Operating Instructions
Minebea Intec Combics 3
Filling Basic (Option H3) and Filling Plus (Option H4)
Models CAISL3 | CAIS3 | CAW3P | CAW3S
Automatic Single-Component Filling
98646-003-50
98646-003-50
2 Operating Instructions Combics 3 Filling Plus (Option H3+H4)
Intended Use
Intended Use
Controls for pausing, continuing
and canceling filling operations
Only option H4:
Stabilization timer: User-definable
delay after filling operation and
before tolerance test, with digital
output control
Only option H4:
Filling level control for discharge
filling:
Control of a servo-component for
refilling the storage container.
Only option H4:
Residual amount control for
discharge filling: Display of the
residual amount in the storage
container.
Only option H4:
Control of draining mechanism for
storage container
Password protection
Key lock function to prevent
unauthorized operation
Manual toggling between up to 3
platforms.
Control signals (via RS485, YSB02)
Only option H4:
7 inputs: Start, Interrupt, Cancel,
Continue, Key assignment.
Only option H4:
8 outputs: Coarse flow, Fine flow,
Filling active, Ready, Underfill,
Within-tolerance, Overfill, Material
flow too heavy, Material flow too
light, Stabilization timer active,
Drain, Refill
Digital I/O (option A5)
5 inputs: Start, Interrupt, Cancel,
Continue, Key assignment.
5 outputs: Coarse flow, Fine flow,
Filling active, Within-tolerance, etc.
Control signals - only for option H3
1 input: Start, Interrupt, Cancel,
Continue, Key assignment.
4 outputs: Filling active, Coarse
flow, Fine flow, Within-tolerance.
Note
“Filling Basic” (option H3) and
“FillingPlus” (Option H4) are
application programs for Combics3
devices. Whenputting the
equipment into operation, refer to
the operating instructions for the
particular Combics3 complete scale
or Combics3 indicator and weighing
platform, as well as the operating
instructions for the relay box.
Explanation of Symbols
The following symbols are used in
these instructions:
t
Indicates a required action
y
Describes the result of an action
1. If a procedure has multiple
steps...
2. ... the steps are numbered
consecutively.
Indicates an item in a list
! Indicates a hazard
h This symbol indicates useful
information and tips.
Technical advice/hotline:
Phone: +49 (0) 40 / 67960444
Fax: +49 (0) 40 / 67960474
E-mail:
technical.support.hh@minebea-intec.
com
The “Filling Basic” (Option H3) and
“Filling Plus” (Option H4) applications
for Combics 3 enable single-
component filling of liquid, pasty
and pourable samples up to a target
weight using either additive filling or
discharge filling.
The “Filling” application offers the
following features:
Coarse/fine control of material flow,
only option H4 with automatic
optimization of valve shutoff points
Totalization of all filling operations,
all operations with results that
lie within tolerance limits, or all
operations that were canceled.
– Statistics: transaction counter,
standard deviation, mean, minimum
and maximum values.
User-definable transaction counter
starting and ending numbers, up
to 9999, for automatic filling of
specified batch sizes.
Only option H4:
Product data memory for up to
100products
Only option H4:
Material flow monitoring:
An alarm is triggered or the filling
operation is canceled if the material
flow exceeds specified minimum or
maximum levels
Only option H4:
User-definable tare range for
monitoring container weights
Input of product-specific filling
parameters (e.g. product name,
target value, shutoff points for
coarse and fine flow, permissible
tolerance ranges for filling quantity
and container weight only)
Tolerance control with automatic
follow-on filling
Manual follow-on filling in case of
underfill
Analog bar graph for weighing in
up to the target value
Contents
Intended Use ...............................................................................2
Notes..................................................................................2
Contents ..................................................................................3
Connection Options ..........................................................................4
Combics 3 with Filling Basic (Option H3) .......................................................4
Combics 3 with Filling Plus (Option H4) ........................................................5
Operation .................................................................................6
Filling Procedure .........................................................................6
Soft Key Functions........................................................................6
Creating the Product Data Memory............................................................7
Additive Filling........................................................................... 8
Discharge Filling ........................................................................ 11
Discharge Filling with Auto. Refill of the Storage Container......................................... 13
Stopping and Canceling Filling Operations ..................................................... 17
Follow-On Filling ........................................................................ 18
Totalizing ............................................................................. 19
Effect of Parameter Settings on Printout Content ................................................ 22
Accessing Application-Specific Information..................................................... 23
Configuring Application Parameters .......................................................... 24
Multi-I/O Converter ...................................................................... 30
Data Interfaces............................................................................. 32
GMP-Compliant Printouts ................................................................. 32
Accessories................................................................................ 34
Contents
Operating Instructions Combics 3 Filling 3
4 Operating Instructions Combics 3 Filling
Connection Options
Connection Options
Combics 3 with Filling Basic (Option H3)
Combics 3 Dosiersteuerung
Analog
Input
WP1
COM2
UniCOM
COM1
4 Ausgänge (Relais)
1 Eingang (Optokoppler)
Ser.
Par.
Relaisbox YSB01 YCC02-RELAIS02 (CAIS); 6 m
bzw. Option M12;
YCC02-RELAIS01 (CAISL); 6 m
Spannungsversorgung
kundenseitig
Zentralrechner
A5
Digital I/O
Drucker
PG
standardmäßig
Power Supply
by Customer
Central Computer
Printer
Combics 3 Filling Controller
Analog
Input
A5
Digital 1/0
Relay Box YSB01
4 Outputs (Relay)
1 Input (Optocoupler)
YCC02-RELAIS02 (CAIS); 6m
or Option M12;
YCC02-RELAIS01 (CAIS); 6m
PG
Default
Ser.
Par.
Operating Instructions Combics 3 Filling 5
Connection Options
Combics 3 with Filling Plus (Option H4)
Combics 3 Dosiersteuerung
Analog
Input
WP1
COM1
COM2
UniCOM
WP2 (option RS485)
WP1 (option RS485)
8 Ausgänge (Open Kollektor)
7 Eingänge (TTL-kompatibel,
Uemax = 30 V)
Ser.
Par.
Digitales
Ein-/Ausgabemodul
YSB02 YCC02-RELAIS02 (CAIS); 6 m
bzw. Option M12;
YCC02-RELAIS01 (CAISL); 6 m
Spannungsversorgung
kundenseitig
Zentralrechner
A5
Digital I/O
SPS
Drucker
YSB02, IE11357 can be connected to the Combics via:
- Option A7 (WP1-RS485); UniCom can be used freely here.
- Option A72 (WP2-RS485); UniCom can be used freely here.
- UniCom RS485; Option A3; if WP1,2 are already in use.
The activation of YSB02, IE11357 is done in the menu via:
Setup; Control I/O; Externer RS-485 Multi-I/O-Wandler
Central Computer
Printer
Combics 3 Filling Controller
Analog
Input
A5
Digital 1/0
Power Supply
by Customer
8 Outputs (Open Collector)
7 Inputs (TTL Compatible,
Uemax = 30 V)
WP2 (Option RS485)
WP1 (Option RS485)
Digital Input/Output
Module
YSB02
Ser.
Par.
YCC02-RELAIS02 (CAIS); 6m
or Option M12;
YCC02-RELAIS01 (CAIS); 6m
6 Operating Instructions Combics 3 Filling
Operation
Filling Procedure
The sample being measured is auto-
matically added to (or removed from)
the tared container through vibrating
chutes or filling valves until the target
value is reached. The filling procedure
comprises a series of five steps:
Automatic tare: The container
weight is automatically tared and
the filling procedure is started
Coarse flow: Allows a rapid
approach to the target value; the
container is filled (or emptied) until
the defined coarse flow shutoff
point is reached and filling switches
to fine flow.
Fine flow: The container is filled
(oremptied) until the defined fine
flow shutoff point is reached.
Post-flow: Material continues
flowing at fine flow rate after the
fine flow shutoff point is reached
Follow-on filling:
If the weight value is not within
tolerance limits and/or does not
meet the target value after the
end of filling, fine flow can be
switched on again (automatically
or manually) to add material to
thefilling container.
Gewicht
Zeit
Sollwert
Toleranz-
Toleranz+
Schaltwert fein
Schaltwert
grob
Dosierstart
Autotara
Grobstrom
Feinstrom
Nachstrom
Dosierende
Tara
Gewicht
Zeit
Sollwert
Toleranz-
Toleranz+
Schaltwert fein
Schaltwert grob
Dosierstart
Autotara
Grobstrom
Feinstrom
Nachdosieren
Dosierende
Tara
Nachstrom
Dosiervorgang (Option H3) Dosiervorgang (Option H4)
Operation
Soft Key Functions
Param only option H3
Opens product data
memory and lets you
create, edit or load a data
record.
Delete only option H4:
Deletes the data record for
a product from the data
memory.
Load only option H4:
Loads product data from
the product data memory.
Change only option H4:
Lets you edit data in the
product data memory.
Start Starts a filling operation
with the currently loaded
product data.
Continues an interrupted
filling operation.
Canc. Cancels a filling operation.
ProDat
or R
button
Inter Interrupts a filling
operation.
Man.F. Opens the fine flow valve
for manual follow-on
filling.
M+ Saves the filling operation
results in totalization
memory.
Pr.Sum Prints the data in
totalization memory and
then clears the memory.
StartC Stores the value entered
as the start value for
transaction counting.
StopC Stores the value entered
as the end value for
transaction counting.
Fill only Option H4:
Starts a discharge filling
operation (active only if
the “Min. and fill wt.”
parameter is active; see
“Configuring Application
Parameters”).
Tolerance +
Target
Tolerance -
Fine flow switch
Coarse flow switch
Tare
Filling start Filling end
Autotare
Coarse flow
Fine flow
Filling Procedure (Option H3) Filling Procedure (Option H4)
Weight
Post-flow
Tolerance +
Target
Tolerance -
Fine flow switch
Coarse flow switch
Tare
Filling start Filling end
Autotare
Coarse flow
Fine flow
Weight
Time
Post-flow
Follow-on filling
Time
Operating Instructions Combics 3 Filling 7
Creating the Product Data Memory
Before you can perform a filling operation, you need to create a data record on
the product to be filled. To do this, begin by pressing “Param” (optionH3) /
ProDat” (optionH4), or press the R key with either option.
Only option H3:
Input parameter.
Press soft key “oo” to activate the parameter input and load the product.
Only option H4:
You can create data records for up to 100 products. Data records can be stored,
edited and deleted from product memory. Once you store a data record, you can
load it at any time for filling the particular product.
The first step is to enter a product name (max. 20 characters). Then select the
product and press the “Change” soft key to enter the required filling parameters.
Press the “Delete” soft key to delete a product from memory. Press the “Load
soft key to load the filling parameters stored for the selected product.
Example:
Create a new product in product data memory and then load the new data record.
t
Press the “Param”/“ProDat” soft key or the R key.
Only option H4:
y
The “Memory” menu will open and the first menu item is selected.
For the next steps, see the description of 'Product Data Memory' (without saving of
tare values).
Operation
8 Operating Instructions Combics 3 Filling
Example:
Change product
t
Only option H4: Load the product to be changed and press the “Change
soft key.
y
The menu will open and the first line is selected.
t
Change the product values via the keypad and confirm using the “l” soft key.
Enter here:
Product Info: Granulate blue;
Target: 2.5 kg;
Tolerances as positive values relative to the target value:
Tolerance range = 2.4…2.7 kg
Values relative to the target value for switching from coarse flow to fine flow
(“coarse flow shutoff point”) and for fine flow shutoff:
Switch from coarse to fine flow at 1.5 kg, and fine flow shutoff at 2.3 kg);
ID1: Prod. Schmidt
y
The next line is selected.
t
Only option H4: Press the “o” soft key to return to the overview.
t
Only option H4: Press the “o” soft key to return to the “Memory” menu.
t
Press the “oo” soft key to exit the Product Data Memory menu.
h The lines “ID1…4” offer the option to input an individual ID code.
Operation
Operating Instructions Combics 3 Filling 9
Operation
Additive Filling
In additive filling, an amount of product is transferred from a storage container
into a filling container that is on the weighing platform. With this procedure, the
“target value” filling parameter is a positive value.
The display shows positive net weight values during this filling operation.
The bar graph is shown during filling, with symbols indicating the target value and
upper and lower tolerances. Weights from 0 up to the lowest tolerance limit are
represented logarithmically; beyond this point the bar graph display is linear.
The control LEDs to the right of the keypad and the internal switched outputs
(O, o, =) (only option H4) indicate the position of the filling result value in relation
to the tolerance limits.
Red: Result is below the lower tolerance limit
Green: Result is within the tolerance range
Yellow: Result is above the upper tolerance limit (overfill)
Example:
Additive Filling
t
Load parameters from product data memory.
Here:
Memory name: Additive Filling 01 (only option H4)
Product info Granulate red
Target: 2.500 kg
Lower tolerance (-): 0.100 kg
Upper tolerance (+): 0.200 kg
Coarse flow shutoff point: 1.000 kg
Fine flow shutoff point: 0.200 kg
ID1: Prod. Schmidt
t
Place empty filling container on weighing platform.
y
If the “Start” soft key is pressed without a filling container being placed on
the weighing platform, the following is displayed.
t
Press the “Canc.” soft key and place the filling container on the platform.
10 Operating Instructions Combics 3 Filling
t
Press the “Start” soft key to start the filling application.
y
The filling container is tared automatically (Can be switched off via menu
parameters).
The digital output signal for “coarse” is active up to the coarse flow shutoff
point (the point at which filling switches from coarse to fine flow).
y
The digital output signal for “fine” is active up to the fine flow shutoff point
(the point at which the fine flow is stopped).
y
End of filling.
t
Press the p key to print the results.
h If the “Save results” option is set to “Automatic mode” (factory setting:
“Manual mode”), a printout is generated automatically at the end of filling,
provided the result is within tolerance limits.
The printout documenting the filling can be configured in the menu
Parameters: Printout of results”.
t
Press the “End” soft key to end the filling application.
G# + 2.569 kg
T + 0.104 kg
N + 2.465 kg
Additive Filling 01 only option H4
Granulate red
Target + 2.500 kg
Prod. Schmidt
---------------------
Operation
Operating Instructions Combics 3 Filling 11
Discharge Filling
Discharge filling entails transferring an amount of product from a container on the
weighing platform to the filling container. With this procedure, the “target value”
filling parameter is a negative value.
The display shows negative net weight values during this filling operation
(indicating amounts removed from the storage container and added to the filling
container).
The bar graph is shown during filling, with symbols indicating the target value and
upper and lower tolerances. Filling results from 0 up to the lowest tolerance limit
are represented logarithmically; beyond this point the bar graph display is linear.
The control LEDs to the right of the keypad and the internal switched outputs
(O, o, =) (only option H4) indicate the position of the filling result value in relation
to the tolerance limits.
Red: Result is below the lower tolerance limit
Green: Result is within the tolerance range
Yellow: Result is above the upper tolerance limit (overfill)
Example:
Discharge Filling
t
Load parameters from product data memory.
Here:
Memory name: Discharge Filling 01 (only option H4)
Product Info: Flour
Target value: -1.500 kg
Lower tolerance (-): 0.050 kg
Upper tolerance (+): 0.100 kg
Coarse flow shutoff point: 0.500 kg
Fine flow shutoff point: 0.100 kg
ID1: Prod. Mueller
t
Place filled storage container on weighing platform.
y
If the “Start” soft key is pressed without a storage container being placed
on the weighing platform, the following is displayed.
t
Press the “Canc.” soft key and place the storage container on the platform.
Operation
12 Operating Instructions Combics 3 Filling
Operation
t
Press the “Start” soft key to start the filling application.
y
The weight of the filled storage container is saved in the tare memory.
y
The digital output signal for “coarse” is active up to the coarse flow shutoff
point (the point at which filling switches from coarse to fine flow).
y
The digital output signal for “fine” is active up to the fine flow shutoff point
(the point at which filling stops).
y
End of filling.
t
Press the p key to print the results.
h If the “Save results” option is set to “Automatic mode” (factory setting:
“Manual mode”), a printout is generated automatically at the end of filling,
provided the result is within tolerance limits.
The printout documenting the filling can be configured in the menu
Parameters: Printout of results”.
t
Press the “End” soft key to end the filling application.
G# + 2.265 kg Gross: Container weight + contents after the filling operation
T + 3.788 kg Tare: Container weight + contents before the filling operation
N - 1.523 kg Net: Discharged product
Discharge Filling 01 Memory name (only option H4)
Flour Product info
Target - 1.500 kg Target value
Prod. Mueller ID1…4
---------------------
t
If desired, press the “Start” soft key to start a new filling operation.
Operating Instructions Combics 3 Filling 13
Discharge Filling with Automatic Refill of the Storage Container
(only Option H4)
You can define an amount of product for automatic refilling of the storage
container. To do this, activate the “Minimum weight” and “Fill weight” parameters
in the application menu.
The filling operation is started either manually by pressing the Fill” soft key or
automatically (must be activated in the Application menu) when the weight reaches
or drops below the minimum weight after a filling operation.
You can enter a container tare weight.
Example:
Discharge filling with prior filling and subsequent refilling of the storage container,
without tare weight input.
Configuration:
Parameter activation for “Minimum weight” and “Fill weight” is selected.
t
Press the H key and select in the menu “Parameters:
Parameter activation: Min. and fill weight”.
t
Load parameters from product data memory.
Here:
Memory name: Discharge Filling 02
Product Info: Flour
Target value: -1.500 kg
Lower tolerance (-): 0.050 kg
Upper tolerance (+): 0.050 kg
Coarse flow shutoff point: 0.200 kg
Fine flow shutoff point: 0.075 kg
Min. weight: 1.200 kg
Fill weight: 5.000 kg
Tare weight: 0.000 kg
ID1: Prod. Mueller
ID2: Param. min. active
t
Place empty storage container on weighing platform.
Operation
14 Operating Instructions Combics 3 Filling
Operation
y
If the “Fill” soft key is pressed without a storage container being placed on
the weighing platform, the following is displayed.
t
Press the “Canc.” soft key and place the storage container on the platform.
t
Press the “Fill” soft key.
y
The weight of the storage container is saved in the tare memory.
y
The digital output signal “Refill” is active until the specified fill weight is
reached (in this example: 5.000 kg).
t
After the end of the filling operation, press the “Start” soft key to begin the
discharge filling, see page 11.
To check the amount remaining after a number of filling operations:
t
Press and hold the D key to load the information display.
y
Press the “oo” soft key to close the information display.
t
Press the “Start” soft key to start the next filling operation, see page 11.
y
If the residual amount at the end of a filling operation reaches or drops below
the specified minimum (“Min. wt.”, in this example: 1.200 kg), the refilling
operation starts automatically.
The digital output signal for “Refill” is active until the specified fill weight
(netweight) is reached
t
When the refilling is completed, press the “Start” soft key to start the next
filling operation, see page 11.
Operating Instructions Combics 3 Filling 15
Operation
Example:
Discharge filling with refill of the storage container
and prior input of the container tare weight.
Configuration:
Parameter activation for “Minimum weight” and “Fill weight” is selected.
t
Press the H key and select in the menu “Parameters:
Parameter activation: Min. and fill weight”.
t
Load parameters from product data memory.
Here:
Memory name: Discharge Filling 02
Product Info: Flour
Target value: -1.500 kg
Lower tolerance (-): 0.050 kg
Upper tolerance (+): 0.050 kg
Coarse flow shutoff point: 0.200 kg
Fine flow shutoff point: 0.075 kg
Min. weight: 1.200 kg
Fill weight: 5.000 kg
Tare weight: 0.350 kg
ID1: Prod. Mueller
ID2: Param. min. active
t
Place filled storage container on weighing platform.
16 Operating Instructions Combics 3 Filling
Operation
t
Press the “Start” soft key to begin the discharge filling, see page 11.
Press the p key to print out the result of the filling operation.
h If the “Save results” option is set to “Automatic mode” (factory setting:
“Manual mode”), a printout is generated automatically at the end of filling,
provided the result is within tolerance limits.
The printout documenting the filling can be configured in the menu
Parameters: Printout of results”.
G# + 4.204 kg Gross: Container weight + contents after the filling operation
T + 5.727 kg Tare: Container weight + contents before the filling operation
N - 1.523 kg Net: Discharged product (material removed from storage container)
Discharge Filling 02 Memory name
Flour Product info
Target - 1.500 kg Target value
Prod. Mueller ID1
Param. min. active ID2
---------------------
t
Press the “Start” soft key to start the next filling operation, see page 11.
y
If the residual amount at the end of a filling operation reaches or drops below
the specified minimum (“Min. wt.”), the refilling operation starts automatically.
The digital output signal for “Refill” is active until the specified fill weight
(netweight) is reached.
t
When the refilling is completed, press the “Start” soft key to start the next
filling operation, see page 11.
Responses of the Combics 3 during Discharge Filling with Active “Min. and Fill Weight” Parameter
Parameter input Begin by
pressing
Specified residual amount Refilling
operation
depends on
No tare input
No tare input
Container tare specified
Container tare specified
Fill
Start
Fill
Start
Gross weight minus tare weight
Gross weight
Gross weight minus specified tare weight
Gross weight minus specified tare weight
Net weight
Gross weight
Net weight
Net weight
Operating Instructions Combics 3 Filling 17
Operation
Stopping and Canceling Filling Operations
h Applies to option H3 + H4
You can pause an additive or discharge filling operation at any time by pressing the
Inter. soft key and then later start it again with Start” or stop it with
Canc.”.
The c key also cancels a filling operation in progress.
Example:
Interrupting and canceling a filling operation
t
Press the Inter.” soft key to pause the filling operation at any point
(coarse and fine flow valves are closed).
t
Press the Start” soft key to continue the filling operation.
t
Press the “Canc.” soft key to cancel the filling process.
18 Operating Instructions Combics 3 Filling
Operation
Follow-On Filling
If, for example, the weight value briefly swings too high, the fine flow is shut off
too early, meaning that the current weight value lies below the target value.
The “follow-on filling” function opens the fine flow valve until the target is
reached or the weight is within tolerance limits. You can configure the application
parameters for manual or automatic follow-on filling.
Example:
Manual follow-on filling
Configuration
Option H4 only: Coarse/fin flo optimization is switched off.
t 0Press key H and select Application parameters: Optimization of coarse/fine
flow: OFF«.
Manual filling is selected.
t
Press the H key and select in the menu “Parameters: Add within
tolerance range: Manual”.
The fine flow valve is open until the “fine flow” shutoff point is reached. If the
weight value is below the target value or outside the tolerance range, it is possible
to activate follow-on filling until the target value is reached.
t
The fine flow valve is opened for as long as the “Man.F.” soft key is pressed.
t
Press the p key to print the results.
G# + 2.377 kg
T + 0.375 kg
N + 2.002 kg
Additive Filling 01 only option H4
Granulate red
Target + 2.000 kg
Prod. Mueller
---------------------
Operating Instructions Combics 3 Filling 19
Operation
Totalizing
When the totalizing function has been activated in the application menu, filling
operations can be totalized automatically or manually.
Configure application parameters to define whether:
all,
only filling operations within the tolerance range, or
only canceled filling operations are totalized.
You can define starting and ending values for the transaction counter; for example,
to define a specific series of operations. When the last transaction (filling operation)
of a series has been performed, a total data record is printed automatically.
To print the data in totalization memory before the end of a series or when the
transaction counter is not active, press the Pr.Sum.” soft key (print summary
data). Any time you press Pr.Sum.” to print a total data record, the data in
totalizing memory is subsequently deleted.
Example:
Manual totalizing with preset transaction counter
Configuration:
Manual totalizing is turned on.
Start/stop transaction counter is activated.
t
Press the H key and select in the menu “Parameters:
Totalizing: On, only fill. oper. in tolerance”.
t
Press the H key and select in the menu “Parameters: Parameter
activation: Start/stop transaction counter”.
20 Operating Instructions Combics 3 Filling
Operation
t
Press the 1 key to enter the start value of the transaction counter (here: 1).
t
Press the StartC.” soft key to apply the start value of the transaction
counter.
t
Press the 2 key to enter the end value of the transaction counter (here: 1).
t
Press the StopC.” soft key to apply the end value of the transaction
counter.
t
Press the Start” soft key to execute the first filling operation.
t
Press the M+” soft key to save the result in totalizing memory.
G# + 2.698 kg Gross weight
T + 0.104 kg Tare weight
N + 2.594 kg Net weight
Additive Filling 01 Memory name (only option H4)
Granulate red Product info
Target + 2.500 kg Target value
n 1 Transaction counter
Prod. Schmidt ID1
---------------------
t
Unload weighing platform.
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