Minebea Intec CAW3P Owner's manual

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

2 Operating Instructions Combics 3 Filling Plus (Option H3+H4)

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

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

Container tare specified

Fill

Start

Fill

Start

Gross weight minus tare weight

Gross weight

Gross weight minus specified tare weight

Net weight

Gross 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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