt n tee one Be ts Sa et reg aot a hn ates iD A a ee ere 5 2 2 Controller Enclos re miissen ou ew bleak is de pi oh ea 5 2 3 Controller Front Panel Controls and Display 0 0 eee ee nena 5 2 4 Controller Internal Components 2 0 0 rururaa 6 AP Passive BUS Oat dl nyu oad eye Beene oad a Rae eee Oa Meee a 6 ATO CPU Cad eset haw when ees ee id oot a ete eh Aki e vets ahs owes iy get R 6 AT 2POWEL SUPPLY Cal is Lace ee PATAS dee Od cele Soe bend Wee DE Be eee a 6 413 LIO VAC VO Card sana pe bi btn RA e CRUSADE OUT ita 6 414 Scale Digitizer card career eee eset eee ee he ee Sete eee E eee 6 Alterado Board fn chy dade feud a ii eee sek Oars 7 Arrate onto cardo ani tet E o axl tte bale a ea O aE ee el te 7 True Bag Discharge Traffic Control 0 0 eee 7 Broken Bae Detecta oe de 7 Robotic Placer terface onrein Ga see ww
65. UM OF 5 SECONDS 0 0 ENTER 0 0 TO DISABLE THIS FUNCTION ESC EXIT Dwell Timer Settings Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 25 4 5 4 Spout Purge Timer Main Menu 4 also contains a sub menu for setting a spout purge timer As with the placer dwell timer this setting affects both spouts of a dual filler controller Set spout purge time for the amount of time in 10ths of a second for discharge of product from the fill spout at the end of the fill Spout purge time should be set to 0 0 if your specific system does use a spout purge Setting this to a value greater than 0 0 will increase bag to bag fill time since the timer must expire before a final weight is derived and the bag fill is complete 4 5 5 Traffic Control Timers Two spout fillers sometimes require special interlocks between each spout to allow bags to discharge in an orderly fashion If this is not done bags may fall too close together or worse on top of one another The Traffic control timers allow the operator to directly control the discharge of bags from a dual filler system Systems with three or four spouts that require traffic control use the optional 477 Traffic control feature described in Chapter 8 To enable this feature on a dual 4693 filler controller filling on a 2 spout packer enter into sub menu 5 an
66. a typical fill takes 10 seconds the timer should be set to some tolerance value above 10 seconds If the bag becomes broken or the spout plugged this timer will elapse during the fill initiating the Broken Bag output A broken bag fill sequence is shown below 1 All outputs from the 4693 controller will be OFF at this time 2 The robot places a bag onto a spout When the bag is fully on the spout the robot drives the START input for that spout in the 4693 controller ON The robot must hold the START input ON throughout the fill This is described further in the sequence as well 3 The 4693 controller actuates the bag clamp for that spout and turns ON the FILLING output on the 477 card 4 Either due to a mis spouted bag or exceeding the broken bag timer the 4693 controller detects a broken bag condition The current fill is aborted and the BROKEN BAG output on the 477 card is turned ON The FILLING output also remains ON 5 The robot retrieves the broken bag removes the bag from the fill spout and turns the START input OFF At this time the 4693 controller turns both the FILLING and BROKEN BAG outputs OFF The 4693 controller contains inputs for a stop push button that should be placed outside of the robot area Manually actuating the stop button for either or both spouts will initiate a Broken Bag sequence as described above Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www t
67. allows total access to every feature of the system without the need to enter passwords To enter a password select item 3 from the Enter Edit Products Main Menu The following display will appear and allow the entry of up to 10 characters for the password The password can be constructed of any alpha numeric characters with exception of special characters such as or Each character will be displayed as an asterisk when entered and will also display when actually entering a password during normal operating conditions In cases where the password is forgotten or incorrectly entered you may select Item 3 from the Enter Edit Products main menu and at the Enter Password prompt type the following string SCALE This must be entered in all capital letters by holding down the Caps Lock key on the front panel while entering each letter Once entered the controller will ask for the new password A new password may be entered or a Space hit space bar once can be entered to disable the password protection ENTER NEW PASSWORI Password Entry 4 6 4 Take Product Sample Many applications require periodic sampling of product To facilitate this need the filler controls offers a mode in which either a Bulk or Dribble 0 5 second sample of product may be delivered Choosing Item 5 will display a user screen directing the operator through taking a sample Select the appropriate fill bulk or dribble and then place the bag on
68. an be entered along with the operating parameters for this product All data entered on each product set up is held in an EEPROM within the system s 470 CPU card An EEPROM is an electrically erasable program read only memory device that does not require battery back up If you loose power and battery back up simultaneously product set up s will still be retained See trouble shooting guide in Chapter 7 for details on transferring memory modules between CPU boards Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 27 NEW PRODUCT NUMBER 02 CHOOSE ONE 1 CUSTOMER NAME 2 PRODUCT TYPE 3 EDIT WEIGHTS L LOAD THIS PRODUCT TO RUN X RETURN NEW PRODUCT SAVED ESC ESCAPE NEW PRODUCT NOT SAVED New Product Menu Selecting sub menu item 1 or 2 will open a data entry box You may enter up to 28 characters in this entry box Although the screen will display more only the first 28 will be held in memory and displayed or printed on production reports Selecting sub menu item 3 Edit Weights will step you into another sub menu requesting the input of the current password if enabled A password is provided at this point to protect changes to parameters by unauthorized personnel See Password Entry and Edit below for more information on this feature 4 6 1 1 Editing Target Weight in
69. ated to the converter board and is terminated on the other end with a DB 25 connector for interface to the printer This box also requires a separate 110 VAC power source and is provided with a 6 0 long power cord The printer interface enclosure should be placed within six 6 feet of the printer DO NOT place this enclosure in a wet corrosive or dusty environment Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 67 The 20mA serial port used in the 4693 controller can transmit up to 1 4 mile via a 4 conductor cable This cable is not included as part of the STPR package and is the customer s responsibility to purchase and install The cable does not require a shield The cable should not be run in conduit or strapped to conduit containing high voltage wiring nor should it be laid into a cable tray containing high voltage wiring More detailed information on the printer and serial converter are available in Appendix A and drawings found at the back of this manual The 52394 contains several indicator lights to provide diagnostics of communications between the 4693 filler controller and the dot matrix printer To use these indicators the communications cable between the 4693 filler controller and 52394 serial converter must be connected per drawing 4693 E2 found at the back of this manual The pre wi
70. beled U1 This is above and slightly to the left of the PL1 terminal strip U1 is a six 6 pin device with pin 1 at the upper left corner Pin 4 is the bottom pin on the right side of the chip PL3 terminal strip 3 amp 2 Should produce 9 VDC with printer On Should produce 0 VDC with printer OFF 3 amp 1 Should produce 8 VDC with 4693 controller On Should produce 7 5 VDC with controller OFF If you experience a problem with the 52394 board make the above measurements and provide actual readings to Thompson Scale via Fax E 713 932 9379 Attention Service Department We will respond within 1 to 2 hours A connection diagram can be found on the previous page Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 88 A 2 2 Okidata Printer There are occasions where the customer may want to use a printer that is already available to the customer or a need for the end user to purchase a printer separately from the optional STPR package Although we strongly recommend purchasing the standard Okidata printer from Thompson Scale as part of a complete STPR package we offer protocol and configuration information below The STPR Interim and Final reports are heavily formatted to provide a pleasing and organized report Due to this formatting it is critically important that the printer your custo
71. bove 30mV it is an indication of an overload condition and the load cell should be replaced You should be able to pull up or push down on the fill spout and change the reading More load will increase the mV output and less load will decrease it Mechanical interference with the scale structure The flexure plates tying the load cell to the main structure of the filler frame are designed to act as a parallelogram Meaning that any force is transmitted through the load cell in only the vertical plane This also prevents any side loading to the load cell which would interfere with the weighment operation If product build up or mechanical interference is allowed the flexures may not always return to their proper position This variation would be detected by the controller and calibration would not be accepted 7 1 5 Display Goes Blank or Resets The main display should remain on and illuminated at all times when the controller is on The display is directly driven by the 470 CPU and is powered through a connection on the 476 Keyboard interface board Static Discharge can be a difficult problem to solve but creates sever problems for the 4693 controller if not properly addressed The build up of static can discharge through the wiring in the 4693 controller causing the 470 CPU card to crash or reset The process of running a dry bulk product through pneumatic or other conveyors to the product supply bin above the filler may be the source
72. by digital potentiometers and gain amplifier adjustments Each sub menu within calibration steps the operator through the entire process displaying important calibration data as it proceeds The controls are equipped with password protection can be disabled for both calibration and product set up Information regarding entering or editing a password is contained in Chapter 4 Calibration should be performed with a known certified test weight whenever possible Use of other weights or filled product containers often leads to inaccurate calibration which ultimately affects system accuracies The system can be calibrated in Pounds or Kilograms but does not require calibration in both Product set up s can also be entered as Pound or Kilogram with all weight conversions handled automatically by the controller The entire calibration procedure takes approximately 2 to 3 minutes to complete and should be done on a regular schedule In applications where product accumulation on the filler may be a factor the entire scale mechanism should be completely cleared of all product to insure as accurate as possible calibration We recommend calibration on a monthly basis with calibration checks performed on either a shift or daily basis or whenever the filler has been subjected to cleaning or maintenance 3 2 Calibration Check The Filler controller has been programmed with a means for the operator to check calibration and scale accuracy without the need to
73. cale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 98 This setting allows the user to select the proper rate of change for their particular product or application Some products fill much faster than others while some products actually present periods of time during the fill that may actually present a negative rate of change In particular auger fillers or fillers greatly influenced by the bag product or fill method may see a sero or negative flow rate change If the rate of change method for detecting a broken bag is not to be used select item 1 OFF After selecting the desired value that value will be displayed on the first line of this display Confirm before hitting Esc to return to the previous menu B 3 Broken Bag Handling Methods Along with selection of Broken Bag Detection from the configuration menu the 4693 controller also offers a second configuration step for method to be used to handle the broken bag Select item 2 from this screen BROKEN BAG DETECTOR PRESENTLY SET TO OFF 1 TURN ON OFF BROKEN BAG DETECTOR 2 SETUP BROKEN BAG HANDLING ESC RETURN TO PREVIOUS MENU The following information will be displayed BROKEN BAG HANDLING PRESENTLY SET FOR DUMP BROKEN BAGS 1 DUMP BROKEN BAGS AUTOMATIC DISCHARGE 2 HOLD BROKEN BAGS FOR OPERATOR AUTO DISCHARGE AFTER ACKNOWLEDGE 3 HOLD BROKEN BAGS FOR OPERATOR MANUAL DISCHARGE AFTER ACKNOWLEDGE 4 HOLD BROKEN BAGS FOR ROB
74. carriage return 6 lines per inch 11 page length American Character set Bi directional graphics Thompson Scale offers consultation and technical assistance free of charge for printers provided by Thompson Scale We also offer this same service for our customers with other types of printers at a rate of 35 00 per hour billed in 1 2 hour increments Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 89 A 3 477 Traffic Control Card The 477 card is a multi function card that can be provided with either a RS 232 or RS 422 communications port This card also contains four 4 110 VAC Inputs and four 4 110 VAC solid state outputs that may or may not be used with the particular configuration or function of this card Appendix B describes the use of this card for detection of Broken Bags and or Robotic Placers Appendix C describes the 477 card as a bi directional serial port for use with product recipe creation and management via a remote terminal This port also transmits out each final fill weight to the user s terminal The 477 card is also used for true traffic control or bag drop control from multiple fill spouts on a common production line and is described in full in Chapter 8 1 SERIAL PORT 4 CONNECTION 5 6 7 8 9 10 11 12 CONNECTION 1 2 INPUT A CONNECTIONS 5 6 OUTPUT
75. ce These jumpers are from Pin 12 to Pin 11 and Pin 11 to Pin 10 The 4693 filler controller also contains two 473 I O cards responsible for operating the filler for each respective spout The robot will interface to each of these cards to initiate a fill The 4693 differentiates Spout 1 from 2 via an address jumper located on one of the two 473 I O cards The card dedicated to Spout 2 MUST have a jumper from Pin 12 to Pin 10 on the Input terminal strip Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 101 Spout 1 typically the left spout 473 card Input 1 Terminal 1 Start 473 card Input 2 Terminal 2 Stop Abort 477 card Output 1 Terminal 5 Broken Bag 477 card Output 2 Terminal 7 Filling Spout 2 typically the right spout 473 card Input 1 Terminal 1 Start Must have address jumper on this card 473 card Input 1 Terminal 1 Stop Abort 477 card Output 1 Terminal 6 Broken Bag 477 card Output 2 Terminal 8 Filling The filling sequence is described below Assuming an idle filler and robot starting a new production run All outputs from the 4693 controller will be OFF at this time 1 The robot places a bag onto a spout When the bag is fully on the spout the robot drives the START input for that spout in the 4693 controller ON The rob
76. configuration turns off Bulk and leaves the Dribble cylinder actuated The significant difference found between these two valve types is that the combination valve must go to the Bulk position before going to Dribble That is to say the air cylinder cannot be driven directly to Dribble first The separate air cylinders can be driven to Dribble directly A menu selection is also provided for Auger Filler with Reversing Motor This valve selection must be made if the machine is an Auger filler Selecting Auger Filler with Reversing Motor will not change the output assignments for Bulk and Dribble but will change the function of the Spout Purge timer found in Main Menu item 4 to Auger Reverse Timer 10 2 3 Set Offset Compensation Offset compensation allows adjustment of the final fill weight displayed verses the actual fill weight of the bag Even though the 4693 controller does an outstanding job influences from variances in each filler and the time allowed for capturing a zero and final fill weight can cause the final displayed weight to be slightly different from actual weight The compensation routine allows you to induce a negative minus compensation or positive plus compensation to the filler For example Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 75 The final displayed weight of a
77. controller This card also provides connection points for eight 8 optically isolated 110 220 VAC inputs Inputs are received from sensors on the packer and optional placers processed by the 470 CPU card and corresponding outputs are turned on or off in response 573 24 VDC I O Card Available in place of or in addition to the standard 110 VAC I O card Thompson Scale Co offers a 24 VDC solid state I O card The 573 I O card differs in appearance from the 473 110 VAC I O card The face plate of the 573 is black with white lettering and clearly states the DC voltage on the face plate As an option Thompson Scale Co can also provide a 110 VAC to 24 VDC switching power supply module This module normally mounts to the controller back panel directly below the card cage 110 VAC power from the L1 OUT and L2 terminals of the 472 power supply card are connected to the source power connection of the switching power supply The 24 VDC power output from this supply is then connected to the L1 and L2 power connections on the 573 card The 573 I O card can be configured by the connection of source power and the device to each input as either sinking voltage in reference to ground or sourcing voltage in reference to 24 VDC A truth table on the face plate of the 573 describes interconnection of either sink or source See the schematic drawings at the back of this manual for more information 474 Scale Digitizer card The scale digitizer m
78. controller OFF if maintenance is needed on the filler If the filler is running too slow check the refill timers and bag discharge timer settings for that product They may be set too long which slows down the machine as it waits for that timers to elapse You should also check Main Menu item 4 Set Time Date Placer Dwell Time and confirm that placer dwell time and spout purge or auger reverse timers are set to their minimum value for your application set to 0 0 if not used It is always important to keep the controller door closed This enclosure is rated for wash down and dusty environments but only if the door is closed tightly Dust and product build up inside the controller can cause many problems so keep it closed Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 50 Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Chapter 7 Trouble Shooting When trouble shooting this equipment remember that mechanical components are subject to wear while the electronic components are not Therefore you will most likely encounter a mechanical problem over an electrical one There is nothing magical about the filler controller Its layout and operations are very similar to an ordinary PLC programmable logic controller and simply contains inputs
79. ction box Theory of Operation When the first fill weight is produced its value is stored in a register within memory on the 470 CPU card and is given a counter for the number of times this exact value has occurred As each weight value is generated by the Filler its weight is compared to weight values already stored in memory If the weight value already exists in memory its associated counter is incremented by one If the weight value does not exist a new value is opened in the register and its counter is set to one 1 An additional flag within memory is associated with each weight value to state whether it is an accepted or rejected weight value Values are continuously stored throughout production and are constantly compared to the product set up values being run The List feature can be turned on to simultaneously print each weight value as it occurs or can be left off and the CPU will continue to store each value The weight registers and counters described above are used in place of storing each individual unit weight to reduce the overall amount of memory requirements so it is not possible to generate a unit weight listing for data previously stored At the moment a Production Report Interim or Final is called STPR sets an internal flag and the value list buffer is closed While the current report is being transmitted values of new bag weights are stored in a queue or buffer so a report may be called without interrupting prod
80. d If Bulk Only mode is being executed program skips Dribble feed rate test and advances to step 7d b When the timer times out the current Net Weight is measured again The weight measured in step 7a is subtracted from the current weight and the result stored for future use A two 2 second time delay is started c At the end of the 2 second delay the DRIBBLE status indicator is turned off the pinch valve closed and current weight is measured and stored Dribble feed rate is also measured at this time and stored d After a 0 5 second time delay which allows the scale reading to stabilize the weight measured in step 7c 7a for Bulk Only fill is subtracted from current weight and the result is stored for future use This completes the 1 Cycle In essence what is happening here is the measurement of flow rate for the product in both Bulk and Dribble The controller also measures the amount of product flowing into the bag from the instant the outputs are turned off for Bulk and Dribble what some refer to as Pre act 8 10 11 12 The cut off cylinder s on the rubber pinch tube is set to Bulk position in a normal cycle it is already in that position This is in case of entry into step 8 from the 1 Cycle routine described above The controller uses the variables measured in previous fill cycles or the 1 Cycle to calculate a Bulk cut off point that will result in a three 3 second Dribble A Dribble cut of
81. d select Enable Traffic Control from the screen If Traffic control is not enabled timers to control bag discharge will not operate Once the feature has been enabled there are two sets of two timers that must be set to allow the fillers to discharge properly From sub menu 5 select 1 Set Spout 1 Timers Keep in mind that regardless of conveyor flow beneath the fillers spout 1 is always the LEFT spout When Set Spout 1 Timers is selected a new screen will appear offering two timers as shown below SET TIMERS FOR SPOUT 1 TIMERS FOR SPOUT 1 ARE TRIGGERED BY CHAIR DISCHARGE OF SPOUT 2 1 SET SPOUT 1 DELAY TIMER 2 SET SPOUT 1 DURATION TIMER ESC RETURN TO PREVIOUS MENU Setting Traffic Timers The bag filling process fills each bag to Target Weight and then discharges the bag from the spout onto a bag take away conveyor The time required for a bag to fall from the spout and travel to a position that would interfere with the bag being discharged from the next spout is considered the Delay Time The Duration Time is the amount of time required for one bag to pass and clear beneath another bag ready for discharge Timers for both Spout 1 and Spout 2 must be set for the traffic control feature to work properly Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 26 4 6 Main Menu Item
82. different numbers if damage to the load cell or Scale Digitizer card occurs Pressing Enter will bring the operator to the next step in calibration Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 13 CALIBRATION PROCEDURE SETTING SPAN PLEASE PLACE TEST WEIGHT ON BAG CHAIR PRESS ENTER WHEN READY X RETURN TO MAIN MENU Span Screen At this point the operator is instructed to place the test weight onto the bag chair of the filler and give the system a moment to settle before pressing Enter The controller now automatically adjusts the internal digital potentiometer to achieve the highest possible span ratio as shown in the screen below SETTING SPAN PLEASE STAND BY Setting Span As with the calibrating zero screen values within this screen automatically adjust There is no need for operator input at this time Upon completion of these variable adjustments the controller automatically advances to the next screen Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 14 CALIBRATION READING IS LB CALIBRATION FACTOR IS GAIN SETTING IS X RETURN TO MAIN MENU Calibration Data This last display shows all data calculated during ca
83. e offered with the controller as described in Chapter 8 of this manual When activated this printer port transmits data via 20mA current loop digital signal not analog Data from this port is very heavily formatted delivering detailed reports to the Okidata dot matrix printer supplied with the STPR package A 20mA current loop port is used since the robust signal is highly immune to ambient line noise and can transmit up to 1 4 mile without requiring any boost The Okidata 320T dot matrix printer supplied with the STPR package includes a serial expander card that has been installed in the printer This card accepts RS 232 serial data Between the PRINTER port and the Okidata printer resides the 52394 Converter This device converts the 20mA current loop signal to RS 232 and is provided with a pre wired connector for the printer See section A 2 1 below for more information Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 85 Protocol for the PRINTER port is as follows data structure is to complex to print here 1 Start Bit 1200 Baud 8 Data Bits No Parity 1 Stop Bit The drawing below and system drawings found at the back of this manual shows the proper wiring for this port PRINTER Pre wired 52394 PORT 20mA to RS 232 cable 20mA 2 Converter SOURCE E O O a E E i ae a
84. e keyboard power lines This provides complete protection for the keyboard making the standard controller usable in virtually any environment 477 Traffic Control card Although labeled as a traffic control card this card is a multi purpose serial port and specialized I O card used for the following True Bag Discharge Traffic Control In applications with multiple fill spouts on a common production line a dual filler controller is used to control two spouts and an additional filler controller is used to control the 3 and or 4 spouts By adding the 477 card to both controller racks the two separate controllers can be interfaced together providing control of bag drops on all spouts and serial communication between the controllers Special Inputs and Outputs are activated and used to provide traffic control for the discharge of each bag The traffic control algorithm used in the 4693 controller maintains the highest possible production rate while avoiding the possibility of discharging one bag on top of another The 477 card also invokes the display of additional front panel menus for configuring traffic control for right to left or left to right flow of bags away from the packers That is the packer farthest up stream will be allowed to discharge its bag at any time while each successive spout will be required to wait its turn to discharge Refer to Chapter 8 and Appendix A and drawings at the back of this manual for more details on
85. e previous menu Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Chapter 5 Fill Sequence The 4693 Filler controller has a default setting of Automatic Setpoint Mode requiring the entry of the Net Target weight for the fill Flow rates cut off points and Pre Act amount still flowing into the container after stopping the fill are automatically determined for either Bulk Only or Bulk and Dribble Fill The user may change the controller to operate in a Manual Setpoint Mode requiring the entry of Net Target weight Bulk cut off to Dribble if used and Pre Act values In either mode the 4693 controller will track final fill weights and attempt to correct for over or under weight fills on subsequent fills This feature is hidden within the Automatic Setpoint Mode but is displayed in the Manual Setpoint Mode on the lower portion of the fill screen and can be turned on or off as needed In either mode consistent and reliable flow of product is essential to consistent and accurate fills Rapidly changing product levels above the filler and or poor fluidization of product into and through the filler will compromise performance and final fill weights It is strongly recommended that the supply bin above the filler be equipped with low and high bin level sensors and the low bin sensor accommodates at least 5 or more bag s worth of product If running batch processes fill one compl
86. e report is called The Final report CLEARS ALL PRODUCTION DATA FROM MEMORY This report is typically called at the end of a run or campaign to clear memory before changing to a different product type or lot number Units Minute Total Units and Total Weight are also cleared P Product Load allows the operator to quickly load a new preset product from the main fill display Pressing the letter P will pop up a display asking for the new product number Simply enter the number and hit Enter This product is now automatically loaded as the current product C Clear Totals displayed on systems not using the STPR production reporting package Allows the operator to clear the units per minute total units and total weight production total boxes If the filler controller has been configured for Manual Set Points two additional Quick Keys will be displayed Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 22 A Autotrack Autotrack can be turned on or off by actuating the A key This feature stores the error from Target weight on the last fill averages this with the number of fills set in the Number of Filter Samples entered in the product set up see Pg 18 and automatically adjusts the Preact value for the next fill This feature should be used once the operator has completed at l
87. e same character If this operates properly then the transmitting and receiving ports on the card are functioning properly 10 2 6 2 3 Remote Loop Back Test The remote loop back test is dedicated to testing two 477 cards used as traffic control cards with each card residing in separate 4693 controllers These cards are exclusively configured for RS 422 and require the standard interconnection shown in drawings 4693 E3 and 4693 E4 found at the back of this manual The test must be turned on in both units for it to function properly The Leading unit controller will transmit a character starting with A and will transmit a new character every 1 second The Trailing unit controller will echo this character if it properly receives it and will then transmit a character back to the Leading Unit controller If both units display updates to both transmission and reception of characters the cards are functioning properly 10 2 6 3 Test Fill Routine This test is provided as a means of dry cycling the filler Entering into this menu choice will present a screen to turn the test routine on or off To use this test turn the test on and then Esc back to the controller s Main Menu Select Item 1 Run Filler then initiate a fill by either hitting the front panel Start switch only operates spout 1 or by actuating remote Start switches or placer interfaces The spout associated with the Start input just received will automatically begin a normal
88. east 5 fills to establish consistent flow rate Turning this feature Off will not delete correction factors stored in memory Turning the feature back on will allow the filler controller to effectively pick up where it left off S Preact In the initial product set up the operator will enter the Target Weight and Bulk Cut Off point if dribble is used and a Preact Value This value is the amount of product that continues to flow into the bag once the cut off point s are reached It may be necessary to periodically adjust this Preact value throughout production Actuating the S key on the keyboard while in the Run Filler screen will pop up a window for making small incremental changes to the existing Preact Value The operator can adjust the Preact up or down for either Spout 1 or Spout 2 from this screen 4 5 Main Menu Item 4 Set Time Date and Placer Dwell Timers Select item 4 Set Time Date Placer Dwell Time from the Main Menu A series of screens will follow prompting the operator through time and date settings as well as settings for placer dwell time and spout purge timers Each of these screens are shown below for reference THE PRESENT TIME IS 12 15 04 THE PRESENT DATE IS 09 18 06 1 SET TIME 2 SET DATE 3 SET PLACER DWELL TIME 0 0 SEC 4 SPOUT PURGE TIMER 0 0 SEC 5 SET TRAFFIC CONTROL TIMERS X MAIN MENU Main Time amp Date Menu Thompson Scale Company Houston TX Phone 713 932 90
89. enclosure Conduit openings can be installed on the bottom or lower sides of the enclosure and are to be used for routing power load cell and I O wiring to and from the enclosure Additional conduit openings for the wall mount style enclosure may be made in the enclosure in accordance with specifications shown on the controller layout drawing found at the back of this manual The recommended operating temperature for the 4693 controller is 10 to 40 C Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 3 1 4 Warning amp Caution Statements CAUTION SENSITIVE SCALE COMPONENTS The 4693 filler controller and load cell assembly of your filler are precision weighing instruments Standing on side loading or overloading the scale WILL damage the electronic load cell rendering the system inoperable WARNING FILLING EQUIPMENT MAY START AUTOMATICALLY LOCK OUT PROCEDURES SHOULD BE FOLLOWED BEFORE WORKING ON THIS EQUIPMENT Thompson Scale strongly urges that proper lock out procedures are used to disable the filler controller prior working on or around the equipment The 4693 filler controller can be started by actuating the auto start limit switch or Start pushbutton or front panel Start key Placing the filler controller into the Main Menu will disable the controller from starting a fill
90. endix D provides information on creating editing and calling product recipes and summary production reports from a remote terminal such as a PLC or PC One of the most common options purchased with the 4693 controller is the use of the traffic control card for 3 and 4 spout filling systems This feature provides bi directional communications between two 4693 controllers used to operate these multiple spouts giving the operator a single operator interface for calling and loading a new product or changing setpoints or other system features 8 1 Traffic Control Sequencer The Filler controller has been designed to allow the addition of an optional traffic control sequencer that permits the highest possible production rates and eliminates the problem of bags falling out of sequence which creates traffic jams on the production line The 477 Traffic Control card is for use with filler systems containing two Filler Controllers It can be used with either three 3 or four 4 spout systems The 477 card installs in an open slot of each Filler controller and consists of a bi directional RS 422 serial communications port four 4 110 VAC Inputs and four 4 110 VAC Outputs Before describing the functions of the 477 Traffic Control card we must first clarify and define the respective positions of the fill spouts and controllers Production filling systems are typically installed with a filled bag take away conveyor running perpendicular to the filling
91. ensure that both bags discharge at the same time The setting of 2 Stage Chair discharge will add a variable in the recipe used for Raising the Bag Chair assembly Bag Chair Raise Weight As soon as this weight is reached the Bag Chair assembly is raised VIA Output 8 on Card 1 This is our standard Fill Complete Bag Placer Interlock output BUT this function will be disabled and used for raising the Bag Chair assembly when set to this type of Bag Chair 10 2 W__Weight Limits Enable Disable This feature when enabled will add low and high weight reject limits to each product recipe To enable this feature the 4693 controller must have the 477 Traffic Control card installed and configured for Broken Bag feature See Appendix B for more information on this feature Please note if using this feature you must also select and configure the broken bag handling method This will either keep an off spec bag on the fill spout for manual or automatic handling or will set the interface for use with a placer or robot 10 2 D_Enable Disable Top Off Function Please refer to Chapter 5 Section 5 1 for information on the use of this feature Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 82 Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Appendix A
92. enter or execute calibration Upon entering Main Menu Item 2 Calibration Check the display shows current Gross weight in the current conversion Lbs Kg etc as shown in the following figure In two spout applications the screen prompts the operator to select which spout to check before proceeding to the Gross weight screen In this mode the filler is zeroed and current weight is continuously displayed To facilitate a stable displayed weight the display is updated at a slow rate of approximately 3 times per second A known test weight value can be placed onto the filler bag chair and Gross weight will be displayed If the operator decides that the weight value displayed is out of tolerance a complete calibration should be performed Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 10 PRESS Z TO ZERO PRESS X TO RETURN TO MAIN MENU Calibrate Check 3 3 Calibration Procedure Calibration consists of several screens that prompt the operator to clear the filler spout and chair and apply the test weight with the controller automatically setting zero and span Following are the sub menus in order of occurrence for calibration Password must be entered first if enabled Each menu screen is followed by a brief description of each step THE CALIBRATION TEST WEIGHT IS 50 00 LB IS THIS CORRECT Y YES CONTINUE N NO ENTER CAL TEST WEIGHT X RETURN TO MAIN MENU Cal Test Wei
93. er Refer to The 4693 controller and all of its features are described in detail within this manual Information is provided on sequence of operation product set up calibration reporting and diagnostics 2 2 Controller Enclosure The 4693 controller is housed in a NEMA 4X wash down and corrosion resistant fiberglass enclosure This enclosure includes a stainless steel hinge pin and cover screws The enclosure measures 16 high x 14 wide x 8 deep and includes four 4 mounting feet for wall mount Optional Stainless Steel enclosures are available 2 3 Controller Front Panel Controls and Display The front panel of the controller enclosure is covered by a membrane switch overlay that contains a complete alpha numeric keyboard special function keys and a clear scratch resistant display window measuring 4 3 high x 5 wide All operator inputs for adjusting variables and setting product weights is done through this keyboard Operator prompts are displayed for each function of the controller The display used with this equipment is a high resolution Seiko brand active matrix Liquid Crystal Display with 240 x 640 pixels The display presents both alpha numeric and graphical data to the operator The LCD is housed in a display module that also contains a Cold Cathode Vacuum Fluorescent back light This back light is a thin tube mounted to one side of the display and a layer of transparent filter material that distributes the back light across
94. er This TARE is stored and used only for this particular fill This is done since air auger and impeller packers and bulk bag amp box fillers may have variations in the empty container weight for each fill When the fill is complete the Settling Time is invoked again finding a stable scale reading and using it as the final checked weight of the fill TARE stored at the beginning of the fill is subtracted and a final Net weight is displayed before discharge of the filled container Settling time is set to 1 0 second as a default Since many machines may settle much faster than 1 second a variable is provided to allow adjustment from 0 1 to 5 0 seconds 10 2 2 Select Valve Type Different manufacturers of bag packaging equipment use different techniques for operating the Bulk and Dribble if available actuators on the packer The two most common methods of operating the Bulk Dribble actuators are l Combination air cylinder either two cylinders that are mechanically linked or a single two stage cylinder that requires two signals to operate 2 Separate air cylinders that oppose one another Both valve type selection operate nearly the same In both selections the Bulk and Dribble outputs are turned on simultaneously to actuate the air cylinder s to the full open position When Dribble fill is required the Bulk output is turned off and with the combination valve the air cylinder moves to the Dribble position The separate valve
95. et PortOpllON Vicario eius cebada dio hb a beeen Pee Meri Ge 90 A 4 1 Ethernet Port Installation A A 91 AA Ethernet Connection to PE iia dp E de e e 92 AMO Ethernet Port Redirector Option 24 542 a es wee oa oe aed ee ate 92 Broken Bag Detection Option A A AA RARA 95 B Broken Bag Timeout Detection 25 4 ae Wanna Oks Mla waaay A e das 95 B 2 Broken Bag Rate Of Change Detection 22 2004 A ieee 96 B 3 Broken Bag Handling Methods 0 0 cece eeaeee 98 B 3 1 Dump Broken Bags Automatic site nee Sets BEERS e 99 B 3 2 Hold For Operator Automatic s 24 444 bau dewey a ed 99 B 3 3 Hold For Operator Mandala nc ds E E hed eto a e 99 B 3 4 Hold For Robot Manual oo ooccocococr eee een eens 99 B 4 Broken Bag Sequence Of Operation 24 2 02 06 rta bade ea Ce ees Pode eae Deedee 99 B 5 Broken Bag Interface to Robot 22345 s ese A AA See as Gee 100 Remote Product Loads is oad SEA lee seen ERRE IR EA A as 103 EL Al Card Protocol 42 pees IA pee SORE ee AOR E A ENEG 103 22 Port Connections dai dota eG tbe ait alee te 104 C 3 Product oad Commands tact sehen lt fe Ee hd a a E ae Ne 104 C 3 1 Entering or Editing A Product 2 2 6 s 0ce pete devaeye eed a ee nyi weeds 106 Checkweigher Feedback For Gross Filler Controller 0 cece cece wee c cece cece e eens 109 Aol Feedback DESCUIDAR ed Ly eee ye ange Sy ee AS 109 A 2 Hardware Interconnection 2 0 1 2 i2ic s0inbcisen tubes bee e bhetileshehianee E ia 109 A 2 1 Use with Thompson
96. ete batch into the bin and when levels drop add another Y2 batch of product It is better to run smaller more frequent batches than allow bin levels to fluctuate dramatically Fluidization of product is very important to proper filling Too little fluidization and product tends to bridge and or plug Too much fluidization and typically the product won t fit properly into the container Over stuffing a bag will always result in erratic and inaccurate fills regardless of the controls used to operate the filler 5 1 Top Off Functionality Before getting involved in the theory behind how the filler controller operates let s first discuss the typical production filling operation of this equipment The operator or automatic bag placer places bags onto the fill spout Production problems do occur and the filler controller tries to accommodate the operator in these situations The most common occurrence is either the automatic or manual abort of a fill in progress Whether it is due to faulty placement of the bag or simply running out of material partially filled bags do occur and must be either filled to Target weight or recycled When an empty container is placed onto the spout the 4693 controller executes several steps including a TARE before the fill begins If a partially filled bag is placed upon the spout and the fill started the 4693 controller will automatically detect if the TARE weight on this container differs by more than 2 from
97. f the removed cards Apply power and conduct the test observation again Continue this process until the faulty card is found Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Chapter 8 Options amp Accessories The 4693 filler controller can be upgraded to provide additional control and features for collecting and reporting on production weight data production down time and efficiencies and provide traffic control on bag discharge from multiple fill spouts on a common production line Thompson Scale also offers a comprehensive data collection analysis and reporting software called StatPak PC This software loads into a PC connected to one or multiple fillers and or checkweighers automatically logging and reporting on weight data and offers an optional down time reporting and efficiency analysis module Please contact Thompson Scale Co or visit our website at either www thompsonscale com or www statpak pc com for more information on this product Appendix A of this manual describes the serial ports included with the 4693 controller and uses of the 477 Traffic Control card Appendix B describes the use of our optional broken bag detection feature and interface to bag placers and robotic placers Appendix C covers the use of the remote product load option that can be used to create and call unique product recipes from a remote terminal such as a PC PLC or robotic system App
98. f approximately 100 feet per minute Bags need to be a minimum of 18 apart leaving approximately 6 of travel before the bag from one spout would interfere with a bag discharged from the next down stream spout A bag dropping off spout 1 defined above hits the take away conveyor rolls onto its face and travels below spouts 2 and 3 on its way down the production line The amount of time required for that bag to reach a position that would inhibit the discharge from spout 2 would be approximately 1 0 second and 1 9 seconds before it interferes with spout 3 This would be considered the delay time There are six 6 Delay timer settings each having control of one spout over another These timers are found in Main Menu 4 Sub menu 4 Choice 1 in this sub menu offers Delay Timers and choice 2 offers Duration Timers Timer 1 sets the delay between spouts 1 and 2 Timer 2 sets the delay between spouts 2 and 3 Timer 3 sets the delay between spouts 1 and 3 Timer 4 sets the delay between spouts 3 and 4 Timer 5 sets the delay between spouts 2 and 4 Timer 6 sets the delay between spouts 1 and 4 In our example we have only three spouts In this case timers 4 5 and 6 would be set to 0 0 since the 4 spout does not exist Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 58 8 3 1
99. f point is also calculated that will result in a final weight of exactly Net Target Weight In Bulk Only fills the Dribble calculation is not required The filler controller constantly monitors current weight and compares it to Bulk cut off calculated in step 8 While current weight is less than the cut off value the controller remains in this loop When current weight equals or exceeds the Bulk cut off current weight is measured and stored The BULK status indicator is turned off and the DIBBLE indicator turned on and the cut off cylinder s on the rubber pinch tube is set to the Dribble position A timer is then started to allow feed rate to change to Dribble When the timer times out the controller calculates the current Bulk overfeed and averages it into previous measurements for a cycle by cycle update to Bulk feed rates The controller compares current weight to Dribble cut off calculated in step 8 While current weight is less than the cut off value the controller remains in this loop Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 43 13 When current weight equals or exceeds the Dribble cut off a The cut off cylinder s on the rubber pinch tube is closed b The low pressure air intake valve is closed The spout purge solenoid if any is opened to purge the fill spout d The
100. f the 477 Traffic Control card Two sets of timers operated by this card will track the discharge of filled bags from each spout and inhibit the discharge of other filled bags until the first bag has passed below the next Descriptions of these timers and their settings is found below The Trailing Unit automatically changes its main fill screen when the properly configured 477 Traffic Control card is installed Weights fill status indicators Ist or normal cycle indicators and product name are still displayed However the production data box at the bottom of the screen and menu selection for the optional statistical package are removed The 477 card within the Trailing Unit automatically down load s all production and statistical information to the Leading Unit which combines this data with that of the Leading Unit The Trailing Unit also adds an additional menu choice to its Main Menu 4 Set Time Date amp Placer Dwell Time Within Menu 4 is an additional selection Traffic Control Timers This menu holds delay and duration timers used to control the discharge of bags from each spout of both the Leading and Trailing Units 1 SET DELAY TIME 2 SET DURATION TIME Traffic Control Menu Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 57 Once both 477 cards have been installed into the
101. f your controller has a single 473 card single spout filler then only the tests for the 1 card will operate Tests for the 2 card will be disabled The Rotating test allows each output to be turned on for one 1 second When invoked this test will automatically turn on output 1 for 1 second turn it off for one 1 second then turn on output 2 for 1 second etc The 4693 controller will remain in this test until it is stopped by exiting from the screen This test also displays a set of eight 0 s on the screen each representing one of the eight Inputs Applying 110 VAC through a switch or contact will change the corresponding Input s 0 to a 1 This confirms that the Input circuitry and the 4693 s program are responding correctly The Keyboard test allows each output to be turned on individually by pressing a corresponding number key on the front panel If output 1 is to be turned on simply hit the 1 key on the 4693 s front panel To turn the output off hit the 0 key on the 4693 front panel As with the rotating test the Keyboard test allows for testing of each Input 10 2 6 2 477 VO Test If your system is equipped with the 477 Traffic Control Card you can test both the Leading and Trailing unit cards for I O and serial communication function Entering into this menu selection will present a screen with several choices 1 Input Output Test Ze Local Loop Back UART Test 3 Remote Loop Back UART Test 10 2 6 2 1 I
102. fill cycle so there is no need for concern about running different bag sizes or types If the optional Broken Bag Detection card is installed into the 4693 controller a configuration feature becomes available to allow for selection of upper and lower checkweigh limits When this feature is enabled entering into the Target Weight setting of the product recipe will present the following screen BROKEN BAG CARD INSTALLED SELECT DESIRED FUNCTION 1 TARGET WEIGHT 50 00 LB 2 SET UPPER WEIGHT LIMIT 50 25 LB 3 SET LOWER WEIGHT LIMIT 49 80 LB X RETURN L LB K KG Set Check Wt Limits If a fill results in a bag weight that is under the low limit or above the high limit an error will be displayed in the Run Filler screen and the bag will be handled through settings made for discharge of a broken bag See Appendix B for a description of the broken bag detection option and settings for handling discharge of these bag types Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 29 Menu item 2 refers to the filling mode to be used with this product There are four 4 variables found within this menu Following is an example of this screen BULK AND OR DRIBBLE OPERATION PRESENTLY RUNNING BULK amp DRIBBLE 1 BULK ONLY 2 BULK AND DRIBBLE 3 DRIBBLE ONLY 4 SET NUMBER OF FILLS TARE
103. flow rates have changed dramatically less than 3 fills 5 3 Standard Input amp Output Configuration The 4693 Filler Controller is equipped with one 1 473 Input Output card containing eight 8 110 VAC Inputs and eight 8 110 VAC Triac Outputs Each of these detect inputs from switches and other devices and drive the output devices such as solenoids on the filler Below is a list of the standard input and outputs In controllers equipped to operate two 2 fill spouts the controller will contain one 473 card for each spout The controller will also contain one 474 Scale Digitizer card for each spout and may contain special cards for traffic sequencing or serial data transmission Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com INPUTS 01 Start Auto Start Switch 01 02 Stop Abort Switch 02 03 Bag Not In Place 03 04 N C 04 05 N C 05 06 JOG Switch 06 07 N C 07 08 Discharge Inhibit 08 Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 44 5 3 1 Alternate Output Configurations The 4693 controller can be configured slightly differently depending upon the application and type of filler Alternate Outputs are shown below Output 4 Output 7 Output 8 OUTPUTS Bulk Fill Dribble Fill Refill Recharge Valve Chamber Exhaust Valve Bag Clamp Bag Chair Spout Purge Auger Reverse Bag Placer Interlock New Bag Re
104. ght The filler controller offers a default test weight setting to be used for calibrating the filler You have the option to accept this test weight value or enter a new value which will be retained in memory as the default or exit back to the main menu The sub menu shown below describes the selection for entering a new test weight value Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 11 ENTER CALIBRATION TEST WEIGHT L CALIBRATION WEIGHT IN LBS K CALIBRATION WEIGHT IN KILOS O CALIBRATION WEIGHT IN OUNCES G CALIBRATION WEIGHT IN GRAMS ENTER ENTER NEW TEST WEIGHT X RETURN TO PREVIOUS MENU Enter Cal Weight This menu also allows for the selection of a new weight conversion for calibration Please note that selection of ounces and grams is restricted to systems with a full weight capacity of 20 Lbs or less Refer to project drawings and filler load cell for information on your system s capacity Once a valid calibration weight has been selected the sub menu shown below automatically appears instructing the operator to clear the weigh station before proceeding In two spout systems the screen first prompts the operator to select either spout 1 or spout 2 for calibration Once this selection is made the screen advances to the screen shown below CALIBRATION PROCEDURE SETTI
105. gins the value will not be updated and accurate for the first few minutes of production In applications using multiple controllers and the 477 Traffic Control card data from the Trailing controller is down loaded to the Leading controller Total Units is based on the number of units that have been produced during this production run and is updated at the completion of each fill Total Weight is displayed and updated as each fill completes The weight conversion is not displayed in this box but is the same as the value 1b kg shown at the top of the screen 4 4 5 Quick Keys Directly below the production Data box are located a set of single key commands for several different system functions Several of these items List Interim Report and Final Report are only shown if the optional STPR production reporting package has been installed in your controller Each key is described below L List will toggle the print of each unit weight on or off Current status is always displayed List On Off X Main Menu will exit the operator back to the Main Menu display D Interim Report will generate a production report containing production information up to the instant the report is called Interim reports are handy for obtaining one or more reports during a run or campaign Calling an Interim report does not clear production data from memory F Final Report will also generate a production report containing information up to the instant th
106. hat room on the initial screen entering this selection will produce a second screen with other variables as shown below 1 SET SETTLING TIME 2 SELECT VALVE TYPE 3 SET OFFSET COMPENSATION 4 SET FILLER TYPE 5 SET LANGUAGE ESCOGER LENGUAGE 6 4693 TEST ROUTINES 7 SET REMOTE PORT MODE OF OPERATION 8 VIBRATOR ENABLE DISABLE 9 SET BAG PLACER INTERFACE MODE 0 SET AUTO MANUAL TARE S SET AUTO MANUAL SETPOINTS A BROKEN BAG DETECTOR B BLAST AIR ENABLE DISABLE C CHAIR DISCHARGE MODE W WEIGHT LIMITS ENABLE DISABLE D ENABLE DISABLE TOP OFF FUNCTION Esc RETURN TO MAIN MENU Secondary Menu 10 2 Secondary Configuration Menu The secondary configuration menu offers a selection achieving a final reading at the end of the fill and choices for different types of feed mechanisms Each of these are factory set to defaults but may require modification depending upon the application Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 74 10 2 1 Settling Time Settling time is invoked at both the beginning and the end of each fill Once the filler machine is ready to begin filling a timer is run to allow the filler and its mechanisms to come to rest before the filler controller takes a TARE Once the timer expires the 4693 takes the next scale reading as a reference and zero s the fill
107. he screen below each weight display This status line tells you exactly what the filler is doing at any time During a normal production run the display will start off with READY which means the filler is ready to start the next fill This will be displayed before you place a bag onto the spout or when the fill is complete The controller will then turn on the Bulk feed and the display will change to BULK When the Bulk feed is shut off and Dribble feed is turned on the display goes to DRIBBLE At the end of the fill the display will change to FILL COMPLETE If the bag cannot be discharged from the filler the status line will show the error DISCHARGE INHIBIT This information is very helpful when trying to trouble shoot a problem like a faulty bag in place sensor or weigh bucket that won t close properly Always look to the status line on the display to find out where the current fill is 6 4 Fill Errors and Error Corrections The filler controller is always monitoring the fill process If something goes wrong the controller will display information on the screen to tell you what has happened The main errors displayed by the controller are listed below Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 49 NO PRODUCT This means that the controller does not see any product falling into FLOW
108. hompsonscale com Appendix C Remote Product Load The remote product load feature is offered as an option to the Model 4693 filler controller Remote product load is comprised of a specifically addressed 477 Traffic Control card that enables the use of serial string commands to make changes to settings within the controller The transmit port on the 477 Traffic Control card issues an ASCII data strings containing possible error and or acknowledge codes to the host computer system It is essential that this portion of the port is connected and properly used to ensure proper and safe operation of the filler controller and filler machinery The receive port on the 477 card receives ASCII command strings as set forth later in this document These strings include commands for changing from one product type to another modifying product set up fields and calling for summary production reports This port cannot be used for controlling operation of the filler I O or calibration of the filler C 1 477 Card Protocol Protocol for the 477 card is fixed at the factory to the settings shown below 1 Start Bit No Parity 9600 Baud Eight 8 Data Bits 1 Stop Bit Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 104 C 2 Port Connections The 477 Traffic Control card serial port can be either a RS 232 or RS 422 depending upon the card specified and purchased The top connector of this card consists of a twelve
109. id fill If fill rate drops considerably or is non existent the fill will abort Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 97 To use this feature enter the 4693 configuration menu by From the Main Menu hold the Shift key down while typing EXIT Upon striking the T key the display will change to the configuration menu The first item displayed on this menu is 1 Sample Rate Select item 8 Get The Next Menu This will bring up the second page of configuration variables Select A Broken Bag Detector Upon pressing the A key the following screen will display BROKEN BAG DETECTOR PRESENTLY SET TO OFF 1 TURN ON OFF BROKEN BAG DETECTOR 2 SETUP BROKEN BAG HANDLING ESC RETURN TO PREVIOUS MENU Selecting item 1 from this menu will present the following screen BROKEN BAG DETECTOR PRESENTLY SET TO OFF 1 BROKEN BAG DETECTOR OFF FILL RATE PER SEC MUST BE GREATER THAN 2 BULK 10 OF TARGET WEIGHT 3 BULK 5 OF TARGET WEIGHT 4 BULK 2 OF TARGET WEIGHT 5 BULK 0 OF TARGET WEIGHT 6 BULK 2 OF TARGET WEIGHT 7 BULK 5 OF TARGET WEIGHT DRIBBLE SETTING IS 1 10 BULK SETTING ESC RETURN TO PREVIOUS MENU Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson S
110. ill see the following Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 96 1 TARGET WEIGHT 50 00 LB 2 BULK AND OR DRIBBLE B amp D 3 CHAIR RETURN DELAY 5 SEC 4 REFILL VALVE TIME 5 BROKEN BAG TIMEOUT 7 OF FILTER SAMPLES ESC RETURN TO PREVIOUS MENU Recipe Edit Weigh Screen Setting the timeout value to 0 0 will disable the broken bag detect feature The Broken Bag timer runs ONLY during Bulk and Dribble fill That is to say this timer does not start when the bag is first placed onto the spout and does not start as the controller attains a TARE reading It begins the instant the Bulk output is turned on and runs until the Dribble if used output is turned off To compensate for additional fill time required during a Ist cycle an additional three 3 seconds is added to the broken bag timer during a Ist cycle only This is an internal timer that does not appear on the screen and is not adjustable by the operator See below for a sequence of operation for this feature and information on methods for responding to a broken bag condition B 2 Broken Bag Rate Of Change Detection The 4693 Filler Controller program can be configured to use an alternate method for detecting a broken or mis spouted bag This method examines current fill weight and compares to both time and the target weight A specific amount of product must flow into the bag increasing bag weight to be recognized as a val
111. inning of Chapter 5 for more information on these options The filler controller offers a feature that lets you finish off any under weight bags During normal production NOT during a 1st Cycle place the partially filled bag onto a spout If your system has an auto start switch the bag clamp will come down and the fill will start If not place the bag on the spout and hit the START switch The controller uses the zero from the last fill to TARE out the empty bag weight and then fills the partially filled bag to weight WARNING This can only be done three 3 times in a row on any one spout The controller will not allow a fourth partially filled bag to be topped off WARNING Do Not ever place a partially filled bag onto the filler if the status display says Ist Cycle The controller will zero out all the weight in the bag and then try to fill to Target 6 3 3 Fill Status On Screen There is a status line below the weight display or displays if it s a dual filler scale that tells you what the filler is doing In normal production this line says NORMAL If you hit the STOP button once this line changes to ABORT If you hit the STOP again the display changes to Ist Cycle If your system uses the conveyor interlock or traffic control feature the bag may not discharge and the display line may change to DISCHARGE INHIBIT which means that it cannot dump the bag until the interlock signal goes off There is another status line on t
112. ins on the display for 5 seconds and is replaced by the Main Menu Display An example of this display is shown on the following page as well For the sake of simplicity most menus and displays shown in this manual will be for a single filler controller The displays for a two spout filler controllers are essentially the same with the exception of showing two fill weight in the main filler display and asking the operator to select which spout to calibrate or check Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 18 1 DIGITIZER RESPONDING 2 DIGITIZER RESPONDING DUAL SPOUT FILLER OPERATIONAL 2 SECOND TIME DELAY ON POWER UP ALLOWS SYSTEM TIME TO SETTLE INITIALIZING DIGITIZER 1 INITIALIZING DIGITIZER 2 Power Up Screen 4 2 Filler Main Menu The Main Menu shown below offers access to all adjustable settings within the controller If you are not familiar with these menus take a few moments to step through them or review the menus shown within this manual Following are descriptions of each Main Menu item and associated sub menus as well as default settings and instructions for adjustment of system variables MAIN MENU CHOOSE ONE OF THE FOLLOWING 1 RUN FILLER 2 CHECK CALIBRATION 3 CALIBRATE FILLER 4 SET TIME DATE BAG PLACER DWELL TIME 5 SELECT EDIT PRODUCT 6 STATISTICAL AND DIAGNOSTIC REPORTS Main Menu Display Thompson Scale Company Houston TX Phone
113. ir respective positions outputs of the Trailing unit 477 card are tied to Input 8 Discharge Inhibit on each 473 VO card within the Leading and Trailing controllers to enable or disable discharge of bags from each spout at specific times Output 6 on each 473 VO card is in turn tied back to inputs on the 477 card within the Trailing Unit This signals a fill complete and ready for discharge from each of the fill spouts See Traffic Control Drawing at the back of this manual 8 3 1 Traffic Control Timers Once all interfaces have been established between the Leading and Trailing Units timers must be set to properly operate the discharge and inhibit from each fill spout This is done using two sets of timers Delay timers and Duration timers It is necessary to have two sets of timers since fill spouts can be on a variety of different center to center distances and take away conveyors are available in many different configurations and speeds Each timer is defined below 8 3 1 1 Delay Timer Settings The bag filling process fills each bag to Target Weight and then discharges the bag from the spout onto a bag take away conveyor The time required for a bag to fall from the spout and travel to a position that would interfere with the bag being discharged from the next spout is considered the Delay Time For example we will use a typical three spout filling machine on 24 spout centers and operating with a take away conveyor running at a speed o
114. ite www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 79 10 2 7 Set Remote Port Mode of Operation The remote port can be configured to transmit data in one of two ways Entering this menu selection offers three choices 1 Turn Port Off 2 Stream Mode continuous transmission 3 Ticket Mode one transmission per weight 10 2 8 Vibrator Enable Disable An optional feature available on a number of manufacturer s baggers is an air or electrically operated vibrator that assists in settling product into the bag during the fill For systems with this feature enable the Vibrator setting If this feature is enabled each product set up 1 thru 75 will display a setting for turning the vibrator feature on or off for that specific product If the vibrator is turned on for a specific product the 4693 controller will automatically operate the vibrator for the longest possible time during each fill 1st cycle will turn the vibrator on and off to measure the amount of time required to actuate and stop the device In a normal cycle the vibrator will be turned on after 10 of the product is filled into the bag The vibrator will then turn off when Bulk weight is 10 from Bulk cut off so that it will come to rest before going into Dribble fill or reaching final weight in Bulk only applications 10 2 9 Set Bag Placer Interface Mode As a default the 4693 controller is configured to generate an Out
115. lation since it offered a more varied character set Any printer connected to the 4693 must have Epson emulation Since the vast majority of printers on the market today are provided with only a parallel port the printer will most likely require an optional serial interface board This serial interface must be compatible with either 20mA current loop passive power source for the port comes from the printer or RS 232 If RS 232 is used a serial converter will also be required to accept and convert the 20mA current loop sent from the Thompson Filler Thompson Scale offers a dedicated serial converter for use with our STPR package which is also available as a separate unit Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 68 The printer must be configured for Epson emulation and for the following protocol and data formats Protocol Printer Configuration ASCII Data set No skip over perforation 1 Start Bit Auto line feed 8 Data Bits No auto carriage return 1 Stop Bit 11 page length No Parity Bi directional graphics 1200 Baud Draft mode Ready Busy Protocol 10 CPI pitch Busy Line DTR 6 lines per inch DSR Inactive American Character set Busy line timeout approx 200ms EPSON FX CHARACTER SET EMULATION Thompson Scale offers consultation and technical assistance free of charge for printers pr
116. ler to perform successive fills without taking a TARE at the beginning of each fill As a default the value for this variable is set to one 1 which causes a TARE to be taken at the beginning of each fill cycle This value can be set to a maximum of 99 fills between TARE s If the TARE value is set to a number greater than one 1 the filler controller will always perform a TARE on the Ist Cycle fill perform a TARE on the next fill which is a normal fill and will then fill the third thru x number of bags without taking a TARE The TARE values taken on the Ist Cycle and next fill are used to determine an average TARE for all successive fills Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 30 If your packaging machinery experiences fluctuations in the amount of product left in the fill tube at the end of each fill or 1f your machinery spills an excessive amount of product during each fill cycle it is recommended that the TARE to fill ratio be kept very low However if your packaging machinery runs cleanly and with a minimum amount of left over product in the spout this number can be increased up to 99 fills between TARE s Item 3 Chair Return Delay pertains to operation of the power discharge bag chair if any The bag chair actuator will be energized for the period of time set in this timer Typica
117. libration These constants are now stored in EEPROM electrically erasable program read only memory which does not require battery back up A portion of this data is also stored in a serial EEPROM that resides on the 474 Scale Digitizer along with time and date Although this may first appear to be a rather complex operation in truth it goes very quickly and with little chance for error 3 4 Calibration Errors There are several error screens that reside within the calibration routine The data within these error screens should be recorded for reference when discussing calibration problems with a service technician In most cases the errors are caused by a problem with the scale and relate to the controller s inability to properly span the scale due to load cell damage or weigh station mechanical restrictions The four error screens are Cannot Zero Scale No Test Weight On Scale Span At Either Max Or Min Cannot write to serial EEPROM Cannot Zero Scale is typically encountered when the load cell output is at either zero millivolts or below or is greater than 30 millivolts Check the load cell mount for mechanical restrictions such as improperly adjusted shipping bolts within the scale or mechanical binds caused by interference between the spout or bag post and the surrounding structure Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Compa
118. ligned sensor wand A corresponding LED on the 473 I O card should light when a bag is placed on the spout and the sensor actuated Check the fill display Warnings errors and fill status are displayed below the fill weight It may be that the filler is in the middle of a sequence or is waiting for operator or equipment input before beginning the fill Low pressure air supply not working properly or Impeller Auger motor not turning on If a bag is placed onto the spout and the bag clamp is actuated and the BULK status indicator is shown then the pinch tube cylinder should go to the Bulk fill position and product should flow from the machine Check the low pressure blower and or chamber pressure gauge if these other mechanisms appear to be operating properly Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 52 Defective 473 I O card output It is possible for one or more channel of the 110 VAC output card to fail Other aspects of the fill cycle should operate properly so check to see if the bag clamp is actuating If this one function works but the pinch tube doesn t open there may be a problem with the output channel or solenoid valve Refill timer within the product set up may be set to an invalid or extremely high value Also check the Placer Dwell Time setting in the Time Date Placer Dwell Time menu This timer may also be set to an invalid or very high value 7 1 3 Final Bag Weights Not Consistent Fi
119. lly the timer is set to a value between 0 7 and 1 0 second If a longer time is required simply increase the amount of actuation time Setting this timer to 0 0 will leave the chair in the fill position and will not actuate the chair at the end of the fill cycle Item 4 Refill Valve Time is for air packers using a butterfly or refill gate at the top of the upper chamber and is used to set actuation of this valve for a minimum time required to refill the upper chamber Each product run through your filler has its own unique characteristics and flow rates This adjustable timer is provided to allow the operator to set the optimum time required to refill the upper chamber of the filler The refill valve timer sets the minimum amount of time required to refill the upper chamber The valve will be actuated at the moment the Bulk or Dribble pinch tube cut off is closed to allow the chamber to refill at the earliest possible moment in the fill cycle However the refill valve will remain open until a new bag is placed onto the spout and the next fill cycle is initiated High density free flowing products may refill the chamber in less than 2 seconds while lighter or difficult products may take as much as 6 seconds or more to refill It is important to experiment with this refill time and adjust for the minimum time required to completely refill the upper chamber Impeller packers should set this timer to 0 0 second If your filler is configured for u
120. machines If the operator is facing the fill spouts of the machine and the conveyor below the operator is taking bags away to the right then the fill spout farthest to the left is considered Spout 1 If the conveyor is taking bags away to the left then the fill spout farthest to the right is considered 2 Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 56 This appears a bit confusing at first but keep in mind that a dual filler controller always has the primary or first filler dedicated to the left side of the display screen Please refer to the traffic control drawing found in the back of this manual If the bag discharge from the filler goes from left to right then the left spout would correspond with the filler controller s spout 1 If the bag discharge is from right to left the right hand of the two spouts controlled by the dual controller is farthest up stream but is considered spout 2 Three or four spout filler operations must have the Leading Unit filler controller mounted to the two up stream fill spouts The 2 controller used for operation the other spout s is considered the Trailing Unit controller Leading and Trailing controllers are configured via a jumper located on the 12 pin connector on the face of the 477 traffic control card Refer to drawing 4693 E3 located in the rear of this manual for installation of this jumper This spout arrangement is essential to the proper operation o
121. mall Standard Deviation the zone width may be only one unit of resolution this is the minimum zone width For reports having a larger Standard Deviation each zone will expand to contain as many weight values as necessary to meet the plus and minus 3 Sigma requirement Definition of Standard Deviation Statistical analysis of your production is an important part of your quality assurance program and can be of great benefit in improving the efficiency of your packaging operation However it is important that all terms within this report are understood to make the report meaningful Standard Deviation is a mathematical term whose definition loosely translates to average error Standard deviation is used to evaluate a population and determine the average error from the mean or average value In this report Standard Deviation describes the calculated average error of product weight from the Target weight To derive Standard Deviation all weight values occurring are compared to the Target weight The difference or error between this value and the Target weight is stored in a table in memory Once all errors are calculated each error is squared and then all values are added together This number is then divided by the number of values in the table and the square root of this is calculated This is the Standard Deviation When evaluating a production report the Standard Deviation will provide information on the overall performance of your packaging
122. mber key while in the Main Menu The screen will automatically change to the Run Filler screen which shows the fill weight product name and product Target Weight To check calibration hit the Esc key to get to the Main Menu then hit the number 2 key This will display a live weight reading Now you can place a test weight on the filler and make sure it reads accurately To calibrate the filler go to Chapter 3 of this manual and follow the directions in that section Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 46 6 2 Changing to a New Product The filler controller can hold up to 75 different product set up s in memory Your system may be set up by different Target Weights Bag Sizes or Product Names Each of these product set up s contains information on the Target weight if the product will fill in Bulk only or Bulk and Dribble and timers for the Refill Valve and Chair Discharge time For more information on setting up a new product or changing an existing product see Chapter 4 of this manual While in the Run Filler screen you can change from one product number to another without ever leaving the Run Filler screen At the bottom right corner of the screen you will see several instructions including P PRODUCT LOAD When you are ready to change from one product number to another hit the letter P on the keyboard The screen will change and tell you that you are currently running product number
123. mer purchases has the capabilities and features required to handle the text and graphics commands transmitted by the 4693 controller Some years ago Thompson Scale selected between two distinctly different emulations that were considered standards by the industry These two types are IBM emulation or Epson emulation We selected the Epson emulation since it offered a more varied character set Any printer connected to the 4693 controller must have Epson emulation Since the vast majority of printers on the market today are provided with only a parallel or USB port the printer will most likely require an optional serial interface board This serial interface must be compatible with either 20mA current loop Active current source for the port comes from the 470 CPU s port or RS 232 If RS 232 is used a serial converter will also be required to accept and convert the 20mA current loop sent from the Thompson controller Thompson Scale offers a dedicated serial converter for use with our STPR package which is also available as a separate unit The printer must be configured for Epson emulation and for the following protocol and data formats Protocol ASCII Data set 1200 Baud 1 Start Bit Ready Busy Protocol 8 Data Bits Busy Line DTR 1 Stop Bit DSR Inactive No Parity Busy line timeout approx 200ms EPSON FX CHARACTER SET EMULATION Printer Configuration No skip over perforation Draft mode Auto line feed 10 CPI pitch No auto
124. n Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 32 CHOOSE ONE 1 TARGET WEIGHT 50 00 LB 2 BULK AND OR DRIBBLE B amp D 3 CHAIR RETURN DELAY 0 70 SEC 4 REFILL VALVE TIME 2 3 SEC 5 BROKEN BAG TIMEOUT 7 OF FILTER SAMPLES X RETURN L LB K KG Fill Values Before entering into menu item 1 Target Weight it is important to first select the Bulk and or Dribble fill mode Selecting item 2 Bulk and or Dribble will open a new screen offering options to operate the filler in several modes and to allow for selection of the number of fills to complete before taking a new TARE Following is an example of this screen BULK AND OR DRIBBLE OPERATION PRESENTLY RUNNING BULK amp DRIBBLE 1 BULK ONLY 2 BULK AND DRIBBLE 3 DRIBBLE ONLY 4 SET NUMBER OF FILLS TARE ESC RETURN TO PREVIOUS MENU Bulk Dribble Settings Selecting Bulk Only will fill to the Bulk Target Weight minus the Preact value Bulk and Dribble will fill Bulk to a pre set cut off point Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 33 The filler controller has a very high sample rate and does an outstanding job of tracking and calculating final cut
125. n Terminal Plug Green 473 card 200 112 12 Pin Terminal Plug Orange 477 card All recommended stock items are normally in stock in our factory and can be delivered within 2 to 3 days from receipt of your order Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 70 Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Chapter 10 Controller Configuration The 4693 Filler controller contains an additional configuration menu that allows for modification of system variables specific to the type and kind of filling machine to be operated This menu also allows certain features or options to be turned on or off or configured for your specific equipment and or application The following chapter describes each of the variables found within the configuration menu WARNING Read this chapter very carefully before attempting to change any configuration variable Changes to some variables may change the operation of the packaging machinery To access the configuration menu you must first exit or Escape back to the Main Menu While holding down the Shift key type EXIT The display will automatically change over to the configuration menu You may exit this menu at any time by hitting Esc until you return to the standard Main Menu 10 1 Configuration Menu The configuration menu contains two sets of screens to display all configuration settings Only the fir
126. n accurate TARE can be taken When this timer expires TARE is read 5 The controller checks the refill timer When the refill timer times out the status line below current fill weight changes from REFILL to READY The controller calculates 10 of Target Weight which is loaded into a buffer in memory 6 The low pressure air intake valve is opened pressurizing the upper chamber The cut off cylinder on the pinch tube is opened to Bulk position The status line below the current fill weight changes from READY to BULK de When the controller detects that current fill weight is equal to or greater than 10 of Target Weight the controller checks to see if this is a Ist Cycle If not the controller advances to step 8 If it is a 1 Cycle steps 7a through 7d are executed Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 42 a The controller displays the word 1ST CYCLE on the second status line below the current weight to indicate that the filler is within a 7 Cycle Status indicator directly below the current weight changes from BULK to DRIBBLE if dribble is included in the fill cycle set through Main Menu 5 Select Edit Product The current Net Weight is read and stored at the end of the forced Bulk fill Finally a time delay is started to allow feed rate to change to Dribble if use
127. n the initial screen indicating that Feedback has been enabled The 477 Traffic Control Card can be supplied with either an RS 232 RS 422 or 20mA current loop active serial port It is important to order the correct card to be compatible with the serial port used in the checkweigher controller A 2 1 Use with Thompson Scale Model 4693 Checkweigher If the 4693 Filler controller is connected to the Thompson Scale Model 4693 Checkweigher 1t is important to configure the checkweigher s Remote Port to transmit only Unit Weight and set the port to operate in the Ticket mode only These settings are found in the configuration menu of the checkweigher controller Please reference the 4693 Checkweigher manual for information on accessing this menu and these settings A 3 Theory of Operation The 4693 filler controller as a stand alone controller contains programming to monitor and automatically correct variations in final fill weights in comparison to the Target weight of the fill By enabling the Feedback feature the automatic adjustment of fill weight errors is based upon weight information gathered from an independent scale Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 110 As each bag is filled the final weight is displayed on screen of the filler controller and the bag is discharged onto the customer s take away conveyor The filled bag then crosses an in motion checkweigher to independentl
128. n until the next bag is filled If a report is called at the end of a shift and several hours or days elapse before production begins again the clock will not start until the first bag is filled Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com INCLUSIVE 50 50 50 54 50 45 50 49 50 40 50 44 50 35 50 39 50 30 50 34 50 25 50 29 50 20 50 24 50 15 50 19 50 10 50 14 50 05 50 09 50 00 50 04 49 95 49 99 49 90 49 94 49 85 49 89 49 80 49 84 49 75 49 79 49 70 49 74 49 65 49 69 49 60 49 64 49 55 49 59 49 50 49 54 Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 63 INTERIM REPORT PRODUCT LOT NO PVC PELLETS NATURAL CUSTOMER x5203 BLEND DATE TIME 01 17 07 08 10 52 SUMMARY OF 13 HR 04 MIN OF PRODUCTION TARGET WEIGHT 50 00 LB TOTAL UNITS 8854 TOTAL WEIGHT 442904 88 PRODUCTION RATE 11 3 UNITS MIN MEAN UNIT WEIGHT 50 023139 STD DEV 1 SIGMA 0 113 HEAVIEST UNIT 50 28 LIGHTEST UNIT 49 76 3 SIGMA DISTRIBUTION FOR 8854 UNITS PRODUCED PERCENT OF TOTAL PRODUCED 15 20 25 30 35 Nn UAN ooooo 00 39 l 166 eee 1292 E 2035 B 2075 1923 SSS 1157 E 123 as ooooo Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com 40 Thompson Scale Compan
129. nd Placer Dwell Timers 00000005 22 4 3 1 Setting Curent Time 2454 dso oink sas 23 4 5 2 Setting Current Date a esate bk SA IG eee Ca ea Dee bees 23 400 Bag Placer Dwell Times vx fe ods RA AE E ERAT E ARAE 24 4 5 4 Spout Purse Timer Votos a E SSA Oe ES Mande aes 25 AO Trate Control FIMES wasara E ioe E E Rie AD RA al eo ta RATA Ee 25 4 6 Main Menu Item 5 Select Edit Product 0 0 ccc cece eee nee 26 4 6 4 Entering a New Product weet eee irere ee hve oe a dete eee eee 26 4 6 1 1 Editing Target Weight in Automatic Set Point Mode 27 4 6 1 2 Editing Target Weight in Manual Set Point Mode 31 4 6 2 Editing an Old Productiva A aa 36 AO Edit PASS WOT O 2050 pd 5 we Bands eee so he aaa Bad als eee a ele Reena se eed 37 4 6 4 Take Product Sample das a tas las 37 46 3 Punt Produce Report 42 22 3000 e ia a A A ean 38 SA A a OR EE Re CSE ROR CR ORNS ERI HERS 39 5 1 Top Off F nctionality vita are Hawa PEA Oot aad Dus bee Gee Hee Hes 39 5 1 1 Disabling Top Om Function 2241445562 a ee a ON eke ro es he 40 5 1 2 Disabling Auto TARE Function 0 0 eee eens 40 2 Faller SeQUe NCGS td kus deena date re Menten AL se Oe Meee ee aS 40 5 3 Standard Input amp Output Configuration 0 eee eee nen eee 43 5 3 1 Alternate Output Configurations 000 IA ates GG E Gide ee Se AA ES 44 BASIC Operatii sess 05s WSR OSE SG Re Oe HERO OE EEE PRTG MOR SURE as Oe SRR M
130. nd then stop the production line when one bag is fully on the checkweigher conveyor Now count the bag on the checkweigher up to the bag currently on or just discharged from the fill spout Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 112 CURRENT FEEDBACK SAMPLE FREQUENCY IS 05 SAMPLES ENTER NEW FEEDBACK SAMPLE FREQUENCY MAXIMUM OF 100 AND ZERO IS NOT ALLOWED X RETURN TO PREVIOUS MENU Feedback Sample Frequency Parameters As an example of use let us say that there are 5 bags between the checkweigher and fill spout As production is being run the checkweigher will transmit each unit weight to the filler controller Once the Sample Count of unit weights have been received the filler controller will then induce any necessary correction to the next fill Any bags that are still in transit from the fill spout s location to the checkweigher and occurring after the Sample Count has been collected and before the correction has been induced at the filler cannot be used for feedback and are considered part of the Sample Frequency A 3 3 Correction Factor This variable dictates that actual amount of error that will be corrected from the last sample of bag weights It can be set to correct for 25 50 75 or 100 of the error Please refer to the example on the previous page PRES
131. nes show the current condition of the filler A typical sequence for this first status line will show REFILL during the time out required to refill the upper chamber with product Once this timer has timed out and the upper chamber valve has closed the status line will increment to READY indicating the filler is ready to fill a bag Once a bag is placed on to the fill spout and the bag sensor switch is actuated the filler controller zero s the scale and begins the fill At this moment the status line changes to BULK to indicate that Bulk fill is in progress If the filler has been configured for dribble the status line will indicate DRIBBLE as the filler changes states Upon completion of the fill and closing of the pinch tube the status line will again display REFILL to indicate that the upper chamber is refilling with product The second status line directly below the first provides status on any errors that may occur during the fill Unless an error has occurred this line is typically blank Errors detected by the controller are described in the trouble shooting guide in Chapter 7 These include No Product Flow Over Weight Error Discharge Inhibit and Abort These errors assist the operator or maintenance personnel locate the source of the problem with the filler The third status line directly below the first indicates whether the current fill cycle is a 1st Cycle or Normal Cycle fill A 1st Cycle fill is described in Cha
132. ntroller can be upgraded to include a TCP IP Ethernet port This port is fully bi directional and offers a re router routine for emulation of Ethernet streamed data as a serial port within the PC Command sets and data are the same as described for the remote product load feature found in Appendix C TSC Part Number 51 501 consists of the following components e 477 232 Traffic Control Card e DB 25 connector pre wired and ready to terminate on 477 card Serial to Ethernet converter e Mounted and pre wired 110 VAC to 12 VDC power supply Mounting bracket with converter and power supply attached Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 91 The Ethernet converter is intended to mount to the vacant space on the back panel just below the 4693 controller s CPU and Load Cell Digitizer card If the Ethernet port is purchased after installation of the 4693 controller four 4 mounting holes must be drilled to install the kit A 4 1 Ethernet Port Installation The Ethernet converter is configured with a dummy address and must be configured for use with your network You must use a straight thru serial cable to connect from the input serial port on the converter to the serial port on your PC or laptop The Ethernet converter requires a DB 25 Male connector Typically laptops and PC s require a
133. ny 4693 Gross Filler Controller User s Guide Version 11 0 Page 15 No Test Weight On Scale is displayed if the millivolt output of the load cell when the test weight is applied is either no different than or only slightly different than the reading without the test weight applied This usually indicates that either the test weight is too small the load cell is damaged or shipping links have not been removed from the scale There should be a minimum of a 2 5mV change in the load cell output from no test weight on the filler and the load cell applied A larger test weight may be used which should equal at least 10 of the full load capacity of the load cell Span At Either Max Or Min indicates that the digital potentiometer used to adjust Span is either adjusted to its minimum or maximum value and that the Span of the load cell cannot be captured This typically indicates one of two problems The first is that the size of test weight used in proportion to the load cell full load capacity is not adequate to induce the minimum required offset between the zero established in the first part of calibration and the current load cell reading The controller requires a minimum of 2 5 mV offset between the zero reading and the test weight applied reading Use of a larger test weight typically remedies the problem The second possibility is that either the 474 card or the load cell are damaged and should be tested and or replaced Cannot Write To
134. o be strictly followed to insure both personnel safety and proper operation of the equipment Please carefully read this chapter and chapters 2 amp 3 regarding mechanical and electrical installation and controller configuration before attempting to install or operate this equipment 1 1 Electrical Requirements amp Wiring Methods The 4693 controller requires 110 VAC power from a dedicated branch circuit breaker rated at 15 Amps Max This breaker is to be used as the primary means of disconnecting power from the controller when preforming maintenance Please practice safety when working on or around this equipment The 4693 controller does not typically require an isolation or power conditioning transformer Power from 89 to 130 VAC 50 60 Hz is acceptable Minimum wire gauge for supply wiring is 16 Ga stranded conductor provided with an Earth Ground Solid conductors should not be used Although isolation or condition of incoming source power is not normally required the controller is sensitive to static discharges Potential sources for static include Dust collection duct work Product supply or intermediate supply bins connected to the filler Product flow through the filling machine chamber fill spout etc Properly installed and maintained grounding and drains should be used to eliminate these static discharge sources All wiring routed to or from the 4693 controller must be provided in accordance with National Electrical Code
135. of the problem Another common source of static is dust collection duct work If this duct work is constructed of PVC pipe there is no means to drain the static charge to ground and the build up of static may actually be potentially harmful to operators and surrounding equipment EMI RFI fields Electro mechanical interference amp Radio Frequency interference are potential sources for pulse discharges that can disrupt the 4693 controller s CPU card Sources such as dirty or worn contacts on relays motor starters solenoid valves or other inductive devices that turn on and off near the filler may generate enough of this type of field effect noise to reset the 470 CPU Placement of snubbers quench arc devices across the coils of these devices may snub the field effectively and solve the problem Defective 470 CPU card As with other devices using microprocessors our 470 card uses support electronics such as memory buffers filters etc to run in conjunction with the program chip and microprocessor chip on this card If one of these components fail it may cause the processor to loose its place in the program process and then stop and reset Remove all cards from the card rack except the 470 CPU and the 472 Power Supply Apply power to the controller and observe operation of the display and CPU card If the problem is resolved it may also be another card within the rack that is causing the CPU to crash Turn power off and replace one o
136. off weight With this in mind an option is presented to operate the filler in a Bulk Only mode instead of the standard Bulk and Dribble mode Typically the Bulk Only mode produces final fill weights only slightly less accurate than with both Bulk and Dribble but greatly reduces each fill cycle time thus increasing overall production rates Bulk and Dribble produce the most consistent and accurate fills and rely on a pre set Dribble time of 4 0 seconds The filler controller will automatically calculate a Bulk Cut off point that will deliver three 3 seconds of Dribble Dribble only fill is available for applications filling both large and small containers on the same packaging machinery Bulk flow rates may be too high to accurately fill a small container and so these particular products can be set to fill in a Dribble Only mode A word of caution Some filling systems use a two stage Bulk Dribble air cylinder to operate the pinch tube These cylinder arrangements require going to Bulk before changing to Dribble in other words you cannot go directly to Dribble from a closed position Running in Dribble Only will cause the pinch tube cylinder to actuate to Bulk for a split second before changing to Dribble fill The final variable Fills TARE allows the filler controller to perform successive fills without taking a TARE at the beginning of each fill As a default the value for this variable is set to one 1 which causes a TARE to be taken
137. onitors the load cell within the filler converts the analog output of the load cell to digital information and transmits this data to the CPU Signal conditioning and filtering are provided as part of this card A serial EEPROM is also contained on this card for storage of Audit Trail information on calibration As with the I O cards an address connection is provided to configure a second 474 Scale Digitizer card on systems configured for dual spout fillers Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 7 Optional Intrinsic Safety Barriers can be used to protect the load cell for use in Hazardous Environment Applications Contact Thompson Scale Co to discuss your specific environmental needs 476 Interface Board This board is mounted outside of the card rack and provides a point of interconnection for the front panel keyboard LCD display and 470 CPU Circuitry is provided to power the LCD display and back light via a Inverter mounted to the 476 Interface Board Keyboard information is read via a dedicated CPU mounted to this board which converts key strokes to serial data which in turn is transmitted to the 470 CPU This keyboard serial interface plays an important role in Hazardous Environment applications The 476 Interface board has been designed to accept Intrinsic Safety Barriers across th
138. ort Sample o 38 Product Recipe Screen icri merret A whe DP bee Shed oe 110 Product Sample Menu ic ere eee Ue eee PY eee Pe ee ee MEAS URL Sea Pyne eo a eared 38 Remote Port Schematic ss 5 bs wags os eee td ha a eee eth eb anaes 83 Secondary Configuration Menu 1 ec eee ennnnene een eb eben eee e eee ee eae 73 Select Edit Main Menu 3 2 5 2s 03 Saved ee emnene bee So ae ee de ee Pa ede eee Ge bbe ne eee dents 26 Setting Dile pegs cee Bo A A oS ar er bev ke a GE revi mee GS ahs 24 Setting Optional Manual Setpoint Weight Limits 0 0 0 eee cece eee een eae 34 Setting Optional Weight Limits 28 Setting Placer Dwell aeria eed Sak oh ee SO ia 24 Setting Recipe Values lt 5 29 aeeea geen ee BOS ees Wenig ba eos oH Pb ee OS ES Gr Pig eae OA OS ey 32 Setting Target Weight err seta wages never aed hela A Seer ed cee ota dl are 28 Setting Times 922 564 A A pha erate sete HM A ees G24 SEV EA SRS RIM oes 23 Setting Traffic Control Timers e des 25 Statistics Data Menu m 5 32 aren sy vig a gs ena eee SEG e obs he eH EA vig RE OS hy 60 Traffic Control Menu 2 5 0 3 5 helactine escent Mt wee where eds Do ae ee todd Bd waa ene eet dis eee 56 Unit Weight Listing Report sirde csini seed a ee ees bee be eve wea deed bbe Woes 61 Chapter 1 Important Installation Information WARNING THIS EQUIPMENT IS TO BE INSTALLED AND SERVICED BY QUALIFIED SERVICE PERSONNEL ONLY Instructions within this manual and attached drawings are t
139. ot must hold the START input ON throughout the fill This is described further in the sequence as well The 4693 controller actuates the bag clamp for that spout and turns ON the FILLING output on the 477 card At the end of a successful fill the 4693 controller will complete the fill raise the bag clamp and turn the FILLING output OFF The Robot retrieves the filled bag When the bag is clear from the spout the robot turns the START input OFF There are two conditions that will cause the Broken Bag output to be actuated The first is a mis spouted bag and the other is a fill that exceeds the broken bag time or rate of change set in the 4693 controller A mis spouted bag is a bag that does not block the filler s bag in place sensor This sensor may be a limit switch photo eye or proximity sensor and is wired to the 4693 filler controller s input for the corresponding spout Once a bag is placed onto the spout this sensor must be blocked and remain blocked throughout the fill If the sensor becomes unblocked at any time during the fill the fill will be aborted and the Broken Bag output on the 477 card will be actuated Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 102 he The 4693 controller also contains a timer setting for the maximum fill time allowed for the fill If
140. out Purge or time to blow remaining product in the spout into the bag An Auger filler has a Reverse Plug feature that actuates the coil of a reversing motor starter The two choices available for Set Filler Type are Air Packer or Auger Filler The default setting is Air Packer 10 2 5 Set Language Menu structures within the 4693 controller are English by default Selecting Spanish from this menu setting will change all controller menus to Spanish Weights timer settings and other system variables are unchanged when selecting either language A controller set to Spanish can be easily changed back to English to perform trouble shooting or other maintenance and then switched back to Spanish when ready to operate 10 2 6 4693 Test Routines Many times it may be advantageous to manually confirm the operation of any or all of the 4693 s Inputs and or Outputs and printer functions This menu selection allows for several types of tests Test 473 I O Card Test 477 VO Card Test Fill Routine On Off Test Printer Remote Port TPAS Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 76 10 2 6 1 473 I O Test Test 473 I O Card provides two distinctly different types of test procedures 1 473 Card Rotating ON Test 2 473 Card Rotating ON Test 1 473 Keyboard ON Test 2 473 Keyboard ON Test I
141. ovided by Thompson Scale We also offer this same service for our customers with other types of printers at a rate of 35 00 per hour in 1 2 hour increments Thompson Scale will not warrant or be responsible for service repairs or support of printers other than those provided by Thompson Scale Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Chapter 9 Spare Parts Following is a list of parts for the 4693 filler controller Recommended spares are preceded by an asterisk Part Number Description 200 031 3AG 1 Amp Glass Fuse 200 032 5mm x 20mm 2 Amp Fuse for 5 VDC on 472 Power Supply Card 200 030 315mA Fuse for or 24 VDC on 472 Power Supply Card 470 CPU Card 472 Power Supply Card 473 VO Card 110 VAC 573 VO Card 24 VDC 474 1 Single Scale Digitizer Card 474 2 Dual Scale Digitizer Card only available with certain systems 476 Interface Card 477 422 Traffic Control Card If used with your system 471 Busboard 200 0243 LCD Graphics Display Module 4693F 30 080 Keyboard Overlay mounted to Fiberglass door 4693F 30 081 Complete Door Assembly w Display amp 476 Board amp Keyboard 200 049 CPU to Display Ribbon Cable Assembly 200 014 5 Pin Terminal Plug for 472 Power Supply card 200 103 8 Pin Terminal Plug Green 200 105 10 Pin Terminal Plug Green 473 card 200 110 10 Pin Terminal Plug Black 474 card 200 111 10 Pin Terminal Plug Orange 477 card 200 106 12 Pi
142. pany 4693 Gross Filler Controller User s Guide Version 11 0 Page 108 Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Appendix D Checkweigher Feedback For Gross Filler Controller A 1 Feedback Description The Thompson Scale Model 4693 Filler controller with Version 8 8 Gross filler program or higher has the ability to receive weight data from a remote checkweigh scale and perform internal feedback based upon this data This feedback feature will override the internal auto correction routines normally used by the 4693 controller PLEASE NOTE The feedback feature is offered in version 8 8 and higher and is only intended for Single Spout filling systems If your system has two or more fill spouts please contact the factory for information on multiple spout feedback options This feature is automatically engaged whenever the filler controller is configured to run in the Automatic Set Point Mode and will operate if the controller is set to run in the Manual Set Point Mode but ONLY when Autotrack is ON If Autotrack is turned off this feature will become disabled A 2 Hardware Interconnection To enable this feature in the 4693 controller a 477 Traffic Control Card must be installed into the controller card rack and jumpers must be installed on the card s upper 12 pin connector Jumper settings are Pin 11 to Pin 12 Upon powering up the 4693 controller a message will appear o
143. power discharge chairs the bag will automatically discharge from the spout If at any time during the fill you need to stop the filler hit the STOP switch This will stop the flow of product raise the bag clamp and discharge the bag if equipped with power discharge chair Hitting the STOP switch once to stop the fill will also cycle the refill valve If you need to regauge product flow and call a Ist Cycle hit the STOP button a second time This will tell the controller to initiate a 1st Cycle on the next fill on that spout Another easy way to stop production filling is to hit the front panel Esc key on the controller This takes the display out of the Run Filler screen and into the Main Menu Since the filler will only fill in the Run Filler screen the fill or fills will stop when they reach weight and will then dump when a bag is in place Once the product is dumped the controller will not start again until you are in the Run Filler screen and hit the START button or buttons Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 48 6 3 2 Topping Off a Partially Filled Bag The 4693 controller can be set to either finish off the fill of a bag from nearly any starting point or to fill the bag to the desired target weight regardless of the weight or where the fill starters Please read the beg
144. pter 5 and basically re gauges product flow for setting bulk and dribble cut offs Normal cycle is any cycle that is not a 1st Cycle 4 4 3 Product Status To assist the operator current product information is constantly displayed This information is found directly below the status display and above the boxed in production data Information displayed here is the Net Target Weight currently being filled and current product number and product name Both pieces of data are entered in Main Menu item 5 Select Edit Product 4 4 4 Production Data The 4693 Filler Controller offers instant status on the filling operation by displaying three 3 important pieces of information on production Contained in a box on the lower half of the Main Fill Display are status on Units per Minute Total Units and Total Weight Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 21 Units per Minute is updated every 30 seconds and provides the operator and supervisor with status on current production levels This value is achieved by averaging the number of units that have occurred over the past 30 seconds and added and averaged with data collected from previous minutes If the operator stops production for any reason this value will begin a steady decline in units minute until it finally reaches 0 Also when production first be
145. put whenever a fill is complete and the packer is waiting for a new bag to be placed on the spout For some types of placing equipment and inverted signal is required Selecting this configuration menu item will open a new window offering two interface modes BAG PLACER INTERFACE MODE PRESENT RUNNING NEW BAG 1 NEW BAG REQUEST SIGNAL GOES HIGH AT START OF FILL STAYS HIGH UNTIL NEW BAG ON SPOUT 2 FILL COMPLETE SIGNAL GOES HIGH AT END OF FILL STAYS HIGH UNTIL CHAIR IS DISCHARGED Esc RETURN TO MAIN MENU Placer Interface Menu By selecting the Fill Complete interface the placer must also be configured for this type of signal Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 80 10 2 0 Set Auto Manual TARE As a default the 4693 controller is programmed to take a TARE at the beginning of each fill This allows the filler controller to eliminate variances seen by product building up on the scale and bag post assemblies and to remove unwanted influence and weight from product residing within the spout Some applications more specifically Auger Packers may find that influence of product between the fill auger and spout vary too much to allow the controller to automatically TARE between fills In these cases setting the controller to Manual TARE will provide the operator with a
146. quest Vibrator Settling in place of Refill valve Typical for Auger Packers Auger Reverse in place of Spout Purge Typical for Auger Packers Fill Complete Signal Depending upon type of bag placer interface required placer may require a signal to indicate that the fill is complete as opposed to requesting a new bag std config Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Chapter 6 Basic Operation This chapter is dedicated to the non technical operator who is simply looking for information on the day to day operation of the filler controller There s no in depth discussions on why it works just simple straight forward information on how to work with the controller in a production environment 6 1 Finding Your Way Around The filler controller has 6 Main Menus These menus are 1 RUN FILLER 2 CHECK CALIBRATION 3 CALIBRATE FILLER 4 EDIT TIME DATE PLACER DWELL TIMER 5 SELECT EDIT PRODUCT 6 FLOW RATES Or Statistical Data if your system has that option No matter where you are in the system hitting the Esc key on the front panel will always take you back one step from where you are If you hit the ESC key enough times you will get to the Main Menu From here you can get to any other place within the controller Most of the time the controller will be in the Run Filler menu This is where you must be to fill bags To enter the Run Filler screen hit the nu
147. r the filler controller to conduct an accurate calibration Typically what will be seen is an Error of NO TEST WEIGHT ON SCALE or SPAN IS AT MIN OR MAX CONTACT FACTORY This indicates that the amount of test weight applied to the scale did not generate enough of a signal to complete calibration The filler controller requires a MINIMUM OF 2 5mV OFFSET between the empty filler and the applied test weight Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 54 Using a digital multimeter set the meter to VDC and select mV range Place the Positive lead on the SIG terminal of the 474 card Place the Negative lead on the SIG terminal of the 474 card Note the millivolt reading Now apply the test weight and measure this signal again If the value has not changed by at least 2 5mV more test weight is required Defective Load Cell To check the load cell first use a voltage meter set to mV millivolts With power on place the negative lead of the meter on the load cell Signal terminal and place the positive lead on the Signal terminal Millivolt reading should be approximately 7 to 14 mV depending upon the type of filler If this value is equal to or less than zero it indicates that there is no load on the cell This can mean a mechanical problem or a defective load cell If the reading is a
148. red DB 25 connector on the 52394 enclosure must be connected to the printer and all three devices 4693 filler controller 52394 serial converter and dot matrix printer must be plugged in and powered up Yellow LED ON Printer On Line OFF Printer Off Line Green LED ON Data line in Marking State OFF Data line in Space State Red LED ON Data line in Space State OFF Data line in Marking State If the Yellow LED is on indicating that the printer is On line and ready to receive data then the Green and Red LED s will toggle back and forth to indicate when data is being transmitted If the Green LED stays on no data is being transmitted 8 2 2 5 Printer Configuration Thompson Scale strongly recommends purchasing the printer that comes with our optional STPR package This printer is field proven pre configured and warranted by Thompson Scale If however another printer is preferred the following specifications must be adhered to The STPR Interim and Final reports are heavily formatted to provide a pleasing and organized report Due to this formatting it is critically important that your printer has the capabilities and features required to handle the text and graphics commands transmitted by the 4693 controller Some years ago Thompson Scale selected between two distinctly different emulations that were considered standards by the industry These two types are IBM emulation or Epson emulation We selected the Epson emu
149. refill valve is opened and the refill timer is loaded with the time value set for the product type currently running e The DRIBBLE status indicator is turned off and the REFILL status indicator is turned on f The controller measures Dribble feed rate or Bulk in Bulk Only fill and averages it into previous measurements 14 After the timer has timed out for the purge solenoid valve the valve is closed and the controller again runs Settling Time to allow the filler and bag weight to stabilize The controller then calculates the current Dribble overfeed and averages it into previous measurements adjusting the Dribble overfeed for the next fill cycle 15 Once Settling Time has expired the controller also measures the GROSS weight of the bag and subtracts the TARE value stored directly before the beginning of the fill cycle A NET weight is then displayed as the final fill weight of the bag 16 The bag clamp is released and the controller looks to the input card for an inhibit discharge signal If none is found the bag chair is actuated and the filled bag discharged A 1 Cycle is automatically invoked whenever a process error is detected over weight error no product flow or when changing from one product type to another The 1 Cycle can also be called manually be pressing the Stop Abort switch twice when between fill cycles This should be done in cases when changes in low pressure air are made or when product bulk density or
150. reliable and repeatable TARE value at the beginning of each fill is not possible By setting the controller from Automatic TARE to Manual TARE the operator can clear the filler to present an empty auger and fill spout then follow prompts on the display to take a TARE This TARE value is then stored in memory and used on all subsequent fills until the next Manual TARE is taken See Chapter 10 for more information on setting this value 5 2 Filler Sequence When set to the Automatic Set Point Mode default the 4693 Filler Controller automatically calculates Bulk and Dribble if used flow rates by using a unique programming sequence that actually measures flow rates of products in a diagnostic mode called 1 Cycle This mode also measures factors such as pinch tube air cylinder performance offsets induced by the auger screw and or bag chair and other mechanical influences and air pressure Once all factors have been tested they are used to develop the proper time periods to operate the filler in Bulk and Dribble modes to produce an accurate final fill weight There are no set points or pre act values required The operator simply inputs Net Target Weight and the filler controller does all the necessary calculations When in the Manual Set Point Mode the operator enters Target Weight and Preact for Bulk Only fills or Target Weight Bulk Cut off and Preact for Bulk and Dribble fills When in the Manual Set Point Mode there is no need to run a 1
151. report is based on weights from the Ist fill to the last unit to that filled before the report is called Data is not lost when calling an Interim report Reports print automatically and contain a heading labeled INTERIM REPORT A sample of this report is shown on the following page Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 62 8 2 2 3 Final Report At the end of a lot or campaign the Final Report is called This report is identical to the Interim report format but has two distinct differences First the heading at the top of the report is labeled FINAL REPORT Second once the report is completed all data for that reporting period is erased from memory Final reports must be called before changing product set up s When entering the Enter Edit Products menu to change from one product set up to another a prompt will appear stating that statistical data will be lost if a report is not called before changing product set up s Although STPR can hold approximately 65 000 unit weights in memory it cannot overlap data from two different product types If this were done data within a production report would be meaningless When the final pieces of data for the Final Report are transmitted to the printer the controller resets all counters and the elapsed time clock This clock will not begin running agai
152. rint Interim Report Print Final Report Print Product Set Up Listing Clear Statistical Memory destroys data collected to this time Load Existing Product Number from EEPROM to Run Load Number of Fills Per TARE 01 to 99 Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 106 C 3 1 Entering or Editing A Product Each product set up within the filler controller contains specific data fields that must be loaded with information before that product number can be called to run as the current product The current product is defined as the product parameters you will be filling to on the next fill Each product set up contains a set number of data fields These fields occur in the specified order shown below Customer Name Product Type Target Weight Bulk or Bulk Dribble Refill Timer Bag Chair Timer Broken Bag Timer Weight Conversion Number of Fills TARE Settings for the Bulk or Bulk Dribble and Weight Conversion offer one of two choices each These two choices are defined as Bulk Only Fill 00000 Bulk amp Dribble Fill 00001 Lbs Weight Conv 00001 Kg Weight Conv 00002 The refill timer bag chair timer and broken bag timer have limits as to maximum allowable time These are Refill Timer 0 0 to 15 0 Sec 10 sec timer would 00100 Bag Chair Timer 0 0 to 15 0 Sec 1 sec timer
153. roller User s Guide Version 11 0 Page 53 Over Filling of bag This is a very common problem Once the product has been fluidized in the upper chamber it may not fit properly into the bag There should not be any spillage or product during the Dribble cycle near the end of the fill If product spills out around the fill spout and or falls out of the bag and spout once the bag has discharged you may need to increase the bag size or reduce entrained air effectively reducing the amount of particle division and increasing density An excellent test for under sized bags is as follows Reduce Target Weight by 10 lb Using the same bag and product fill 10 bags at this lower weight If bag weights are consistent then you may be over filling your bags at your required target weight Do not under any circumstances hit pat kick or press on the bag during the fill cycle This will have a direct affect upon final fill weight and will cause the controller s auto correction routine to induce an offset to fill weight for the next bag 7 1 4 Unable to Calibrate Filler Loss of power source for 474 Load Cell Digitizer card The 472 Power Supply card generates a 24 VDC and a 24 VDC power source for the Digitizer card s With power On check the indicator lights on the face of the 472 Power Supply card If either or both of the 24VDC or 24VDC indicators are OFF this indicates that the fuse for that circuit is blown Before replacing the fuse remove
154. ross Filler Controller User s Guide Version 11 0 Page 31 As the final weight of each filled bag is determined the error from Target weight as compared to this final value is stored in memory These errors are then averaged together and 1 2 of their value is applied to the correction of the next fill For packers with very good flow rates and accuracies a setting of 2 3 or 4 samples would provide a quick response to any changes detected in the flow rate of your product keeping the final weights on target For packers running products that perform poorly higher settings of 8 9 or 10 would slow the response to change effectively reducing the possibility of over correction It is always wise to start with a median value of 5 and then analyze production and adjust this value accordingly You are also presented with the option to choose either Lb or Kg conversions Although Ounces and Grams are shown on the display they are not available with this model of filler Weight values can be entered in either conversion and changed without affecting the accuracy Once all data has been input press X to return to the new product main menu This menu allows two options for exiting back to the main menu The first choice is to select L to load the new product to run This saves all data entered and loads it as the current product to be run by the filler In cases where several new product set up s are being entered within these menus select X
155. rotocol 9600 baud 8 data bits 1 stop bit and no hand shaking Parity none 1 Stop Bit Flow Control none Generate a weight on the 4693 Filler by starting a fill and or simulating a fill by pressing on the fill spout till the fill completes Confirm the weight data is being received in Hyper Terminal Setup is complete If you are unable to connect or have difficulty with these configuration steps contact Thompson Scale s technical support team at the number shown at the bottom of this page Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 94 Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Appendix B Broken Bag Detection Option The broken bag detect feature is activated by adding a 477 Traffic Control card to the controller s card rack The address pins on the top connector of this card must be set as follows Pin 12 jumpered to Pin 11 jumpered to Pin 10 On power up the controller s screen will display the message Broken Bag Card Detected if the 477 card is present and properly addressed There are two different methods for detecting a broken or mis spouted bag on a valve packer fill by time monitoring and change in rate Both methods are described below B 1 Broken Bag Timeout Detection Depending upon the
156. rst look at the mechanical parts of the filler The bag post should be free and clear the flexure assembly and load cell should not be in a bind and the isolation bracket between the pinch tube cylinder and fill spout should be secure Go into the Calibration Check screen and zero the scale Push down on the bag post and release the scale should return to zero If it does not then there is a mechanical bind somewhere in the structure Examine and eliminate the restriction and repeat the test Other suggestions are listed below The rubber pinch tube may be worn out or improperly installed causing the pinch tube to bow inward Actuate the Bulk and Dribble solenoid valve s to open the cut off cylinder s Make sure that blowers for Air packers and motors for Impeller packers are OFF first If the pinch tube does not quickly spring to full open it may require replacement Many times in systems running Bulk and Dribble the pinch tube collapses so badly during the Dribble fill that virtually no product gets thru Dribble feed rate too low If the fill valve Dribble position is set too low the proper amount of product may not be entering the bag Dribble fill rates are displayed in Main Menu 6 See Chapter 8 for more information on interpreting fill rates Defective pinch tube cylinder If the cylinder is binding or not operating consistently then too much time may elapse between changes in position Repair or replace the cylinder or solenoid val
157. s possible for air and product pressure in the bag to require a Negative Preact An example of this would be a fill to 50 00 lb When the controller sees 50 00 Ib in the bag it turns off the fill Pressure within the bag deflates quickly and the final weight of the bag is actually 49 50 lb In this case a Negative Preact of 0 50 lb would be required The filler would then fill to 50 50 1b then turn off Once the bag deflated the final weight would be 50 00 6 3 1 Start and Stop Switches If your controller is operating a single spout system there may be a push button box on the filler with START and STOP push buttons a auto start limit switch that is actuated by the bag or the system may use the START and STOP ABORT buttons on the controller s front panel In either case these switches all work the same A dual or multi spout filler must have a separate START and STOP for each spout In this case the front panel start and stop abort keys on the filler controller don t work When you are ready to start production make sure the controller is in the Run Filler screen and place a bag onto the fill spout If an auto start switch is used the bag clamp will automatically actuate and the fill will begin If your system uses the START and STOP push buttons then place the bag on the spout and hit the START button The controller will automatically fill the bag to weight and then raise the bag clamp If your system is equipped with
158. s under the low limit or above the high limit an error will be displayed in the Run Filler screen and the bag will be handled through settings made for discharge of a broken bag See Appendix B for a description of the broken bag detection option and settings for handling discharge of these bag types Item 3 Chair Return Delay pertains to operation of the power discharge bag chair if any The bag chair actuator will be energized for the period of time set in this timer Typically the timer is set to a value between 0 7 and 1 0 second If a longer time is required simply increase the amount of actuation time Setting this timer to 0 0 will leave the chair in the fill position and will not actuate the chair at the end of the fill cycle Item 4 Refill Valve Time is for air packers using a butterfly or refill gate at the top of the upper chamber and is used to set actuation of this valve for a minimum time required to refill the upper chamber Each product run through your filler has its own unique characteristics and flow rates This adjustable timer is provided to allow the operator to set the optimum time required to refill the upper chamber of the filler The refill valve timer sets the minimum amount of time required to refill the upper chamber The valve will be actuated at the moment the Bulk or Dribble pinch tube cut off is closed to allow the chamber to refill at the earliest possible moment in the fill cycle However the refill valve
159. screen If discharge inhibit is not on bag clamp is released If discharge inhibit is not on bag chair is actuated for time set in product recipe B 5 Broken Bag Interface to Robot The following section describes the hard wired interface between Thompson Scale s Model 4693 filler controller 477 Traffic Control card I O and a robotic articulating arm for placing removing and palletizing bags from a valve Gross packer Past applications of our filler controller and robot have involved a set of two adjacent fill spouts and one robot The 4693 controller is configured to operate as a dual filler controller operating both spouts simultaneously and independently The 477 Traffic Control card is an optional card installed into one of the remaining slots in the 4693 controller s card rack The 477 Traffic Control card contains two sets of terminals The upper twelve pin connector is a serial communications port intended for interface to the robot and is addressed in detail in a separate document The lower 10 pin connector is for connection of 110 VAC I O between the two control systems This card contains four 4 Inputs and four 4 Outputs Two of each are dedicated to each spout although only the Outputs of this card are used to interface to the robot IMPORTANT NOTE The 477 Traffic Control card is a multi purpose card and must be properly configured to operate with the robot Address jumpers on the top 12 pin connector must be in pla
160. se with an Auger Packer this timer is disabled As a purchased option item 5 Broken Bag Timeout detects that the current fill has exceeded the maximum allowable fill time and is aborted This is a feature commonly used in conjunction with unmanned automatic bag placers or robots See Appendix B for more information on this feature If this feature has not been purchased or configured this menu item will not be displayed Item 6 Vibrator On Off is enabled through the configuration menu 2 item 8 Enabling this feature in the configuration menu will make item 6 appear in the product recipe Certain applications and fillers are equipped with either a pneumatic or electrically controlled vibratory settler on the bag chair or saddle This vibrator assists with settling a fluffy or bulky product into the bag during the fill Timing of the vibrator is handled internally by the 4693 controller The fill begins and at the earliest possible moment the vibrator is turned on and run to within one 1 second of either cut off or change over to Dribble fill If this feature is not enabled in the configuration menu this recipe menu item will not be displayed Item 7 Of Filter Samples sets the number of past fills to use when calculating error correction for the next fill This value is adjustable from 02 to 10 Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 G
161. st eight are displayed in the initial configuration screen To access the remaining sub menus select item 8 Get The Next Menu to display the secondary screen 1 SET SAMPLE RATE 2 SET FILTER FREQUENCY 5 3 SET MAX PRODUCT NUMBER 4 SET 1 A D GAIN 5 SET 2 A D GAIN 6 SET DECIMAL POINT 7 INITIALIZE A D SERIAL EEPROMS 8 GET NEXT MENU Esc RETURN TO MAIN MENU Configuration Menu Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 72 10 1 1 Setting Sample Rate Internally the 4693 controller makes over 200 analog to digital conversions per second This is a read of the load cell output and conversion to a digital value by the 474 card s circuitry which is then transferred to the 470 CPU Sample rate setting selects the number of samples used in weight averaging routines and in the base filler program The factory default for this setting is 100 samples per second Sample rate has an adjustable range up to 150 samples per second but it is recommended that this value be kept between 80 and 100 The higher the value the more time required by the CPU to extract the next A D conversion and average it into the filter A value above 120 may produce delays in other areas of the fill routine such as finding steady scale at the end of the fill or zeroing routines 10 1 2 Setting Filter Frequency The 4693 controller contains a 4 pole low pass filter that offers and adjustable frequency from 1
162. stency from fill to fill If using Dribble fill this value should be between 40 and 60 of the Bulk fill rate and should be consistent from fill to fill If not examine the position of the pinch tube cut off assembly during the Dribble portion of the fill and adjust accordingly As with any diagnosis of a problem make small single changes and watch carefully before attempting to make other changes To access flow rates go to the Main Menu and select 6 Flow Rates The following screen will be displayed Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 59 DISPLAY BULK AND DRIBBLE FLOW RATES 1 DISPLAY SPOUT 1 LEFT 2 DISPLAY SPOUT 2 RIGHT 3 CLEAR ALL FLOW RATE BUFFERS ESC RETURN TO MAIN MENU Diagnostics Sub Menu In single spout filler systems this menu will offer only one spout to choose as well as the option to clear the buffer or exit from the menu Selection of a spout will advance the screen to the next display shown below FLOW RATES FOR SPOUT 1 BULK DRIBBLE 12 8 6 2 12 6 6 2 12 9 6 5 12 8 6 3 12 7 6 2 X RETURN TO MAIN MENU FLOW RATE SCREEN The flow rate screen is used as a diagnostics tool when trouble shooting the filler for inaccurate bag weights Flow rates are categorized as Bulk and Dribble In cases where Dribble has been disabled
163. the bag This is usually caused by a blockage in the feed or it could be that we can t read the load cell properly Check to see if the pinch tube clamp is open and the blower or impeller or auger motor is on before trying to clear this error OVERWEIGHT The controller constantly tries to predict exactly when to shut ERROR off product flow to get a perfect fill If a big clump of product falls into the bag at the end of the fill we might over shoot Target weight This could also happen if the flow rate of the product changes very quickly during the fill In either case we know we have gone over weight so the error is displayed and the controller automatically calls a Ist cycle DISCHARGE The filler may be equipped with an interface signal that stops the INHIBIT bags from discharging if the take away conveyor is off or in multiple spout systems the traffic control may hold the bag until another one passes below the fill spout TARE FAULT A TARE FAULT occurs when a partially filled bag is placed onto a fill spout This error will be displayed on three top off fills in a row but will stop the bagger from working if you try to top off a fourth bag This keeps the controller from loosing track of a good zero on the empty bag weight 6 5 Other Important Items If you wish to stop the filler to do maintenance hit Esc to go to the Main Menu The controller will not fill if it is not in the Run Filler screen It is also advisable to turn the filler
164. the last TARE If the container weight is more than 2 off from the last TARE the previous fill s TARE is used and the container is filled to Target weight Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 40 There are a few restrictions 1 A partially filled bag should NEVER be placed onto the filler during a 1 Cycle described below This would adversely affect the accuracy of the 1 Cycle readings and could possibly produce off spec bags 24 No more than three 3 partially filled bags can be filled consecutively That is to say once the third partially filled bag has been completed a new empty bag must be filled This is done to avoid any problems that may exist with a drastic change in the empty bag weight from one lot of bags to another 5 1 1 Disabling Top Off Function Some applications such as certain types of auger fillers may require disabling this feature since the TARE weight may vary substantially from fill to fill even under normal circumstances A variable in the 4693 controller s configuration menu secondary configuration menu item D allows the user to disable this function See Chapter 10 for more information 5 1 2 Disabling Auto TARE Function Som applications such as certain types of auger fillers may experience undue influence of product against the fill spout especially when the auger reverses to stop or plug product flow In these applications taking a
165. the load cell terminal block from the face of each 474 card With power Off remove the 472 Power Supply card and replace the blown fuse These fuses are small rectangular brownish red opaque fuses found on the left side of the card The card is marked with these fuse locations and output power value and a spare fuse is found adjacent to each Replace the 472 card and turn controller power On If the fuse blows again it indicates that the voltage regulator or other component on the 474 card is defective and the card must be replaced If the fuses remain intact and the indicator lights stay on turn power to the controller off and plug one of the load cell terminal blocks back onto the 474 card Turn power back on If the fuse blows again it is an indication that the load cell cable may be cut or pinched shorting wires together or that the load cell itself is defective Defective 474 card Although this is not normally the case digitizer cards may be swapped out to determine if the card is indeed defective Bad serial EEPROM Each 474 card contains a serial EEPROM responsible for maintaining data on each calibration of the filler If the controller displays the message DIGITIZER 1 OR 2 NOT RESPONDING REPLACE CARD the serial EEPROM is not being properly read Not enough Test Weight Most but not all fillers can be calibrated with a standard 50 lb or 25 kg test weight In some cases this test weight may not provide enough signal fo
166. this option Broken Bag Detection Applications using automatic bag placers or robotic placers may require monitoring of fill status to detect and abort fills on either mis placed or broken bags This optional feature will quickly and reliably detect either a fill that has taken longer than normal to complete and or a fill that does not maintain a certain fill rate for the bag Refer to Appendix B for more details on this option Robotic Placer Interface As with the Broken Bag detection the robotic placer interface monitors fill progress on each bag In addition specific I O interfaces to the robot can accommodate either placers or robots that place empty bags and take away filled bags from the fill spout Refer to Appendix B Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 8 Remote Product Recipe Loading Using this option product recipes target weights settings for bulk or bulk amp dribble chair discharge timers etc can be created in the user s PLC or PC and then loaded into the 4693 controller A set of pre defined serial commands offer the ability to call reports create new recipes or call existing recipes from a remote location Applications with a central HMI or control room may find this feature beneficial since automated commands can be created from within the remote control system
167. tion on the model number and current version Once the STPR upgrade chip has been installed into the 470 card replace the card in the rack and tighten the thumb screws to secure the card Upon power up of the controller you will notice that Main Menu item 6 is now available and ready for configuration The printer provided with your STPR package has been pre configured for use with STPR This printer has two 2 connectors on the rear of the printer one for the RS 232 connector on the printer interface enclosure and another for a standard Centronics parallel cable This second connector is not used The printer is not designed for use in production environments and should be placed in an office or storage room that is free from dust or other contaminants Place the printer on a desk or table with paper feeding from the rear and a clear space for collection of printed paper exiting from the printer All STPR packages include the printer manufacturer s operation and trouble shooting guide so please review before operating printer 8 2 2 4 52394 Serial Converter for Optional STPR Package The final component of this package is the 52394 serial converter STPR resident in the Filler controller transmits data to the printer via a 20mA current loop serial port digital data not to be confused with 4 20mA analog signals used with process equipment which is then converted by this box to RS 232 for use by the printer A 6 0 long cable is termin
168. to automatically configure the 4693 controller for the next or new production run Command sets and instruction on use are found in Appendix C Production Reporting Applications using two 4693 controllers to operate a 3 or 4 spout packer and using our optional STPR or StatPak PC data logging software must use the 477 card to consolidate weight data from all fill spouts Either the STPR or StatPak PC products connect to the filler controller via a serial port If two controllers are used for filling the 477 card is used to transmit weight data from the Trailing controller to the Leading controller so that all weight data is available from a single serial output port The traffic control I O portion of the 477 card does not need to be used and no special configuration of the 477 card is required to provide this functionality Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Chapter 3 Calibration Entering into Main Menu Item 3 allows access to the calibration procedure for this system While in the Calibrate Scale menu all filling operations are interrupted and will not continue until exiting back to the Main Menu Fill in progress when entering into the calibration check or calibrate filler menus will be completed 3 1 About Calibration The 4693 Filler Controller does not require the adjustment of potentiometers to set Zero or Span for the scale All adjustments are performed
169. to the 1 fill spout we only deliver samples on spout 1 When the auto start limit switch or Start push button is actuated the pinch tube will open for the time set and discharge product into the sample bag Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 38 PRODUCT SAMPLE SPOUT 1 LEFT SIDE CHOOSE ONE B OPEN BULK VALVE FOR 5 SEC D OPEN DRIBBLE VALVE FOR 5 SEC X RETURN TO PREVIOUS MENU Product Sample Menu 4 6 5 Print Product Report Filler systems that have the optional statistical analysis package installed see Chapter 8 will display menu item 4 in the Enter Edit Product Main Menu This feature will automatically down load all product data to your printer package providing you with a hard copy of product types entered into the controller This printout is also helpful in providing a work sheet of sorts for working out the details of each product type before actually entering the data PROD NO CUST LD TARGET FILL MODE REFILL 01 YOUR NAME LOT 12 50 00 LB B amp D 23 02 THEIR NAME BATCH 3 25 00 KG BULK 2 1 A E e Product Listing Report Reports will print only the number of products you have entered into the system If there are no products entered only the headings will print As with all menus in this controller hitting the X key will step you back to th
170. uction If a report is called as a lot is finished and another begins immediately the unit weights from the new lot will be queued until the report is completed Upon completion those values are taken out of the queue in the same order that they occurred and STPR treats each as if it had just occurred There is a very slight distortion of elapsed time on the first listing line or two because STPR always prints current elapsed time and transmission of the report may have taken one or two minutes to complete If the printer is inadvertently set Off Line due to paper out or loss of power during transmission of a report STPR will terminate the report transmission but will not clear memory on a Final Report It will then add the queued values to those previously collected The elapsed time counter will not be reset Keep in mind that the printer contains a buffer and may have received all data before going Off Line Do not turn the printer off Reload paper or correct the current problem and turn the printer back On Line The remainder of the report should complete printing Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 66 Optional Remote Report Switch As an option STPR can be provided with a remote report switch that enables the operator to call for a report at the printer s location instead of
171. ve The cut off cylinder s need to respond quickly and reliably Changing pressure in the upper chamber Due to defective seat on refill valve or other leak Check pressure directly before fill begins It should drop off approximately 2 lbs once the pinch tube is open but should remain constant throughout the fill Interference or binding of flexure assembly Can be caused by obstruction such as a loose air line or a restriction from product build up between the overload screw and stop Bridging or clumping material Make sure that the displayed weight increases consistently Check Fill Rates in Main Menu 6 Fills should produce consistent feed rates for both bulk and dribble If these rates fluctuate and there are not visible signs of mechanical or electrical problems check the product itself Changing head pressure in supply bin Auger and impeller packers may suffer from a problem with a change in the push given to product from the supply bin from above As with taking water from a water cooler when the jug is full water comes out very quickly When the jug is near empty water only trickles out If the supply bin product level changes from full to nearly empty during the fill process flow rates and bulk densities of the product change Try to maintain a constant level in the bin Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Cont
172. wires from the 470 PRINTER port are used for transmitting data The other two are used for PRINTER READY interface between the printer and the transmitting serial port STPR will not transmit data until the PRINTER READY signal is in the proper state If the PRINTER READY signal is not in the proper state and a report is called from the 4693 controller an error message will be displayed on the controller s front panel alerting the operator to the status of the printer This occurs if the printer is Off Line due to power out of paper condition or the printer being turned off line LED indicators are located on the converter board and confirm proper connection of the serial port When properly connected the GREEN LED will be on steady state When data is transmitting the RED and GREEN LED s will blink alternately The YELLOW LED indicates that the printer is properly connected and On Line Yellow LED ON Printer On Line OFF Printer Off Line Green LED ON Data line in Marking State OFF Data line in Space State Red LED ON Data line in Space State OFF Data line in Marking State If the Yellow LED is on indicating that the printer is On line and ready to receive data then the Green and Red LED s will toggle back and forth to indicate when data is being transmitted If the Green LED stays on no data is being transmitted Following are voltage references for the 52394 serial converter board If the printer is On
173. would 00010 Broken Bag Timer 0 0 to 30 0 Sec 0 1 sec timer would 00001 If any of these timer values are exceeded the filler controller will issue an error E01 Not Valid Data response A typical remote product load would involve sending data as shown below Number of Fills between TARE readings allows the filler controller to use an average of the first two 2 TARE readings on the next x number of consecutive fills This speeds the fill operation by as much as 1 to 2 seconds per fill Fills between TARE is a value from 01 to 99 A value outside of this set will result in an error NOTE Numbers must be sent as 5 BCD digits or 6 BCD digits if decimal point is sent For Example 50 00 lb Target Weight can be sent as either STX 003 050 00 CR LF or STX 003 05000 CR LF The decimal point will be ignored but will be received as a matter of convenience to the programmer Setting of the decimal point is done in the 4693 controller configuration menu Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0 Page 107 Hypothetical data entry for product 1 Customer Name Acme Brick limit 28 characters Product Type Dry Mix 50 limit 28 characters Net Target Weight 50 00 value between 0 00 and 200 00 Bulk or Bulk Drib 0001 bulk amp dribble Refill Timer 6 0 value between 0 0 and 10
174. y 4693 Gross Filler Controller User s Guide Version 11 0 Page 64 8 2 2 3 1 Production Summary Report Details Status Boxes Below the heading of Interim or Final Report there are three connected boxes containing data for this report These boxes are Product Lot No Customer and Date Time Each box is automatically filled in from data contained in the product set up run for this report Summary of Time This line is located below the current settings and status boxes and states the number of hours and minutes of production time included in this report This value is based on the elapsed time at the instant the report was initiated and is used to determine the number of units per minute in the production data below Summary of Production Most of the data contained in the summary of production box is self explanatory The far left hand box contains the titles of each block of data Data is based upon Net Target Weight and averages of time and final fill weights for all bags produced during this reporting period Distribution Graph Below the summary of production is a bar graph or histogram divided into 21 zones showing the total number of units that have occurred in each zone during this report The width of each zone is not arbitrarily set Instead it is calculated for each report so that the 21 zones cover a range of at least plus and minus 3 Sigma from the mean of the population included in this report For reports having a very s
175. y confirm that the weight is within acceptable tolerances The Net weight of the bag is then transmitted back to the filler controller for use in the feedback feature Received weight values are stored in a Que and acted upon according to several variables contained within the filler controller These variables are Sample Count Sample Frequency and Correction Factor and are found in the Product Set Up Menu for each product CHOOSE ONE 1 TARGET WEIGHT 50 00 LB 2 BULK AND OR DRIBBLE B amp D 3 CHAIR RETURN DELAY 0 70 SEC 4 REFILL VALUE TIME 2 3 SEC 7 ADJUST FEEDBACK PARAMETERS X RETURN L LB K KG Product Set Up Screen Entering into menu item 7 shown above will display the following set up screen for feedback FEEDBACK FILL PARAMETER ADJUSTMENT 1 ADJUST FEEDBACK SAMPLE COUNT 2 ADJUST FEEDBACK SAMPLE FREQUENCY 3 ADJUST FEEDBACK SAMPLE CORRECTION X RETURN TO PREVIOUS MENU Feedback Parameters When the proper number of weight values from the checkweigher are received set by Sample Count the filler controller derives the error by averaging these values then subtracting the Target Weight The final result is then multiplied by the Correction Factor to determine the actual correction to induce on the next fill Thompson Scale Company Houston TX Phone 713 932 9071 Fax 713 932 9379 Web Site www thompsonscale com Thompson Scale Company 4693 Gross Filler Controller User s Guide Version 11 0

Thompson 4693_"Gross"_Weigh Manual

Contents

Download Pdf Manuals

Related Search

Related Contents

Thompson 4693_&quot;Gross&quot;_Weigh Manual

Contents

Download Pdf Manuals

Related Search

Related Contents

Thompson 4693_"Gross"_Weigh Manual