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Summary of Contents for CBE 510
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Page 1: Customer Information
CUSTOMER’S NAME: Guar Resources Project#: Q10409 Customer PO#: 1090 Serial#: 140753 Model: CBE 510 BULK BAGGER Controller: ZM405 Electrical Controls: Electrical Motors: Air Requirements: 3.9 CFM @ 80 PSI per bag cycle Special Features: POWER LIFT... -
Page 2: Table Of Contents
Safety-Installation-Operation-Maintenance CBE 510 BULK BAGGER... -
Page 3: Table Of Contents
TABLE OF CONTENTS Topic Page Customer Information…………………………………………………………………………… Table of Contents………………………………………………………………………………… Quick Reference Information…………………………………………………………………… Picture of Equipment…………………………………………………………………………….. Important Notices for Startup Operation……………………………………………………… Warnings…………………………………………………………………………………………… Grounding Recommendations………………………………………………………………….. Recommended Spare Parts List………………………………………………………………… CHAPTER 1 General Information…………………………………………………………. Receipt and Inspection Caution Specific Requirements CHAPTER 2 Installation Guide……………………………………………………………. - Page 4 CHAPTER 7 PLC and Timers Adjustments………………………………………………. Controller Name of Levels and Timers Adjusting the Timers CHAPTER 8 Weigh Controller and Adjustments………………………………………… CHAPTER 9 Maintenance……………………………………………………………………. APTER 10 Trouble Shooting……………………………………………………………. Controller doesn’t return to Zero Erratic weighs Digital readout does not match the floor scale Controller does not lite up Dirty filling Illustrated Parts sheets...
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Page 5: Quick Reference Information
QUICK REFERENCE INSTALLATION INFORMATION Pneumatic Requirements: (One Hookup) Run 1/2" line to main Filter / Regulator with an output of 4 CFM operating at 80 PSI. Electrical Requirements: (One Hookup) A 25 amp dedicated circuit should be supplied to the main control panel. -
Page 6: Important Notices For Startup Operation
BEFORE OPERATING EQUIPMENT: Any personnel working directly with or on this equipment should read this manual before proceeding with equipment use. Electricians should familiarize themselves with the electrical drawings before initial start-up of equipment. Other appropriate operating and maintenance personnel should familiarize themselves with mechanical layout and general arrangement drawings before start-up of equipment. -
Page 7: Grounding Recommendations
Keep fingers, hands, feet, etc. out of path of pneumatically operated components. Safety glasses should be worn in equipment area. Follow the safety regulations for your plant. ALWAYS USE GOOD JUDGEMENT! WITHIN THE TEXT OF THIS MANUAL: "WARNING" indicates possible injury to personnel. "CAUTION"... - Page 8 BACKGROUND NOISE Electrical noise is defined as any unwanted electrical signal which enters the control equipment. Noise signals cover the entire spectrum of frequencies and may have any wave shape. The largest single difficulty with noise is that it is not always present. Continuous, or frequent, periodic noises are generally easy to detect and accommodate.
- Page 9 AC POWER CONSIDERATIONS Electrical devices should not be operated at the low end of their input power voltage rating for extended periods of time. When input voltage is low, current input is forced higher to provide the devise with the power of needs. Additional current means additional heating.
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Page 10: Recommended Spare Parts List
Recommended Spare Parts List for Model 510 BBL Description Part Number Load Cell 501-005 Summing Box 104-009B Bag seal cuff 301704SP Pilot valve 145301 Quick Dump Exhaust 703-014 Valve Solenoid Valve 105-020 Solenoid valve 105-020A adapter Kit 405 Controller 104-046... -
Page 11: Chapter 1 General Information
CHAPTER 1 GENERAL INFORMATION... -
Page 12: Receipt And Inspection
RECEIPT AND INSPECTION After uncrating the packer, a check should be made to see that all items ordered have been received and that all equipment is in good condition. Any damage incurred in shipment should be reported immediately to the delivering carrier and a claim for the damage should be filed. -
Page 13: Specific Requirements
8. High-pressure air systems are dangerous. DO NOT service or trouble-shoot systems with air supply on. Be sure to bleed off any trapped air before working on components since it is possible to have high pressures trapped in airlines and cylinders, etc. 9. - Page 14 Connect high-pressure airline to filter regulator, located on back side of packer. A suitable source of supply is a (1/2” pipe connection). It is recommended that an extra water trap (not supplied with machine) be installed prior to the regulator in the high- pressure airline and the packer.
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Page 15: Chapter 2 Installation Guide
Chapter 2 INSTALLATION... -
Page 16: Introduction
The interface cable between the 510 series and the indicator must be secured to the floor or wall and protected against crushing, cutting or water damage. If the site has such potential dangers, a method of protection such as running the cable in conduit is recommended. -
Page 17: Connecting To Supply Bin
CONNECTING TO SUPPLY BIN Our 510 series Bulk Bag Fillers can be fed via slidegate valve, butterfly, valve, auger, rotary air lock. The valve is fastened directly to the customer supply bin. An 8" flex connector hose has been supplied to install from the outlet side of the valve to the bulk bag filler head. - Page 18 Note: If removing the controller from the equipment, secure the controller to the desired location and then the load cell cable to the floor or wall. Re-connect the load cell cable to the weight indicator. Reference the indicator User and Installation Guide for proper connections. Take care not to stretch or bind cable as this will affect weight readings.
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Page 19: Load Cell Wiring Information
Chapter 3 LOAD CELL WIRING... - Page 20 Tighten the strain relief hubs on the junction box with a wrench to assure proper seal. Figure 1: Load Cell Configuration Figure 2: Junction Box Connections Take the cable coming from the junction box of the 510 series and wire it to the indicator connector as follows:...
- Page 21 Table 1: Connector Wiring WIRING DESIGNATION WIRE COLOR (+) Excitation Red (-) Excitation Black (+) Signal Green (-) Signal White (+) Sense Blue (-) Sense Brown Ground or Shield Clear CALIBRATION INSTRUCTIONS 1. Calibrate the scale to indicator per instructions supplied with your indicator. 2.
- Page 22 WARNING: DO NOT CUT THE LOAD CELL CABLE! 3. Pull the load cell cable out of the formed frame channels. The chase wire will be used to pull the new load cell cable through the formed channel. 4. Install the new load cell by reversing the preceding steps. Reference the wiring diagram in Figure 5.
- Page 23 Figure 3: 510 Series Bottom View LOAD CELL CONNECTION GUIDE SHIELD CLEAR EXCITION + BLACK EXCITION + SIGNAL - WHITE SIGNAL + GREEN SENSE - BROWN SENSE + BLUE...
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Page 24: Load Cell Information/ Capacity
Load Cell Information/ Capacity Note: Red to Black is the input resistance. Very important 384 ohms Note: Green to White is output resistance. Very Important. 351 ohms (Measured with no load) Resistance 2.5K Ink Ohms Red Black .384 Red Green .296 Red White .296... -
Page 25: Component Descriptions
Chapter 4 Component Description... - Page 26 The CBE 510 Bulk Bag Filler is comprised of the following assemblies: 1. Digital Filler Controller The digital filler controller controls all aspects of the bag filling cycle. It is directly (104-1050) responsible for controlling the solenoid valves and cylinder operated functions of the machine.
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Page 27: Chapter 5 Optional Equipment
Chapter5 Optional Equipment... -
Page 28: Bag Pre-Inflate/ Exhaust
BAG Pre-INFLATE / BAG EXHAUST (Optional) Our Model 510 can be equipped with a Bag pre-inflate. This feature inflates the bag prior to filling to give you full volume of the bag. -
Page 29: Setup And Operating Procedures
CHAPTER 6 SETUP & OPERATING PROCEDURES... -
Page 30: Operational Sequence
OPERATIONAL SEQUENCE Place an empty pallet onto the deck of the CBE 510. Hang bulk bag strips onto the bag strap support. Place the rear straps first and then the other two. Install the bulk bag neck onto the dust tight fill head until spout reaches full contact with inflatable balder (OPTIONAL). - Page 31 Caution: DO NOT WEIGHT THE BAG FROM THE BAG STRAP SUPPORTS. THE BAG STRAP SUPPORTS ARE ONLY DESIGNED TO KEEP THE UP RIGHT DURING THE FILLING CYCLE WITH THE WEIGHT SETTING ON THE PALLET.
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Page 32: Bag Seal Cuff
BAG SEAL CUFF (OPTIONAL) The bag seal cuff is a feature that keeps the dust from coming out of the bulk bag during the filling process. A. Bag Cuff PB The operator presses the blue PB to inflate and bag seal cuff. Check the pressure on the regulator, to make sure the pressure is between 3-5 PSI to start. - Page 33 B. Bag Cuff Regulator and Quick Dump Exhaust Valve: The regulator, gauge and quick dump valve are mounted directly to the bulk bag filler head. The pressure adjustment was factory set to 3 PSI; however, this will need to be fine adjusted in the field using the customer's bulk bag.
- Page 34 Caution: Never operate vibratory deck without filling the bag to 20% of the weight of the bag. You could damage the equipment. If equipment is equipped with a Vibrator deck, it is recommended that ear protection be worn when operating this machine. C.
- Page 35 CAUTION: WHEN ADJUSTING VIBRATORY MOTORS YOU MUST ADJUST EACH MOTOR TO THE SAME SETTING AND EQUIPPED WITH TWO VIBRATORY MOTORS THEY ASLO MUST MATCH EACH OTHER. PRE-BAG INFLATE/ BAG EXHAUST (OPTIONAL) The Bag Pre-Inflate system consist of the following components: Bag Inflator Fan 3 way valve Exhaust System The system is designed to inflate the bulk bag to its full volume prior to being filled.
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Page 36: Chapter 7 Plc And Timers Adjustments
CHAPTER 7 PLC and AVERY 405 ADJUSTMENTS... - Page 37 PLC means Programmable Logical Controller. Our PLC is programmed with specific programs to work with our equipment. Our programs are set up for Valve filling, O/M net weigh and gross weighing equipment. In the PLC, there are timers going to specific functions on the various types of equipment which we factory set but need to be fined tuned in the field.
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Page 38: Adjusting The Timers
The Order of the timers 1- Choice Bagging 2- Feed Gate Timer 3- Bag Chair Timer 4- Tube Clean Out Timer/ Reverse Timer on Auger Packers 5- Input Output Screen Timer Explanation Feed Gate This timer is used to hold the feed gate closed at the end of a bagging cycle to allow the chamber on an air packer to allow the extra pressure through the exhaust on the three way valve. - Page 39 Setting Target Weight and PreAct Press the The screen will show: To Change the target that is shown. (Same process for Pact and Dribble) o Type in the new weight and press o Or if it is correct just press the ...
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Page 40: Weigh Controller And Adjustments
Chapter 8 WEIGH CONTROLLER ADJUSTMENTS... - Page 41 Controller The style controller CBE uses is an analog controller. We primarily use two different Manufacturers for our controllers. We do this because some customers prefer only a simple digital display and others want a higher end controller that can provide management information.
- Page 42 Calibration 1. Power On, the screen will display “boot” and then “loading.” 2. From start screen, press and hold the key until, The screen will display: 3. Enter the passcode “2580”. 4. Press key to enter the passcode. The screen will display “busy” and then will go into calibration mode.
- Page 43 ZM 405 CONTROLLER Calibration ZM 405 CONTROLLER Calibration 1. Power On, the screen will display “boot” and then “loading.” 2. From start screen, press and hold the key until, The screen will display: 3. Enter the passcode “2580”. 4. Press key to enter the passcode.
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Page 44: Chapter 9 Maintenance
CHAPTER 9 MAINTENANCE... - Page 45 MAINTENANCE OF THE BAG SEAL CUFF AND GAUGE: Periodic inspection of the bag seal cuff for cracks or tears is necessary. Replacement of the cuff is recommended if any wear, tears or thinning is noticed. The pressure gauge should for the bag seal cuff should be kept in good working order. If the gauge does not read pressure, remove and replace it as soon as possible to prevent cuff damage.
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Page 46: Troubleshooting
CHAPTER 10 TROUBLESHOOTING... -
Page 47: Controller Doesn't Return To Zero
Controller does not return to zero: This is typical a mechanical problem with the scale. Check in the following areas that can affect the scale. Check for bad Load cell – Check ohms or each load cell to see if in proper spec. Check Chart. -
Page 48: Controller Does Not Lite Up
Controller doesn’t lite up. Check to make sure the Power switch is “on”. Switch is located on the PLC enclosure. Check 110v fuse on transformer is good. R/R if bad Check E-stop – make sure it is pulled out. Check round in- line fuse in the GSE controller. R/R if bad Check for loose wire. - Page 49 Load Cell Information/ Capacity Resistance 2.5K In K-ohms Red Black .384 Red Green .296 Red White .296 Black Green .294 Black White .294 Green White .351 Note: Red to Black is the input resistance. Very important Note: Green to White is output resistance. Very Important.
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Page 50: Illustrated Parts Sheets
ILLUSTRATED PARTS PAGES... -
Page 56: Schematics /Layouts
SCHEMATICS DRAWINGS... - Page 57 Bulk Bagger 19 pin-Yellow Cord: 202 – Red 204 – Brown 208 – Gray/Pink 210 – Gray/Brown 234 – Gray 236 – Red/Blue 238 – Pink 240 – Blue 252 – Black GND – Yellow Neutral – White Ground – Green/Yellow...