Packaging Line - System Description & Drawing 2

For Tioxide (Malaysia) Sdn. Bhd.
System Description
Packaging Line With Metal Detector & Weigher
Project Code: 10A4901
July 2010
2010
Table of Contents
1.0 Objectives .................................................................................................................... 3
2.0 System Detailed Description........................................................................................ 5
2.1 System Operation ..................................................................................................... 5
2.2 System Flow Chart ................................................................................................... 7
2.3 System Features ....................................................................................................... 8
3.0 Operation Manual for Control Units .......................................................................... 10
3.1 Control Panel ......................................................................................................... 10
4.0 User Manual For Photo-Sensor PD30........................................................................ 13
4.1 Sensor Features ...................................................................................................... 13
4.2 Setting the Sensor .................................................................................................. 13
5.0 Alarm List & Troubleshooting Guide ........................................................................ 15
6.0 Electrical Drawing, Layout & Material List ............................................................... 19
7.0 Operation Manual For Weighing Indicator................................................................. 50
For Tioxide (Malaysia) Sdn. Bhd.| 2

2010
Packaging Line with Metal Detector & Weigher

For Tioxide (Malaysia) Sdn. Bhd.
The intent of this document is to provide a common reference to all resources

involved in the design, and operation of the Packaging Line with Metal Detector
& Weigher for Tioxide (Malaysia) Sdn. Bhd.
1.0 Objectives
x To make sure the bag (product) is flatted to squeeze out the air inside the bag.
x To make sure the bag (product) is free of metal substance before delivery.
x To make sure the bag (product) weight is checked and is within the accepted
weight range.
x To identify the contaminated bag or incorrect weight’s bag automatically and the
inspection result will be shown by tower lamp.

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2010
2.0 System Detailed Description

2.1 System Operation
The system consists of 4 main equipments. These 4 main equipments are: flatenner
with vibrator motor, metal detector, weigher and outfeed belt conveyor. Flatenner will
flat each bag which has passing through it so that all air inside the bag will be squeeze out.
Metal detector checks each bag whether there is any metal substance contained inside the
bag. Weigher will then checks and make sure each bag’s weight is correct and outfeed
belt conveyor will be a stop position for the reject bag or when free roller section is full.
Before startup the system, at first there are few things operator has to make sure:
1) No alarm is triggering. The error lamp and buzzer is turn off.
2) No bag is in between the flatenner and outfeed belt conveyor
3) Metal detector controller & weigher indicator power are turn on with no error.
4) Set the weight reference for weigher indicator. Make sure the minimum and
maximum weight reference for bag is set correctly.
5) The photo sensor is clean and is not blocked by dust.
Now, to start the system, press and hold the “start” button at control panel for at
least1 second, the system run lamp will start to blink and buzzer is turn on and off,
indicating the system is going to start. When system is started, the system run lamp will
turn on.
The outfeed belt conveyor, weigher belt conveyor, metal detector power roller &
flatenner belt conveyor will start in cascade and in sequence. Now, when operator loads
in a bag onto flattener, the bag will be carried forward until it reaches sensor X0010
position. The system will check whether there is there a bag within weighing belt
conveyor sensor X0100 position, to flattener belt conveyor sensor X0010 position. If no
bag is between, this bag (at sensor X0010 position) will start carry in. If there is a bag in
between, this 2nd bag (at sensor X0010 position) will until the 1st bag carry out to outfeed
belt conveyor first, then only it start to carry in.

2010
The bag will pass through the metal detector to confirm no metal substances detect
inside the bag. If metal is detected, the metal detector will turn on the metal detect output.
As the bag continue carrying forward and pass sensor X0011, PLC will memorize the
result. When bag is now reach weigher and sensor X0100 is turn on, PLC will activate
the weigher indicator to check the bag’s weight. The comparison result will then output
to PLC and if the weight check is failed, PLC will memorize the result for next step.
When this bag is finally reach to outfeed belt and sensor X0101 is turn on, PLC will do
checking and stop this bag on sensor X0101 position if found either of metal detected or
weight check is failed. The pilot lamps on operation box 2 and control panel, “Metal
Detect” & “Weight Fail” will show the inspection result. Tower lamp with yellow bulb is
indicates the bag has “Metal Detected”, tower lamp with blue bulb will indicates bag is
under weight and white bulb indicates the bag is overweight. Besides, buzzer is turn on to
warn the operator when rejected bag is stop at outfeed belt conveyor. Those accepted or
not reject bag will stop at outfeed belt conveyor too if the free roller section is full.
To stop the system, press the “stop” button on control panel and the system run will
start to flash, showing system is preparing for cycle stop. During this time, when there is
a bag is been carrying to outfeed belt conveyor, system will not stop. It will wait this bag
to reach outfeed belt conveyor then only will terminate the system run mode. This is to
make sure the bag inspections are done cyclically.

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2.2 System Flow Chart

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2.3 System Features

x In order to speed up the overall process, when 1st bag has pass through the check
weigher, immediately the system will allow 2nd bag at flattener to be carry in.
When 2nd bag arrive to weighing belt position and 1st bag is still stopped at
outfeed belt conveyor, 2nd bag is stop.
x If the photo sensor detected the bag and found the infra red beam diffuse back to
itself is not strong enough, it would assume the sensor head is blocked by dust.
The sensor dust output will turn on to warn PLC, and the system is alarms and
whole system stop.
x There are two ways to reset the system when rejected bag on outfeed belt
conveyor is removed. If “NG bag Reset” selector switch is turn to Auto mode,
when reject bag on outfeed belt conveyor is unloaded, after 2 seconds the system
operation is resume and all conveyor are restart. If “NG bag Reset” selector
switch is turn to Manual mode and reject bag on outfeed belt is unloaded, system
will not restart, until the reset button is press then only all conveyors are restart.
x If there is alarm triggered and “Clean Sensor” lamp is turn on, always remember
to clean all photosensor carefully. Make sure the sensor is clean in order to
guarantee system is working well.
x All cables which wired to site will go through the connector for easy plug & play.
In order to relocate the conveyor, operator has to power off the system, unplug all
connectors and can start relocate to another location easily. After all the
conveyors and equipment are relocated, operator is just need to re-plug in all
connectors and the system operation will be ready.
x Buzzer will turn on when system triggering alarm or rejected bag is found on
outfeed belt conveyor. Operator is allow to press the “reset” button to clear the
alarm, but if alarm is still turn on, the alarm lamp is keep light on and buzzer will
be silent.
x During the bag loading to flatenner belt conveyor, if there is any emergency
situation happening, e.g. bag is jammed inside the flatenner, operator can press
the emergency button on operation box 1 located at right side of the flatenner, to

2010
stop the flatenner belt conveyor to clear out the bag, but all others equipment or
conveyors will continue running.
x In this system, when a bag is loaded in, from flatenner belt conveyor sensor
X0010 position start to carry forward to weighing belt conveyor, PLC will start to
obtain the metal detect signal and weight comparison result. If any of the photo-
sensor is failure causes system unable to detect the bag that pass through it, hence
system will always output “failed” as the inspection result for all bags.
x If any of the photo-sensor is misaligned and keep turn on during conveyor run for
10seconds, system will activate the alarm and stop. This is to make sure the photo
sensors are functioning well before it can carry out the inspection correctly.
x Total of two tower lamps are used to show the inspections result. Yellow bulb
indicates metal detected, blue bulb indicates under weight and white bulb
indicates over weight.

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3.0 Operation Manual for Control Units

3.1 Control Panel
Abbreviation:
PB Push button
ES Emergency Stop Button – Push Lock Turn to Reset
SSW Selector Switch
PL Pilot Lamp
The control panel is located besides outfeed belt conveyor. A padlock-able main
power isolator switch is mounted beside the control panel for maintenance purpose.

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Control Panel Control Button & Lamp
Switches / Lamps Description

Source (PL) Light on when incoming power is supplied to the system.
System Run (PL) Light on when system is in operation mode. Blinking when either
system is starting or preparing to stop.
Error (PL) Light on when system is in alarm mode.
Clean Sensor (PL) Light on when either one photo sensor is in error mode. When this
photo sensor alarm is triggering, system will stop all belt conveyors.
System request operator to clean the sensor head to make sure it is
able to operating well, after that press the reset button to reset this
alarm and the system will resume operation.
Metal Detect (PL) Light on when rejected bag (metal detected) is stop at outfeed belt
conveyor. When system is selected “Reset NG bag” to auto mode
and NG bag is removed, outfeed belt will resume operation

2010
automatically and metal detect lamp is turn off. But if system

selected “Rest NG bag” to manual mode and NG bag is removed,
the metal detect lamp will still turn on, need to press the reset button
to turn off the lamp and all belt conveyors will resume operation.
Weight Fail (PL) Light on when rejected bag (weight check is failed) is stop at outfeed
belt conveyor. Similar features as “Metal Detect” lamp.
Start (PB) Press this button and hold for 1 second will start the system
operation mode. When system run lamp start to blink indicates the
system is now starting.
Stop (PB) During system operation mode and this stop button is pressed,
system will prepare in cycle stop mode. System will make sure all
operations has completed first, then only the system operation mode
is terminated. This is different from emergency stop button which
will stop all operation instantly with no cycle stop functionality. If
system run lamp is start to blink indicating the system is preparing
to stop.
Reset (PB) Press this button to reset all alarms. Besides, during NG bag manual
reset selection and if rejected bag is already been unloaded, operator
has to press this button to restart all operation.
NG Bag Reset, Auto When rejected bag is unloaded from outfeed belt conveyor:
– Manual (SSW) Auto: System will auto reset and restart all conveyors and operation.
Manual: Need to press the reset button to restart all operation.
Emergency Stop (ES) Press this button to stop all operation instantly. When the button is
released, operator has to press the reset button and start the system
again to continue operation.
Buzzer Sound on when:
1) System triggering alarm mode.
2) Rejected bag is stop at outfeed belt conveyor.
3) Sound on and off when system is starting.

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4.0 User Manual For Photo-Sensor PD30
Photo sensor LED & Button with Description
4.1 Sensor Features

This photo sensor is diffuse type sensor. To senses an object, its infra red beam
will hit the object and reflect back to itself. When it received the reflected red beam, it an
object is there. Therefore, if dust block the sensor, the emission of red beam is low and
total red beam reflect back to itself is reduced, hence the sensor know is block by dust,
the alarm output will turn on and system is alarm.
Basically, if the red beam reflects back to sensor itself is reduced, the stability
green LED will not steadily light on, it will slowly turn off or turn darker. The would
ease operator to indicate and identify the problem.
4.2 Setting the Sensor

In order to make sure the sensor is working well and properly, we need to adjust
and teach the sensor, so that it will not always give faulty alarm signal to the system and
cause alarm.

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5.0 Alarm List & Troubleshooting Guide

During alarm mode, operator has to check few things in order to identify the
source of error thereafter they able to troubleshoot and reset it.
No. Alarm Troubleshooting Guide

1 Flattener vibrator motor is 1) Check the vibrator motor supply power = 3Phase 415V
overloaded 2) Check internal wiring of the motor. Resistance among
U-V-W must be approximately same.
3) Make sure the motor cables are not short circuit.
4) Make sure the vibrator motor is not jammed.
5) Make sure PLC cable X0005 is wired to motor overload
relay correctly (Normally Open Contact).
6) Reset the vibrator motor overload relay located inside
the control panel.
7) Press the reset button on control panel.
2 Flattener belt conveyor motor 1) Check the belt motor supply power = 3Phase 415V
is overloaded 2) Check internal wiring of the motor. Resistance among
4) Make sure the belt motor is not jammed.
6) Reset the belt motor overload relay located inside the
control panel.
3 Metal detector belt conveyor 1) Check the power roller supply power = 3Phase 415V
power roller is overloaded 2) Check internal wiring of the power roller. Resistance
among U-V-W must be approximately same.
4) Make sure the power roller is not jammed.

2010

6) Reset the power roller overload relay located inside the
control panel.
4 Weigher belt conveyor motor 1) Check the belt motor supply power = 3Phase 415V
is overloaded 2) Check internal wiring of the motor. Resistance among
control panel.
5 Outfeed belt conveyor is 1) Check the belt motor supply power = 3Phase 415V
overloaded 2) Check internal wiring of the motor. Resistance among
control panel.
6 Emergency Stop button 1) Make sure the emergency button located on control
(control panel & op.box2) panel and outfeed belt conveyor op. box2 are not
pressed pressed.
2) Make sure the button cable connection is not loosened.
3) Check the emergency button cable. These 2 buttons

2010
cable must be connect in series and back to PLC input

X0004 (Normally Close Contact).
4) Release these buttons and press the reset button.
7 Flattener emergency stop 1) Make sure the emergency button located beside flattener
button (op.box1) pressed op. box1 is not pressed.
2) Make sure the button cable connection is not loosened.
3) Check the emergency button cable. The cable is connect
back to PLC input X0108 (Normally Close Contact).
4) Release this button and press the reset button.
8 Photo sensor sensing error 1) Make sure all photo sensors head are clean and no dust.
mode (dust blocked) 2) Make sure each photo sensor, when sensing the bag,
- “Clean Sensor” lamp at both of the sensor’s green and yellow LED are turn on.
control panel will turn on If the stability green LED is not stable, it will output
alarm to the PLC X0102 (Normal Open Contact).
3) The photo sensor is diffuse type sensor. To senses an
object, its infra red beam will hit the object and reflect
back to itself thereafter it knows an object is there.
Therefore, if dust block the sensor, the total red beam
reflect back to itself is reduced, hence know is block by
dust. (If the red beam reflects back to itself is reduced,
the sensor green LED will not steadily light on, it will
slowly turn off or turn darker.)
9 Metal detector alarm mode 1) Check the cable connects to metal detector controller,
contact 21 - 22. During power on and no fault, contact
21 - 22 is open.
2) Check the cable connects back to PLC X0104.
3) Make sure metal detector parameter is set correctly.
4) Make sure the metal detector is operating well.

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10 Photo sensor Failure 1) Check the alignment of all photo sensors.

(Sensor is keep turning on) 2) Make sure the sensor will not keep turning on during
conveyor running.
3) Make sure bag is not jammed during conveying, to
prevent this bag to keep triggering the sensor.

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6.0 Electrical Drawing, Layout &

Material List

1 2 3 4 5 6 7 8 9
Company / customer TIOXIDE (MALAYSIA) SDN. BHD.

C Project description CONVEYOR WITH METAL DETECTOR & WEIGHER
Drawing number 10A4903
Commission
E Edit date 24/06/2010 by BENNY
DRAWN BY BENNY
F
CHECKED BY BENNY SCALE NTS CUSTOMER TIOXIDE (MALAYSIA) SDN. BHD. JOB NO. 10A4903
APPROVED BY DATE 24/06/2010 DRAWING NAME COVER SHEET DRAWING NO. 10A4903
This document must not be copied to any parties and must be returned upon request A4
DRAWING LIST(FORM NO:PQD- E-01) P 1/1
PROJECT CONVEYOR WITH METAL DETECTOR & WEIGHER CUSTOMER TIOXIDE (MALAYSIA) SDN. BHD.
DRAWING NO. 10A4903 PROJECT CODE 10A4903
DRAWN BY BENNY DELIVERY DATE 26/07/2010
CHECKED BY BENNY MANUFACTURE
APPROVED BY DATE 23/07/2010
No Part Name Drawing No Treatment Material Q
ty Unit Price Amount Remark
1 COVER SHEET 10A4903
2 ACRYLIC LABEL 10A4903_
A001
3 ACRYLIC LABEL 10A4903_
A002
4 CONTROL PANEL 10A4903_
B001
B002
B003
B004
8 WEIGHING INDICATOR PANEL 10A4903_
B005
9 OPERATION BOX 10A4903_
B006
10 POWER SUPPLY BRACKET 10A4903_
BR01
11 OP. BOX 1 BRACKET 10A4903_
BR02
12 OP. BOX 2 BRACKET 10A4903_
BR03
13 CONTROL PANEL BACK SUPPORT 10A4903_
BR04
14 JUNCTION BOX WIRING 10A4903_
JB01
15 JUNCTION BOX CONNECTOR PIN ASSIGNMENT 10A4903_
JB02
16 LAYOUT 10A4903_
L001M1
17 LOAD CELL CONNETION 10A4903_
LC01
18 MAIN POWER 10A4903_
M001
M002
M003
21 METAL DETECTOR CONNECTION 10A4903_
M004
22 CHECK WEIGHER CONNECTION 10A4903_
M005
23 PURCHASE LIST 10A4903_
P001
24 PURCHASE LIST 10A4903_
P002
25 PLC INPUT DIAGRAM 10A4903_
X001
X002
X003
28 PLC OUTPUT DIAGRAM 10A4903_
Y001
Y002
Y003M1
DRAWING LIST(FORM NO:PQD- E-01) P 1/1
PROJECT CONVEYOR WITH METAL DETECTOR & WEIGHER CUSTOMER TIOXIDE (MALAYSIA) SDN. BHD.
DRAWING NO. 10A4903 PROJECT CODE 10A4903
DRAWN BY BENNY DELIVERY DATE 26/07/2010
CHECKED BY BENNY MANUFACTURE
APPROVED BY DATE 23/07/2010
No Part Name Drawing No Treatment Material Q
ty Unit Price Amount Remark
1 DRAWING LIST -
2 DRAWING LIST .
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
ELECTRICAL PURCHASE LIST(FORM NO: QP-DE-02)
Store/Purch Symbol Specification Description Quantity Brand Unit Note
PB0000, 0002 XB7-EA31 Push Button, NO, Green, Dia22 6 TELE PCS
PB0001 XB7-EA42 Push Button, NC, Red, Dia22 2 TELE PCS
ES0004 XB7-ES542 E.Stop Button, NC, Red, Dia22, Pushlock Turn Reset 6 TELE PCS
SS0003 XB7-ED21 Selector Switch, 2Position No Spring, Dia22MM 2 TELE PCS
PL01 XB7-EV41 Pilot Lamp, AC220V, DIA22, White 2 TELE PCS
PL1100 XB7-EV03B Pilot Lamp, DC24V, DIA22, Green 2 TELE PCS
PL1101,1103~5 XB7-EV04B Pilot Lamp, DC24V, DIA22, Red 12 TELE PCS
MC1002~6 SC-03 Magnetic Contactor, AC220V 10 FUJI PCS

OL0007, 0008 TRON/3 Thermal Overload Relay, 0.36~0.54A 4 FUJI PCS 110W
OL0005 TRON/3 Thermal Overload Relay, 0.48~0.72A 2 FUJI PCS 250W
OL0006, 0009 TRON/3 Thermal Overload Relay, 0.8~1.2A 4 FUJI PCS 400W
F1 - Fuse, 2A c/w Holder 2 - PCS

PLC CPM1A-40CDR-A PLC, AC240V Power, Relay Output, 18 Input, 12 Output 2 OMRON PCS
PLC-EXP TPM1A-20EDR PLC Expansion Unit, 12Input, 8Output 2 OMRON PCS
PH0009 PD30CND10NPDU Photoelectric Diffuse Sensor c/w Dust Output, 24VDC, PNP 8 CARLO GAVAZZI PCS
P.SUPPLY S-50-24 DC Power Supply, Input: 240VAC, Output: 24VDC, 50W 2 MEANWELL PCS
CR1000~1,1106~ MY2N Relay, Coil = DC24V c/w Base 8 OMRON PCS
MCB1 - Auto Breaker, 3Pole 20A 2 ABB PCS
MCB7 - Auto Breaker, 3Pole 10A 2 ABB PCS
MCB2 ~ 6 - Auto Breaker, 2Pole 6A 10 ABB PCS
V.ST VSS1-2 Single Phase Voltage Stabilizer c/w Metal Casing, 1KVA 2 QPS PCS
FAN - Fan c/w PVC Guide & Filter 2 TOYO PCS
FILTER - PVC Guide & Filter 2 TOYO PCS
SOCKET - PVC Single Socket 2 - PCS
OPBOX1 BOX-221 PVC Box, Dia22mm, 1 Hole 2 CKC BOX
OPBOX2 BOX-224 PVC Box, Dia22mm, 4 Hole 2 CKC BOX
DWN BY DESIGNED BY PROJECT CODE CUSTOMER TIOXIDE (MALAYSIA) S.B. DWN NAME 10A4903_P001
BENNY BENNY 10A4903 DRAWING
CHK BY DATE 01/06/10 DESCRIPTION PURCHASE LIST
ELECTRICAL PURCHASE LIST(FORM NO: QP-DE-02)
Store/Purch Symbol Specification Description Quantity Brand Unit Note
CABLE #1,2,4,6 WS32J4TR Round Shape Connector, 4 Core, Angle, Plug, 50A 8 WEIPU PCS
CABLE #1,2,4,6 WS32K4ZQ Round Shape Connector, 4 Core, Straight, Socket, 50A 8 WEIPU PCS
CABLE #3,5,7~9 WS32J11TR Round Shape Connector, 11 Core, Angle, Plug, 25A 10 WEIPU PCS
CABLE #3,5,7~9 WS32K11ZQ Round Shape Connector, 11 Core, Straight, Socket, 25A 10 WEIPU PCS
CABLE #10 WS24J12TS Round Shape Connector, 12 Core, Angle, Plug, 10A 2 WEIPU PCS
CABLE #10 WS24K12ZQ Round Shape Connector, 12 Core, Angle, Socket, 10A 2 WEIPU PCS
TL01 XVM-B2RAG Tower Lamp, DC24V, LED Light, Red-Amber-Green 2 TELE PCS
TL02 XVM C36 Illuminated Unit, Blue 3 TELE PCS 1set for 1st c/v
TL02 XVM C37 Illuminated Unit, Clear 3 TELE PCS 1set for 1st c/v
TL02 XVM C213T Base unit and cover + 250mm support tube with fixing bracket 3 TELE PCS 1set for 1st c/v
TL02 DL2 EDB1 Light source, LED, DC24V, White 3 TELE PCS 1set for 1st c/v
TL02 DL2 EDB6 Light source, LED, DC24V, Blue 3 TELE PCS 1set for 1st c/v
JBOX-1, 2 ME150 PVC Box c/w Cover, 6"x4" 4 ROSCOI BOX
ISOLATOR 2003/3L On/Off Switch c/w Padlock w/o DC 3Pole 25A 500V 2 BREMAS PCS
BUZZER BM-202 Buzzer, Surface Mounting, Dia30mm, DC24V 2 PATLITE PCS
C.PANEL CR 806025 Metal Enclosure, 800Hx600Wx250D mm 2 CVS BOX
Galvanized Metal Cable Tray, 10" x 8ft/L, G18 8 - 8ft/L
DWN BY DESIGNED BY PROJECT CODE CUSTOMER TIOXIDE (MALAYSIA) S.B. DWN NAME 10A4903_P002
BENNY BENNY 10A4903 DRAWING
CHK BY DATE 01/06/10 DESCRIPTION PURCHASE LIST
1 2 3 4 5 6 7 8 9
R1
R1 / 10A4903_M002.1
A
S1
S1 / 10A4903_M002.1
T1
T1 / 10A4903_M002.1
N
N / 10A4903_M002.1
2 4 6 1 3 1 1 3 1 3
MCB1 MCB2 F1 MCB3 MCB4
CIRCUIT CIRCUIT 2 4 FUSE CIRCUIT 2 4 CIRCUIT 2 4
B 1 3 5 2
BREAKER BREAKER 2A BREAKER BREAKER
20A 6A 6A 6A
R0 S0 T0 R2 R2
R3 R3 S4 S5
N2 N2 N N4 N5
T1 T2 T3 L N
C ISOLATOR P.SUPPLY
PADLOCKABLE L1 L2 L3 POWER SUPPLY
3POLE 25A 50W
+ -
R S T N + -
1 3
MCB6 L1 L2/N
CIRCUIT 2 4
D BREAKER
6A
E x1 L E
PLC
PL01 FAN1 MODULE
P.LAMP x2 FAN N
240VAC 240VAC CPM1A
E
E
SOCKET L E N
1PH 240VAC
DC0V N2
R S T N E 10A4903_M002.6 10A4903_Y001.2
DC24V R2
E 10A4903_X001.1 10A4903_M002.6
INCOMING
DC CONTROL AC CONTROL SOURCE SOCKET
POWER FAN PLC
POWER POWER LAMP 1PH 240V
3PH 415V 50HZ
DRAWN BY BENNY
F
APPROVED BY DATE 28/06/2010 DRAWING NAME MAIN POWER DRAWING NO. 10A4903_M001
1 2 3 4 5 6 7 8 9
MCB7
1 2 R10
10A4903_M001.9 / R1 R10 / 10A4903_M003.1
A 3 4 S10
10A4903_M001.9 / S1 S10 / 10A4903_M003.1
5 6 T10
10A4903_M001.9 / T1 T10 / 10A4903_M003.1
CIRCUIT BREAKER
10A4903_M001.9 / N 10A
1 3
L1 L2 L3 L1 L2 L3
MCB5
CIRCUIT 2 4
MC1002 MC1003
B BREAKER /10A4903_Y001.5 T1 T2 T3 /10A4903_Y001.5 T1 T2 T3
6A MAG. CONTACTOR MAG. CONTACTOR
L-VST
N-VST
L1 N1
DC0V 10A4903_M001.3
MC1A
DC0V 10A4903_M003.2
MC2A
INPUT
V.ST
1PH 240V
1KVA
VOLTAGE
STABILIZER 6 4 2 13 11 6 4 2 13 11
C OL0005 OL0006
/10A4903_Y001.5 5 3 1 14 12 /10A4903_Y001.5 5 3 1 14 12
STABILIZED 0.48~0.72A 0.8~1.2A
L2 N2 OUTPUT OVERLOAD OVERLOAD
R2
R2
X0005
X0006
10A4903_M001.4
10A4903_M003.3
D
10A4903_X001.5
10A4903_X001.5
UM1 VM1 WM1 UM2 VM2 WM3
U1 V1 W1 U1 V1 W1
M1
M M2
M
N-VST N-VST 250W 3~ 400W 3~
10A4903_M002.4 10A4903_M002.2 PE PE
L-VST L-VST
E 10A4903_M002.3 10A4903_M002.2
FLATENNER FLATENNER
SUPPLY POWER FOR SUPPLY POWER FOR VIBRATOR MOTOR BELT CONVEYOR
METAL DETECTOR WEIGHING INDICATOR 3PH 415V 250W 3PH 415V 400W
DRAWN BY BENNY
F
1 2 3 4 5 6 7 8 9
R10
A 10A4903_M002.9 / R10
S10
10A4903_M002.9 / S10
T10
10A4903_M002.9 / T10
L1 L2 L3 L1 L2 L3 L1 L2 L3
B MC1004 MC1005 MC1006
/10A4903_Y001.6 T1 T2 T3 /10A4903_Y001.6 T1 T2 T3 /10A4903_Y001.7 T1 T2 T3
MAG. CONTACTOR MAG. CONTACTOR MAG. CONTACTOR
DC0V 10A4903_M002.8
MC3A
DC0V 10A4903_M003.6
MC4A
DC0V 10A4903_M003.4
C 6 4 2 13 11 6 4 2 13 11 6 4 2 13
MC5A 11
OL0007 OL0008 OL0009
/10A4903_Y001.6 5 3 1 14 12 /10A4903_Y001.6 5 3 1 14 12 /10A4903_Y001.7 5 3 1 14 12
0.36~0.54A 0.36~0.54A 0.8~1.2A
OVERLOAD OVERLOAD OVERLOAD
R2
R2
R2
X0007
X0008
X0009
10A4903_M002.8
10A4903_M003.6
10A4903_M003.5
10A4903_X001.6
10A4903_X001.6
10A4903_X001.7
UM3 VM3 WM3 UM4 VM4 WM4 UM5 VM5 WM5
U1 V1 W1 U1 V1 W1 U1 V1 W1
M3
M M4
M M5
M
110W 3~ 110W 3~ 400W 3~
PE PE PE
E
METAL DETECTOR CHECK WEIGHER OUTFEED
POWER ROLLER BELT CONVEYOR BELT CONVEYOR
3PH 415V 110W 3PH 415V 110W 3PH 415V 400W
DRAWN BY BENNY
F
1 2 3 4 5 6 7 8 9
METAL DETECTOR
A
AC POWER INPUT TERMINAL BLOCK CONNECTOR SIDE

FAULT METAL INPUTS
E L N 24 21 22 32 31 34 24V INI1 INI2 LS RST

B
METAL
DETECTOR
C CONTROL
PANEL
FAULT-MD
9
RST-MD
5
CR1001
D
/10A4903_Y001.4
N-VST
10A4903_M005.2
L-VST X0104 X0105
10A4903_M005.2 10A4903_X002.4 10A4903_X002.5
E DC0V DC0V
10A4903_M005.1 10A4903_M004.5 10A4903_M004.4
E POWER SOURCE FAULT METAL RESET

DETECTION
NORMAL OPERATION: NORMAL OPERATION:

21 & 24 CLOSED 31 & 32 CLOSED
FAULT: METAL DETECT:
21 & 22 CLOSED 31 & 34 CLOSED
DRAWN BY BENNY
F
APPROVED BY DATE 28/06/2010 DRAWING NAME METAL DETECTOR CONNECTION DRAWING NO. 10A4903_M004
1 2 3 4 5 6 7 8 9
WEIGHING INDICATOR
A
AC POWER INPUT RELAY OUTPUT TERMINAL EXTERNAL INPUT
RS-232 CONNECTOR
COMMON
UNDER
PASS
OVER
N.G
EMPTY
N.A
COMMON
ZERO
TARE/TARE RESET
PHOTO SENSOR
PRINT
2 3 5
E L N OC O1 O2 O3 O4 O5 O6 IC I1 I2 I3 I4
WEIGHING
INDICATOR
C
CONTROL
PANEL
D
CW-COM CW-ZERO CW-PH
9 9
5 5
CR1106
CR1107
X0109 SG (PC)
/10A4903_Y002.6
/10A4903_Y002.7
E N-VST X0107 10A4903_X002.7 TXD (PC)

10A4903_M004.3 10A4903_X002.6
RXD (PC)
L-VST X0106
10A4903_M004.2 10A4903_X002.5
E DC0V
10A4903_M004.2 10A4903_X001.1
CONNECT TO
CONTROL ROOM
DRAWN BY BENNY
F
APPROVED BY DATE 28/06/2010 DRAWING NAME CHECK WEIGHER CONNECTION DRAWING NO. 10A4903_M005
F
E
B
C
A
DRAWN BY
1
CHECKED BY
APPROVED BY
10A4903_M005.3 /
10A4903_M001.3 /
BENNY
BENNY
DC0V
DC24V
DATE
SCALE
2
NTS
COM
28/06/2010
DC24V
CPM1A-40CDR-A
PB0000
PUSH BUTTON
START (C.PANEL)
00
14
13
X0000
3
PB0001
PUSH BUTTON
STOP (C.PANEL)
01
14
13
X0001
PB0002
PUSH BUTTON
RESET (C.PANEL)
02
14
13
X0002
SS0003
SELECTOR SWITCH
4
MANUAL RESET / AUTO

03
14
13
RESET (C.PANEL)
X0003
ES0004A ES0004
E.STOP BUTTON E.STOP BUTTON
EMERGENCY STOP
04
12
11
12
11
(C.PANEL)
X0004
X0004A
FLATENNER VIBRATOR X0005

05
5
CUSTOMER
MOTOR OVERLOAD 10A4903_M002.6
DRAWING NAME
X0005
FLATENNER BELT C/V X0006

06
INPUT CHANNEL 00
OVERLOAD 10A4903_M002.8
X0006
METAL DETECTOR X0007
07
POWER ROLLER OVERLOAD 10A4903_M003.2
6
X0007
CHECK WEIGHER BELT X0008
08
X0008
OUTFEED BELT C/V X0009
09
PLC INPUT DIAGRAM

X0009
7
TIOXIDE (MALAYSIA) SDN. BHD.

PH0010
REFLECTIVE SENSOR
FLATENNER
+
10
BK
BR
PHOTO SENSOR
-
X0010
BL
PH0011
WH
REFLECTIVE SENSOR
METAL DETECTOR
+
11
BK
BR
PHOTO SENSOR
-
X0011
BL
8
WH
JOB NO.
DRAWING NO.
This document must not be copied to any parties and must be returned upon request
9
10A4903
DC0V / 10A4903_X002.1
X0101 / 10A4903_X002.1
DC24V / 10A4903_X002.1
10A4903_X001
A4
1 2 3 4 5 6 7 8 9
10A4903_X001.8 / DC24V DC24V / 10A4903_Y001.2
A 10A4903_X001.8 / DC0V DC0V / 10A4903_Y001.2
10A4903_X001.8 / X0101
BR BL BR BL
1 11
+ - WH + - WH
2 12
BK BK
LS0103
ES0108
PH0100
PH0101
LIMIT SWITCH
E.STOP BUTTON
X0104
10A4903_M004.4
X0105
10A4903_M004.6
X0106
10A4903_M005.3
X0107
10A4903_M005.3
X0109
10A4903_M005.4
REFLECTIVE SENSOR
REFLECTIVE SENSOR
C
DC24V X0100 X0101 X0102 X0103 X0104 X0105 X0106 X0107 X0108 X0109 X0110 X0111
D
COM 00 01 02 03 04 05 06 07 08 09 10 11
CPM1A-40CDR-A INPUT CHANNEL 01
E
SPARE
FAULT
SPARE
(OP.BOX1)
DUST ALARM
BAG DETECT
WEIGHT PASS
OVER WEIGHT
FREE ROLLER
METAL DETECT
PHOTO SENSOR
UNDER WEIGHT
OUTFEED BELT
CHECK WEIGHER
CHECK WEIGHER
CHECK WEIGHER
PHOTO SENSOR
PHOTO SENSOR
METAL DETECTOR
CHECK WEIGHER
METAL DETECTOR
EMERGENCY STOP
DRAWN BY BENNY
F
APPROVED BY DATE 28/06/2010 DRAWING NAME PLC INPUT DIAGRAM DRAWING NO. 10A4903_X002
1 2 3 4 5 6 7 8 9
COM 00 01 02 03 04 05 06 07 08 09 10 11
CPM1A-20EDR INPUT CHANNEL 02
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
DRAWN BY BENNY
F
APPROVED BY DATE 28/06/2010 DRAWING NAME PLC INPUT DIAGRAM DRAWING NO. 10A4903_X003
1 2 3 4 5 6 7 8 9
CPM1A-40CDR-A OUTPUT CHANNEL 10

A
COM 00 COM 01 COM 02 03 COM 04 05 06 07
DC0V Y1000 DC0V Y1001 N2 Y1002 Y1003 N2 Y1004 Y1005 Y1006 Y1007
B
DC24V DC0V
10A4903_Y001.8 10A4903_Y001.8
5
CR1000
/10A4903_Y001.3 9
DC24V-BZ
MC1002
/10A4903_M002.5
MAG.CONTACTOR
MC1003
/10A4903_M002.7
MAG.CONTACTOR
MC1004
/10A4903_M003.2
MAG.CONTACTOR
MC1005
/10A4903_M003.4
MAG.CONTACTOR
MC1006
/10A4903_M003.6
MAG.CONTACTOR
A1 A1 A1 13 A1
CH1 CH2 COM
CR1000
/10A4903_Y001.8
RELAY
CR1001
/10A4903_M004.7
RELAY
A2 A2 A2 14 A2
13 13
MC1A MC2A MC3A MC4A MC5A

14 14 BUZZER
11 11 11 11 11
12 12 12 12 12
OL0005
OL0006
OL0007
OL0008
OL0009
/10A4903_M002.5
/10A4903_M002.7
/10A4903_M003.2
/10A4903_M003.4
/10A4903_M003.6
10A4903_X002.8 / DC24V DC24V / 10A4903_Y001.8
10A4903_X002.8 / DC0V DC0V / 10A4903_Y001.9

/ R2
10A4903_M001.4 / N2
E
SPARE
BUZZER
BELT C/V
BELT C/V
FLATENNER
FLATENNER
"FAULT" RESET
POWER ROLLER
CHECK WEIGHER
METAL DETECTOR
METAL DETECTOR
VIBRATOR MOTOR
OUTFEED BELT C/V
DRAWN BY BENNY
F
APPROVED BY DATE 28/06/2010 DRAWING NAME PLC OUTPUT DIAGRAM DRAWING NO. 10A4903_Y001
1 2 3 4 5 6 7 8 9
CPM1A-40CDR-A OUTPUT CHANNEL 11

A
COM 00 01 02 03 COM 04 05 06 07
DC0V Y1100 Y1101 Y1102 Y1103 DC0V Y1104 Y1105 Y1106 Y1107
PL1100
PILOT LAMP
PL1101
PILOT LAMP
PL1103
PILOT LAMP
PL1104
PILOT LAMP
PL1105
PILOT LAMP
CR1106
/10A4903_M005.6
RELAY
CR1107
/10A4903_M005.7
RELAY
x1 x1 x1 x1 x1 13 13
x2 x2 x2 x2 x2 14 14
TOWER LAMP - GREEN

TOWER LAMP - RED
TOWER LAMP - YELLOW
x1 x1 x1
D
TL01
x2 x2 x2
10A4903_Y003M1.2 / DC24V
10A4903_Y003M1.2 / DC0V
E
"ZERO"
(C.PANEL)
(C.PANEL)
(C.PANEL)
SYSTEM RUN
WEIGHT FAIL
(TOWER LAMP)
CLEAN SENSOR
METAL DETECT
SYSTEM ERROR
CHECK WEIGHER
CHECK WEIGHER
"PHOTO SENSOR"
BAG METAL DETECT
(C.PANEL & T.LAMP)

(C.PANEL & T.LAMP)
DRAWN BY BENNY
F
APPROVED BY DATE 28/06/2010 DRAWING NAME PLC OUTPUT DIAGRAM DRAWING NO. 10A4903_Y002
1 2 3 4 5 6 7 8 9
CPM1A-20EDR OUTPUT CHANNEL 12

A
COM 00 COM 01 COM 02 03 COM 04 05 06 07
DC0V Y1204 (PC) Y1205 (PC) Y1206 (PC) Y1207 (PC)
10A4903_Y002.2 / DC0V
WIRED TO CONNECTOR CABLE#10

& ROUTE TO CONTROL ROOM
Y1207 (PC) /
TOWER LAMP - BLUE

TOWER LAMP - WHITE
x1 x1 Y1206 (PC) /
D
TL02
x2 x2 Y1205 (PC) /
Y1204 (PC) /
10A4903_Y002.2 / DC24V DC24V /
SPARE
SPARE
SPARE
SPARE
SPARE
BAG DETECT
WEIGHT PASS
(TOWER LAMP)
(TOWER LAMP)
METAL DETECT
WEIGHT UNPASS
CHECK WEIGHER
CHECK WEIGHER
METAL DETECTOR
BAG OVER WEIGHT

BAG UNDER WEIGHT
PLC SIGNAL TO SCADA
DRAWN BY BENNY
F
APPROVED BY DATE 23/07/2010 DRAWING NAME PLC OUTPUT DIAGRAM DRAWING NO. 10A4903_Y003M1

Packaging Line - System Description &amp; Drawing 2

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Packaging Line - System Description &amp; Drawing 2

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For Tioxide (Malaysia) Sdn. Bhd.

For Tioxide (Malaysia) Sdn. Bhd.| 2

Packaging Line with Metal Detector & Weigher

The intent of this document is to provide a common reference to all resources

For Tioxide (Malaysia) Sdn. Bhd.| 3

For Tioxide (Malaysia) Sdn. Bhd.| 4

2.0 System Detailed Description

For Tioxide (Malaysia) Sdn. Bhd.| 5

For Tioxide (Malaysia) Sdn. Bhd.| 6

2.2 System Flow Chart

For Tioxide (Malaysia) Sdn. Bhd.| 7

2.3 System Features

For Tioxide (Malaysia) Sdn. Bhd.| 8

For Tioxide (Malaysia) Sdn. Bhd.| 9

3.0 Operation Manual for Control Units

For Tioxide (Malaysia) Sdn. Bhd.| 10

Control Panel Control Button & Lamp

Switches / Lamps Description

For Tioxide (Malaysia) Sdn. Bhd.| 11

automatically and metal detect lamp is turn off. But if system

For Tioxide (Malaysia) Sdn. Bhd.| 12

4.0 User Manual For Photo-Sensor PD30

Photo sensor LED & Button with Description

4.1 Sensor Features

4.2 Setting the Sensor

For Tioxide (Malaysia) Sdn. Bhd.| 13

For Tioxide (Malaysia) Sdn. Bhd.| 14

5.0 Alarm List & Troubleshooting Guide

No. Alarm Troubleshooting Guide

For Tioxide (Malaysia) Sdn. Bhd.| 15

5) Make sure PLC cable X0007 is wired to motor overload

For Tioxide (Malaysia) Sdn. Bhd.| 16

cable must be connect in series and back to PLC input

For Tioxide (Malaysia) Sdn. Bhd.| 17

10 Photo sensor Failure 1) Check the alignment of all photo sensors.

For Tioxide (Malaysia) Sdn. Bhd.| 18

6.0 Electrical Drawing, Layout &

For Tioxide (Malaysia) Sdn. Bhd.| 19

Company / customer TIOXIDE (MALAYSIA) SDN. BHD.

E Edit date 24/06/2010 by BENNY

MC1002~6 SC-03 Magnetic Contactor, AC220V 10 FUJI PCS

F1 - Fuse, 2A c/w Holder 2 - PCS

Galvanized Metal Cable Tray, 10" x 8ft/L, G18 8 - 8ft/L

UM1 VM1 WM1 UM2 VM2 WM3

UM3 VM3 WM3 UM4 VM4 WM4 UM5 VM5 WM5

AC POWER INPUT TERMINAL BLOCK CONNECTOR SIDE

E L N 24 21 22 32 31 34 24V INI1 INI2 LS RST

E POWER SOURCE FAULT METAL RESET

NORMAL OPERATION: NORMAL OPERATION:

AC POWER INPUT RELAY OUTPUT TERMINAL EXTERNAL INPUT

E N-VST X0107 10A4903_X002.7 TXD (PC)

MANUAL RESET / AUTO

FLATENNER VIBRATOR X0005

FLATENNER BELT C/V X0006

PLC INPUT DIAGRAM

TIOXIDE (MALAYSIA) SDN. BHD.

10A4903_X001.8 / DC24V DC24V / 10A4903_Y001.2

A 10A4903_X001.8 / DC0V DC0V / 10A4903_Y001.2

CPM1A-40CDR-A INPUT CHANNEL 01

CPM1A-20EDR INPUT CHANNEL 02

CPM1A-40CDR-A OUTPUT CHANNEL 10

MC1A MC2A MC3A MC4A MC5A

10A4903_X002.8 / DC24V DC24V / 10A4903_Y001.8

10A4903_X002.8 / DC0V DC0V / 10A4903_Y001.9

Packaging Line - System Description & Drawing 2

Packaging Line - System Description & Drawing 2