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INTRODUCTION 4
3. RUNNING DISPLAY 6
7. PRINTOUTS 16
13. DIAGNOSTICS 20
22. APPENDIX 33
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1. INTRODUCTION
These instructions cover two basic types of weighing machines controlled by DIGIWAY computer
controller.
AUTOMATIC MACHINES composed of up to three vibratory feeders, feeding into a weighpan and
automatic discharge of the weighpan when requested by a discharge signal.
Although the above two types of machine are the most common, hybrid versions are available for
special applications. Where necessary additional information is supplied.
1) Printer.
2) Optimisation.
4) Multiple discharge.
5) A 0 - 10 volt DAC Output, provided by add-on card PCS3331, fitted with PAL 1206. This may be
supplied upon request. The output voltage from this option provides a linear representation of
current weight, scaled against the Calibration Weight i.e.
Certain functions of the machine depend upon which of the above options are fitted. These are
referred to as they arise in the manual. (See also "Program identity and Option Display".)
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The front panel features a 16 digit vacuum fluorescent alpha numeric display, status lamps and press
button switches.
NORMAL WEIGHING
For normal weighing, after a product has been set up, the vibrator switch should be ON, the auto
switch should be ON and the data change switch must be OFF.
There is a choice of several displays in this mode, depending on options fitted. These are described
under "Running Display".
Before any change to product set up values can be made the ENABLE DATA ENTRY switch must be
turned ON. The entry that requires change can then be selected by the scroll up or down switches.
When the required entry is displayed the digit requiring change can be selected by the SELECT
DIGIT switch and its value incremented or decremented with the INCREMENT or
DECREMENT switches. If either of the switches are held pressed the value will change at ever
increasing speed. The ENABLE DATA ENTRY switch should be turned OFF after all changes have
been made.
Several entries are, display only functions, and cannot be changed. 'Level 1 product setting' gives
full information.
If change is required the method is identical as for product set up except that DIL switch No 1 must
be turned on. 'Level 2 machine settings' gives full information of entries.
DIAGNOSTICS
The indicator in the diagnostic switch marked 'D' will flash if a weighing malfunction has occurred. If
the switch is pressed the display will give the cause of the malfunction. If more than 1
diagnostic exists, they are displayed in rotation.
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3. RUNNING DISPLAY
The following items can be displayed when the lamp in the 'ENABLE DATA ENTRY' switch is OFF.
The required display item is selected using the scroll up or down buttons. If any of items 2 - 19 are
displayed for more than 5 minutes the display reverts to item 1 - Weight.
2) EMPTY F
While this display is selected, the 'Empty' mode can be entered by pressing the 'F' key. This
causes the Bulk, Fine and Weighpan doors to open and all vibrators to run at their
preset 'Fast' speeds.
To return to normal running, press "F" key again. Items 3-6 are available only if the 'Screen data'
option is fitted. If any of these are displayed for more than 5 minutes, the display will revert back
to the normal 'weight' display.
3) TARGET WEIGHT
4) AVERAGE WEIGHT
Displays average of the current batch total.
6) BATCH COUNT
Total number of weighings since last 'clear data' was performed.
Format xxxxx.
Press 'F' key to clear displayed Average Wt, Total Weight and Batch Count.
8) PRINT F
Press 'F' key while this item is displayed to cause a printout of data collected so far.
9) PRINT & CLEAR F
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Press 'F' key while this item is displayed to cause a printout of data collected so far followed
by the clearing of all statistical data.
Items 10 & 11 are only available if the 'Multiple Discharge' option is fitted.
12)RATE
13)RATE RESET F
Press 'F' key while this item is displayed to reset the rate display to 0.
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The setting required for change can be selected using the "scroll keys". The value of a selected setting
is changed as described on page 5.
Most level 1 values can be altered while the machine is running. However there are certain critical
values which cause the machine to stop if a change is made. The vibrators are disabled and the
enable data change switch must be turned off again in order to re-enable them, (if an attempt is made
to press the 'Vibrator' button under these circumstances a diagnostic 'Not allowed' is
displayed).
1) Product code
3) Target weight
5) Overweight tolerance
6) Underweight tolerance
7) MWS
1) PRODUCT CODE
This selects which product is to be weighed or is being weighed. It also selects which product
number parameters are to be changed, if any change is required. If a product code is selected
which has not previously been set up then a diagnostic will be displayed until changes have been
made to at least the Target Weight and Bulk Cut-off Weight.
2) PASSWORD
In order to gain access to the rest of the level 1 Product items the correct password number must
be entered here. (The required number is entered under level 2). If the incorrect number is
entered, the display will return to 'Running Display' mode.
3) TARGET WT
This value should be set to the minimum acceptable weight required if Minimum Weight
system is in operation or the nominal weight if Average Weight system is being used.
i.e:
CYCLIC BAGMAKER: 'Full Bag' signal given on the last discharge of the batch of 'n'.
NON CYCLIC BAGMAKER: 'Ready' signal given when the 1st of the batch of 'n' is ready.
5) OVERWT TOL. - (Printer Option or Optimisation Option Only)
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Maximum allowed underweight tolerance for Average Weight System. (The minimum
underweight level must not be set to a value below - T1).
8) BULK CO WT
BULK CUTOFF WEIGHT is the weight at which the weigher will change from fast bulk feed rate
to slow fine feed rate. On systems fitted with Optimisation Option this value is automatically
adjusted up or down by the same amount as fine cut off weight.
9) FINE CO WT
FINE CUTOFF WEIGHT is the weight at which the slow fine feed will stop and weight settling will
start. This value should be set initially to the same value as TARGET WEIGHT.
On systems without Optimisation Option fitted the value should be adjusted until good
weighments occur.
VIBRATOR 1 SLOW % is the feed rate of vibrator 1 during the FINE FEED part of the weighing
cycle. Values between 0 and 100% may be entered.
VIBRATOR 2 SLOW % is the feed rate of vibrator 2 during the FINE FEED part of the weighing
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cycle. Values between 0 and 100% may be entered. On systems where vibrator 2 is not fitted
this entry should be set to 0.
VIBRATOR 3 FAST % is the feed rate of vibrator 3 during the BULK FEED part of the weighing
cycle. Values between 0 and 100% may be entered. On systems where vibrator 3 is not fitted
this entry should be set to 0.
This entry defines the function of level probes during the fine feed part of the weighing cycle.
0 Vibrators 2 and 3 run without probe control (normal setting if probes not fitted to system).
DO NOT SELECT a mode if the probe controlling the vibrator, that can run during fine feed, is
NOT FITTED.
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This entry defines the function of level probes after weight is complete.
4 Run vibrator 3 if vibrator 2 running with probe control vibrators run at slow speed for all above
functions.
DO NOT SELECT a mode if the probe, controlling the vibrator, that can run when weight
complete, is NOT FITTED.
DISCHARGE TIME is the time in SECONDS that the weighpan remains open during product
discharge on completion of a weighment. The time should be set just sufficiently for all product
to leave the weighpan.
DISCHARGE TIME is the time in seconds that the weighment complete output is turned on to allow
full dispensing of Product after final weight achieved. If the time is set to 00.0 the output remains on
until the start call is received.
20) TOP UP
This entry can only be set to ON or OFF. If set to ON any weight found to be below target weight
if Minimum System is being used or below target minus underweight tolerance if Average Weight
System is being used. At the end of a cycle will be automatically 'TOPPED UP' with additional
product so that its weight equals or exceeds minimum allowed weight.
Selects if this product is to operate with weight control automatically adjusting cut-off points to
compensate for changes in product/feed characteristics.
0 = No weight control
50 = An adjustment of 50% of the error of the 'Control Weight' will be performed.
100 = An adjustment of 100% of the error of the 'Control Weight' will be performed.
This value in SECONDS is the time between the system performing an autotare. If an
autotare is required before each weighment this value should be set to 1. If no
autotare is required this value should be set to 0.
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ANALOG PREWEIGH DEPTH is only relevant on systems fitted with an analog preweigh
probe. On these systems this value sets the depth of product required on the vibrator allocated
to this probe (allocation is set by DIL switch 2 - 3). Its value is in the range of 0 to 100% of
the preweigh calibration weight.
24) CALIBRATE
When this entry is selected CALIBRATION of the weighhead may be initiated by pressing the
CAL key. See weighhead calibration procedure on page 27 for full instructions.
25) LIVE WT DISPLAY LIVE WEIGHT. This "display only" function displays the current
weight on the
weighhead.
N.B. Vibrators must be turned off to allow this display. Dashes are displayed if vibrators
are on.
The display shows 2 digits, each being either 0 or 1. The left hand digit represents the state of the
analog probe and the right hand digit represents the state of the ON/OFF probe. 0 indicates that
product level is not satisfied and 1 indicates product level is satisfied.
a) The Level 2 DIL switch is ON (This switch MUST be OFF for normal operation).
The setting required for change can be selected using the 'Scroll Keys'. The value of a selected setting
is changed as described on page 6.
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Level 2 settings are those values that are normally set up on installation or are adjusted by
experienced Plant Engineers to suit a particular installation.
1) LIVE WT DISPLAY LIVE WEIGHT. This "display only" function displays the current
weight on the
weighhead.
LIVE ANALOG TO DIGITAL CONVERTER OUTPUT. This display only function displays the
current output value of the analog to digital converter. It is provided for diagnostic and basic
machine weighhead setup functions. The 12 bit converter output is displayed in decimal
(0 to 4096).
N.B. Vibrators must be turned OFF to allow this display. Dashes are displayed if vibrators
are on.
3) SETTLE
This entry can only be set to ON or OFF. If set to ON at the end of each weighment a settled
weight will be taken and displayed before discharge is allowed. (Under weights will be topped up
if TOPUP is turned ON). If a faster weighing cycle is required, without settle and topup, settle
may be turned off by entering OFF.
N.B: If settle is OFF, no statistical data is collected for printouts or display and no optimisation
can be performed.
RUN SETTLE TOLERANCE. If settle is turned ON a settled weight value will be taken and
displayed when three consecutive weight readings have been made with a difference between the
readings equal to or less than the value entered here. The units of this entry are in A-D bits. This
entry should normally be set to 3.
7) TARE DELAY
This value in seconds is the delay between the weighpan discharging and the start of an
Automatic Tare. The delay is necessary to allow the weighpan to become steady after opening
and closing. A typical value should be 1.0 to 1.5 seconds.
8) SETL FREQ
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SETTLE FREQUENCY. This value in units of 20 milli-seconds defines how often a weight
reading is taken during settle. Its purpose is to stop false settles being taken due to slow
turning points in weight output. The normal value for this entry is 3 (60 milli-sec).
9) VIB1 FACTR %
VIBRATOR 1 SCALING FACTOR. This value scales vibrator 1 amplitude set in level 1
(vib1 fast, vib1 slow). Its overall effect is to set a maximum amplitude. This entry may be
set in the range 0 to 100%. This entry should be adjusted to the maximum vibration required
when vib1 fast has been set to 100%.
VIBRATOR 2 SCALING FACTOR. This value scales vibrator 2 amplitude set in level 1
(vib2 fast, vib2 slow). Its overall effect is to set a maximum amplitude. This entry may be set
in the range 0 to 100%. This entry should be adjusted to the maximum vibration required when
vib2 fast has been set to 100%.
VIBRATOR 3 SCALING FACTOR. This value scales vibrator 3 amplitude set in level 1
(vib3 fast, vib3 slow). Its overall effect is to set a maximum amplitude. This entry may be set
in the range 0 to 100%. This entry should be adjusted to the maximum vibration required when
vib3 fast has been set to 100%.
This delay time in seconds is the delay between starting to close the weighpan door (on systems
with a weighpan) and starting to feed product. The time should be sufficient to ensure the door
is fully closed before product is fed. Typical time 0.5 seconds.
The value entered sets the decimal point position on all weight displays as follows:-
VALUE POSITION
16) HYSTERESIS %
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If the weight in the pan drops below this % age of the bulk cutoff point after having reached the
bulk cutoff point, bulk feed will restart.
If this value is set to ON, an automatic printout followed by a clear down of all statistical data will
occur every 8 hours. (This is in addition to other printouts).
18) PASSWORD
Value 0-65535
The value set here is the number required at the start of the Level 1 Product Settings in order to
gain access to the rest of the product code values. If no password protection is required, enter 0.
The clock stops immediately any change is made and is restarted by exiting from this entry.
The clock stops immediately any change is made and is restarted by exiting from this entry.
Value 0-9999.
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As there is no 'reject' facility, the 'Maximum' and 'Minimum' weights are for statistical purposes only.
7. PRINTOUTS
- (Printer Option Only) 1) Print Automatic
The computer will automatically print, every hour, an hourly report-to-date, and if selected, every
eight hours will print a final eight-hour report and clear down all statistical data.
2) Print Manual
A printout will occur if the "F" key is pressed while displaying 'Print F' or
'PRINT & CLEAR F' in the running display. This is followed by a clear down of all
statistical data if 'PRINT & CLEAR' was displayed.
N.B: If 'Settle' is set to OFF, ie: no settle occurs during the weighing cycle, no statistical data
can be collected. In this case a message 'No data collected' is printed instead of the
above printouts.
PRINTER 'HAND-ON'
A facility is provided so that several Digiway controllers can use one printer. Each Digiway passes
on any printout generated to the next until it reaches the controller attached to the printer. (The
source of the printout is identified by the 'Machine identity' entered under 'Level 2'.)
If any of the above conditions is not satisfied, bulk and fine cutoff points are set manually.
When a product code is selected, set the bulk and fine cutoff points to the required starting values.
(The last 'Trended' values will be saved in a product code which has been previously
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used).
When the number of weighments equals the correction batch size (set under 'Trend Batch', Level 2) a
correction cycle will occur. This cycle will divide the control total weight by the correction batch size
and obtain an average weight. This average is compared to the target weight, and an error value
determined. This error could be plus or minus. If the error is minus i.e: average was below target
then the error value is added to both fine and bulk cutoff weights.
NOTE:
A maximum error correction (per correction cycle) is set under 'Max adj' (level 2) to make trending a
gentle process. If the value was plus and above target by a value greater than 2 bits (dead zone)
then the error or max error allowed per correction cycle is subtracted from both bulk and fine cut off
weights. Both the control average and optimisation batch count are set to zero after the orrection
cycle is completed. The aim is to control weighments to give average values at target or just above
target. If 'Trending' is set to 50% the error is divided by 2 thus making trending a slower/more gentle
process.
TARGET
X
FINE CUT OFF
X
BULK CUT OFF
X = error value or (error value) /2 or maximum allowed change per correction cycle.
These three possibilities are adjustable under level 2 variables.
When a product code is selected, set the bulk and fine cutoff points to the required starting values.
(The last 'Trended' values will be saved in a product code which has been previously
used).
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1. The lowest weighment weight (before any top-up) in the correction batch.
When the number of weighments equals the correction batch size (set under 'Trend Batch', level 2) a
correction cycle will occur. This cycle will find the lowest weight recorded in the correction batch.
This is compared to the target weight, and an error value determined. This error could be plus or
minus. If the error is minus (i.e: lowest weight was below target) then the error value is added to both
fine and bulk cut off weights.
NOTE:
A maximum error correction per correction cycle is set under 'Max Adj' (level 2) to make trending a
gentle process. If the value was plus and above target by a value greater than 2 bits (dead zone) the
error or max error allowed per correction cycle is subtracted from both bulk and final cutoff weights.
Both the control average and optimisation batch count are set to zero after the correction cycle is
completed. The aim is to control weighments to give minimum weights at target or just above
target. If 'Trending' is set to 50% the error is divided by 2, thus making trending a slower/more gentle
process.
TARGET
X = error value or (error value) /2 or maximum allowed change per correction cycle.
These three possibilities are adjustable under level 2 variables.
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1 2 3 4 1 2 3 4 1 2 3 4
B R O Y B R O Y B R O Y
DILS 1 DILS 2 DILS 3
NOTE *1 This DIL switch must be OFF if ON/OFF type probe is NOT fitted
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On these machines the ready output indicates weighment is complete. The discharge output
changes its use and becomes TARE IN PROGRESS output to indicate to an operator NOT TO
TOUCH THE WEIGHHEAD. The discharge input (call) changes its use and becomes START
WEIGHING input and the weighpan closed switch input becomes STOP FEED.
1. Ensure that the system has been turned ON for a minimum of 15 minutes before performing
weighhead calibration.
3. Press the security switch key to light the security switch lamp.
4. Scroll the display, enter the password and continue scrolling until CALIBRATE - - - - is
displayed.
5. Press the CAL key. The display will either display flashing DISCH indicating a pan discharge
is required (not on manually presented machines) or flashing ZERO. If DISCH is displayed
discharge the weighpan by an external call or by a hand discharge from the front panel. The
display should flash ZERO after discharge.
6. Visually check that the weighhead is empty and clear of product build up.
8. The display will display WAIT, for 5 to 10 seconds and then display the calibration weight. This
weight may changed using the front panel keys if not correct. The correct weight will be
specified by the manufacturer at installation.
11. The display will display WAIT, for 5 to 10 seconds and then display ZERO flashing.
13. Press the CAL key. The display will display WAIT for 1 second and then display LIVE
WEIGHT. Calibration is now complete. Accuracy can now be checked by applying weights
to the weighhead.
If at any stage of Calibration the computer is unable to complete, the stage diagnostic message
will be displayed. See page 28 for diagnostic information.
13. DIAGNOSTICS
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At various stages of calibration and weighing cycle the computer will make checks to determine that
the system is operating normally. If an abnormal condition is detected the lamp in the
'D' button will flash. The cause of the diagnostic will be displayed if the 'D' key is pressed. If more
than 1 error exists, diagnostics will be displayed in rotation. Listed below are the diagnostic messages
and possible causes. Calibration diagnostics are displayed immediately without pressing the 'D' button.
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Locate the two banks of eight DIL switches marked ZERO and RANGE mounted on the top edge of
this circuit board.
1. Scroll the front panel display until LIVE A-D O/P is displayed.
3. ZERO SETUP
With NO weight on the weighpan or weighhead check for a displayed reading between 100 and
300. If the reading is not within this range adjust the ZERO DIL switches to correct. The
DIL switches are in a binary form the Brown switch 1 giving the smallest effect the Grey switch 8
giving the largest effect. Turning a switch ON will cause the displayed value to reduce.
4. RANGE SETUP
If all switches are OFF and the difference is still too small move the GAIN link marked GAIN in this
board to the HI position. If all switches are ON and the difference is too large move the
GAIN link to the LO position.
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Locate the bank of six DIL switches marked RANGE mounted on the top edge of this circuit board.
1. Scroll the front panel display until LIVE A-D O/P is displayed.
2. ZERO SETUP
a) With NO WEIGHT in the weighpan adjust the weighcell Tare Spring until the mechanism has a
1.5 mm to 2.0 mm clearance between the mechanism and the TOP STOP.
b) Adjust the LVDT core until LIVE A-D O/P displays between 100 and 300.
3. RANGE SETUP
Apply the CALIBRATION WEIGHT to the weighpan. Adjust the range DIL switches (for
coarse adjustment) and the potentiometer in the weighcell (for fine adjustment) until
LIVE A-D O/P reads a DIFFERENCE between the reading with and without the calibration weight
at 3550 to 3800.
Note If an adjustment is made to the range DIL switches or the potentiometer in the weighcell
repeat
the ZERO SETUP.
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Adjustment switches are provided for changing the weighhead electronic damping factor.
Adjustments are made by DIL switches on circuit board 2184 on loadcell systems and PCS 2301
on weighcell systems. To gain access to this board remove the computer top cover. The circuit
board is located on the extreme left when viewed facing the front panel. Locate the four banks
of two DIL switches marked FILTER 1 2 3 4. ALL FOUR BANKS OF SWITCHES MUST BE
SET THE SAME.
The damping is normally set to small damping. Increase where large amounts of vibration exist.
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1) Mains Supply
198 to 256 volt 50 hz fused externally at 15 amp. Option factory setting for 98 to 128 volt
supplies (refer to manufacturer).
Channel 2 - ON/OFF type preweigh level probe. This probe if fitted can control either vibrator 2 or
vibrator 3 (DIL switch 2 - 3 choice). In addition DIL switch 3 - 3 selects for either
PROBE ON = product satisfied or PROBE OFF = product satisfied.
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6) Vibrator Channels.
Three vibrator channels are provided each capable of driving a half wave vibrator, 7 AMP max
peak current, with phase switching amplitude control. Each vibrator has two levels of vibration
that are front panel settable with changeover occurring at bulk feed cutoff. In addition channels 2
and 3 may be selected to operate with ON/OFF control controlled by an analog or ON/OFF probe
or switch sensing product depth (see DILS 1 - 4, 2 - 3, and 3 - 3).
Channel allocation will depend on a particular application, however the examples given on sheet
36 should as far as possible be adhered to.
The full scale weight range of the weigher and resolution are defined by the calibration weight
used when the system is calibrated. The calibration weight selected should equal the full scale
weight of the weigher. If a decimal point is required its position can be specified using the
"DECIMAL PLACES" function in level 2 setup.
The following table gives the resolution that will be obtained for different calibration weights
(machine full scale capacities).
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Layout C. Integral bulk and fine vibrator, preweigh vibrator, hopper vibrator.
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The probe is connected to the analog input and fitted over the final vibrator tray (VIBS 1 & 2) in a
position to measure the depth of product arriving on that tray. It switches the selected vibrator to be
controlled on and off in response to the depth of product. A sensing plate is fitted to the end of the
probe rod. The dimensions of this plate (surface area) are chosen to suit the tray dimensions and to
enable the required sensitivity. A greater surface area gives a greater sensitivity to depth
changes. See "Initial Adjustment".
Routine Adjustment:
The zero point of the probe will require occasional adjustment to compensate for small dimensional
changes.
To gain access to the trimmer a 6mm screw is removed from the side of the probe box. It is located
between the two indicator lamps. The trimmer has 20 active revolutions. A quiet "click" can be heard
when its end of travel protection mechanism operates each revolution.
Procedure:
1) Make sure that there is no product on vibration tray beneath and around the sensing plate.
2) If the RED lamp is ON turn the trimmer anti-clockwise. If it is OFF turn it clockwise, until the
point is found where it just switches from off to on.
3) Replace protection screw in trimmer hole, making sure that the nylon washer is fitted and screw
does not penetrate too far and damage the trimmer.
Initial Adjustment:
This is primarily for the commissioning engineer or after changing the surface area of the sensing
plate.
1) Remove the lid from the probe and perform the zero point adjustment as above in "routine
adjustment".
4) Ensure that the distance between the probe plate and the vibrator tray is equal to the deepest
product depth that is ever to be required plus 50% more.
6) Obtain some product, preferably the product with the highest moisture content that is likely to be
used on the machine and place it under the probe plate to a depth equal to the above maximum.
7) Locate the sensitivity adjustment which is on the printed circuit board of the PH8S. It is a small
blue device with a rotary, white screw. There are 16 possible positions 0 to 9, A to F. The
higher the setting the higher the sensitivity. Rotate this device with a small screwdriver
until a position is found where the display just goes from 1 to 0.
If it cannot be made to do so at setting 1, then the sensing plate has too large a surface area. If it
does not change to 1 even at setting "F" then the surface area should be increased.
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8) Replace the probe lid and finally re-adjust the zero-point again as in 1) to compensate for the
capacitance of the lid. Replace 6mm screw. The initial adjustment is now complete except to
point out that it is vital for the vibrator tray to have an electrical connection to the machine
frame.
Normally a flexible lead is installed to bypass the insulating fibre glass springs of the vibrator.
Normal Use:
All that is necessary is to enter the required depth for each product when the other values are set up
under product code. The probe will then stop and start the selected vibrator in order to
maintain that depth.
NOTE:
The green lamp on the PH8S is not used in this application.
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Computer Ready
Not an Output
CALL
Pan Open
Time
DISCHARGE
READY
OUTPUT
CALL
DISCHARGE
Pan Open Pan Open
Time Time
NOTE
Only 1 Disch./Call Allowed.
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DISCH
CALL
DISCHARGES
NOTE
_
Discharge call will be ignored if weigher is not ready for discharge when call arrives. A new call
rising edge is needed to cause a discharge when weigher becomes ready for discharge.
READY
OUTPUT
DISCH
CALL
1 2-n 1
DISCHARGES
NOTE
Ready and Discharge Call must be present together for a discharge to occur.
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22. APPENDIX
22.1.2 LEVEL 1
ENGLISH GERMAN FRENCH
1) PRODUCT CODE PROGR. CODE CODE PRODUCT
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22.1.3 LEVEL 2
ENGLISH GERMAN FRENCH
1) LIVE WT. LEBENDGEW. POIDS VIF
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22.1.4 DIAGNOSTICS
22.1.5 MISCELLANEOUS
2) OFF AUS 0
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