CD-4000 Manual, v300

CompuWeigh Corporation
CD-4000 MANUAL
Includes SmartTech
Version 3.00, April 2003

CD-4000 Bulkweighing Controller User’s Manual
Copyright © 2002 CompuWeigh Corp., All rights reserved.
Published by:
CompuWeigh Corp.
150 Commerce Court
Cheshire, CT 06410
USA
Tel: (203)-699-9000
This User’s Manual is a reference tool that explains the installation, setup, and operation of the CD-4000
Controller. Any questions concerning setup or service of this product should be addressed to CompuWeigh
Corporation or the scale dealer who installed the system.
This User Manual provides information about the standard CD-4000 features of controllers manufactured at the
time this manual was released. The CD-4000 is an evolving product with a number of custom programs so that it
is possible that your unit may not have some of the features listed in the Manual and similarly there may be
features in your system that are not explained in this Manual. Therefore please call CompuWeigh or your dealer
if you have any questions on the use of your system.
The information described in this manual is solely the property of CompuWeigh Corporation. No part of this
manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including
photocopying and recording without the express written permission of CompuWeigh.
If you find errors or have suggestions to make, please email us at sales@compuweigh.com.
CD-4000 with Unit Train

Contents
Introduction 5
Controls and Hardware 7
Start up Procedure 11
Configuration 13
Auto-Test Procedure 29
Operating Instructions 33
Transaction Sorting 47
Lists 53
SmartTech 59
Gate Control (optional) 63
Reports 67
Administrative Tools 71
Statistics 77
DWI Calibration 85
Alarms and Warnings 91
Options 95
Interface Drawings 97
Index 101
Introduction
Unpacking Procedure
Upon delivery of the instrument, the shipping carton should be examined for any sign of external
damage. If any external damage is visible, the shipping company's representative making the
delivery should be notified at once.
WARNING! In order to prevent the internal parts from being damaged during shipment, the CD-4000
controller has packing material INSIDE it. You MUST remove this material prior to turning on power
to the Controller.
An important component in the Compudraft CD-4000 is the GSE-460 digital weight indicator. Since
installing this indicator requires that the scale be recertified by the State, we strongly recommend that
only authorized CompuWeigh technicians install the system. In addition there are a number of
connections that need to be made, which if done incorrectly, can cause serious damage to the
equipment. The systems are thoroughly tested before shipping so CompuWeigh will not be very
supportive if we hear that the controller is not working after a non-authorized person has attempted to
install the system.
Please read the Manual before operating the system.
Warning
Because the CD-4000 has internal high voltage circuitry, only qualified personnel should open the
unit for service. The system does not contain any repairable parts and any attempt to repair
components will void the factory warranty. Repairs are achieved by board replacement only.
Description
The CD-4000 components consist of the controller housed in a ‘3U’ industrial case, an external 17
inch monitor and a 104-key alphanumeric keyboard. The instrument is self-contained. 115 VAC
50/60 Hz power is required and should be isolated and regulated to prevent power line spikes from
adversely affecting the system operation. Because the instrument draws less than 100 watts of
power internal cooling is not required.
Also supplied with the CD-4000 instrument, is a GSE460 digital weight indicator with special code
written for the CD-4000, a 40 or 80 column printer, 56K external modem, protective cover for the
keyboard, a surge suppressor and the SmartTech opto isolation box for external interfacing and
control of the bulkweighing scale.
To provide easy integration to PLC systems, the system can be provided with a Modbus interface. All
major PLC systems have the capability of interfacing to the Modbus protocol. Note that the integrity
of the controller is maintained because it is the controller and not the PLC that has control of the
scale gates.
CD-4000 with Unit Train Introduction • 5

Controls and Hardware
Power Switch
The instrument's 115 VAC power ‘On/Off’ rocker switch is located on the rear panel's right side as
viewed from the front of the instrument.
Power Connector
The 115 VAC three (3) prong polarized power connector is located on the rear panel below the power
switch. Only the power cord that comes with the instrument should be used with this connector to
supply AC power to the instrument.
Fuse Holder
The 5 VAC fuse holder marked ‘5V Fuse’ is located on the rear panel next to the power connector.
Only a 1 amp slo-blow fuse should be used as a replacement, if required.
S m artN et
R eset 5V F use E xpansion V 1 - M on itor J7 - D .W .I. GM S - KVM
H D 15 DB9
E 1 - E the rnet F em ale M a le
P ow er P 1 - T icke t P rin ter J8 - A udit Trail P rinter

D B 25 DB9
F e m ale M a le
J3 - S cale I/O M 1 - M ouse J9 - R e m ote P rinter
D B 37 6 P in DB9
F em ale M in i D in M ale
J4 - S ca le I/O K 1 - K eyboard J10 - G M S C ontro l
D B 37 6 P in DB9
F em ale M ini D in M ale
CD-4000 with Unit Train Controls and Hardware • 7

Reset Switch
The momentary push button reset switch is located on the rear panel above the power switch. It
resets the system and loads the Main CD-4000 Start Screen or to Configuration if there is a problem
with configuration. This is the preferred means of resetting the system rather, than turning the power
switch off and on again.
DWI Connector
‘J7’ is a 9 D male connector, which is located on the rear panel. This is the communication port for
interfacing the GSE 460 Digital Weight Indicator to the CD-4000.
Printer Connectors
‘J8’ is a 9 D male connector for the Audit Printer (Serial only). This can either be a Star 40-column
printer or a full width Okidata 80-column printer. In either case, it records the scale status and all
draft weights. This is printer must be working correctly for the controller to be able to operate, (NIST
requirement).
‘J9’ is a 9 D male connector for an optional Remote Printer (Serial only) or external 56K Modem,
which is used to provide remote technical support or download program upgrades from
CompuWeigh. If your system has both Remote Printer and Modem, only one device can use this port
at a time.
‘P1’ is a 25 D female connector for a Reports Printer (Parallel only). This connector is located
underneath ‘V1’, the monitor connector.
GMS Control
‘J10’ is a 9 D male connector that is used to provide communications to CompuWeigh’s Grain
Management System (GMS), if you have upgraded to that system or to an HMI Control System using
Modbus Serial.
I/O Connector
‘J3’ is a 37 D female connector that connects to the Opto Box. Depending on the system
configuration, ‘J4’ may also be used in conjunction with ‘J3’ to provide additional I/O.
Ethernet Connector
‘E1’ is an Ethernet connector that allows TCP/IP connections between the CD-4000 and other
computer devices. The port supports both 10 and 100 Base-T communications.
Mouse Connector
‘M1’ is a PS/2 connector. This connection is not used at this time because the CD-4000 does not
require a mouse.
Keyboard
The keyboard provides the following functions:
8 • Controls and Hardware CD-4000 with Unit Train

Function Keys
The function keys are labeled ‘F1’ through ‘F12’. These keys perform actions like saving a
transaction, starting the scale etc. To get the maximum use out of these Function Keys, their
meaning changes depending on what part of the system is active. For this reason next to the
function key is the command that the key will activate, for example ‘F9-New’. This means
that by pressing the ‘F9’ function key you will activate the New Transaction procedure.
Another key that falls into the category of function keys is the ‘Esc’, that is located at the top-
left of the keyboard. This key will undo your latest action.
Please note that to minimize training the CD-4000 and the GMS-4000 use the same function
keys.
Cursor Control Keys
The usual method to move from one data entry field to another is to press the ‘Tab’
key (on left side of the keyboard). The ‘Enter’ key will normally achieve the same
result. To move back to the previous field, hold down the ‘Shift’ key and while held
down, press the ‘Tab’ key.
If you are reviewing a list of information (for example the bin list), you can use the
arrow keys (located in the center-right of the keyboard) to move up and down, left
and right.
Special Keys
The ‘Alt’ keys on both sides of the Space Bar at the bottom of the keyboard are used
when you need to reach a Menu item. Holding down the ‘Alt’ key while pressing the
letter of the alphabet underlined in the menu word (for example holding down the ‘Alt’
and pressing the ‘o’ key will show the Options list.
At the bottom of the keyboard are several keys that typically you will not have to
concern yourself with. For example there are two keys with the Microsoft Windows
logo that are not used by the CD-4000.
Alpha-numeric Keys
All other keys not mentioned above are part of the full alphanumeric keyboard. They
are used to enter the data that is required to run the system.
External Screen
The external screen is typically a 17” color display. The CD-4000 program runs at a
resolution of 1024 x 768. An additional monitor can be added for remote monitoring.
Instrument Housing
The CD-4000 is mounted in a ‘3U’ height 19” wide industrial chassis that is designed to
match the ‘4U’ GMS industrial computer case. It can therefore be stacked on top of other
CD-4000s or on top of GMS industrial computers.
Digital Weight Indicator

The GSE 460 digital weight indicator interfaces to the CD-4000 through a serial data connection.
Refer to the Interface Drawing section of this manual. For operation and calibration of the digital
weight indicator, refer to its operating manual. Please note that a stock 460 indicator will not work
with the CD-4000. Significant enhancements have been made to the 460 to allow it to perform at the
level required by the CD-4000.
Opto Isolation
All external wiring is connected to the CD-4000 through the SmartTech Optical Isolation Box (Opto
Box). The Opto box enables the CD-4000, which is running at 5 volts DC, to interface to the scale
CD-4000 with Unit Train Controls and Hardware • 9

components that are using higher AC or DC voltage. Refer to the drawing in Interface Drawings
section of this Manual.
10 • Controls and Hardware CD-4000 with Unit Train

Start up Procedure
Connections for Power and Peripherals

Power
The female end of the three-prong power cord supplied with the instrument, plugs into the
receptacle on the back panel of the instrument. The male end of the power cord should be
plugged into a surge protector, a UPS (Uninterruptible Power Supply), or failing that a stable
electrically clean 115 VAC 50/60 Hz cycle grounded power source. The controller will not
work properly if the site has poor quality power service.
Printer
The serial output to the Audit Printer should be wired to the connector marked J8 located on
the rear panel of the instrument. The parallel output to the Reports Printer should be wired to
the connector marked P1 located on the rear panel of the instrument. Please refer to the
printer drawings in the Interface Drawings section of this Manual.
External Modem
If your system is not equipped with the Remote Printer, connect the modem’s serial cable to
the connector marked ‘J9’ located on the rear panel of the instrument. If the Remote Printer
is present connect the serial cable provided with the printer to establish a link between CD-
4000 and the Remote Printer.
Digital Weight Indicator

The serial output from the self-contained GSE 460 weight indicator should be wired to the 9
D connector marked ‘J7’ located on the rear panel of the instrument. For proper connections
to the digital weight indicator, refer to the digital weight indicator drawing in the Interface
Drawings section of this manual.
I/O Input
The input and output connections for limit switches, gate solenoids, alarms, etc., should be
wired via the opto isolation box to the 37 D connector marked ‘J3’ located on the rear panel
of the instrument. Please refer to the I/O drawing in the Interface Drawings section of this
manual. Depending on your system configuration ‘J4’ may also be used.
Power up Procedure
Checklist
Before turning the power switch to the 'ON' position you must remove the packing inside the
CD-4000 enclosure. Then pleas ensure the following connections are made:
• Power cord is plugged in
• Remote indicator cable is plugged in
• Printer cables are plugged in
• Serial communications cable is plugged in (if required)
• I/O cable is plugged in (if required)
• Key on front turned to 'BACKUP MODE' position (only important if system is
connected to a GMS workstation).
CD-4000 with Unit Train Start up Procedure • 11

Power On
Turn the power switch to the 'ON' position. Allow 15 to 20 seconds and you will see the
screen below. However if this is the first time into the program or the Configuration of the
scale is not correct, you will instead be shown the Configuration Screen. Please refer to
Configuration on page 13
Menu Bar
Hot key
From this screen you can do any of the following:

1. Press the ‘F2’ key on the keyboard to enter the main part of the program to start
weighing.
2. Hold down the ‘Alt’ key and while holding it down, press the letter ‘d’ to review the
Product and Bin lists. You should fill in these sections so the CD-4000 knows what
products you are using and what product is in each of your bins.
3. Hold down the ‘Alt’ key and press the letter ‘r’ to run Reports.
4. Hold down the ‘Alt’ key and press the letter ‘a’ to select Administrative Tools, to set
up new users and modify the operation of the system. Please note only those users
with Administrative rights have access to this Menu item.
We will look at each of these choices in more detail as we progress through the manual.
12 • Start up Procedure CD-4000 with Unit Train

Configuration
Opening Configuration
Configuration is reached by pressing F2 from Main Screen and then holding down the ‘Alt’ key and
pressing the letter ‘s’ for Scale. Then press the letter ‘a’ or press the Down Arrow until the focus is on
‘Scale Configuration and then press ‘Enter’ key. At this point you will have to enter an Administrative
password.
Note: CD-4000 contains several secured areas accessible only after providing the correct password.
There are two passwords in the system:
• General use password is admin
• Please call CompuWeigh if you need to access the Advanced portion of the Scale
Configuration
If the CD-4000 detects a problem at startup or the system has never been configured before, the
system will automatically go to the Configuration system.
Caution
Bulkweighing scales are complicated devices and the configuration settings have a direct impact on
the efficiency and safety of the scale. Only qualified personnel should attempt to reconfigure the
scale. The most complex components are in an Advanced Section and can only be modified by
CompuWeigh certified personnel.
Retaining Configuration
Because the CD-4000 uses non-volatile memory, the configuration values for the scales are always
saved, even when the power is turned off, so normally there is no need to change configuration.
However if the system has not been used before, or not used for some time, the battery may have
discharged and the values lost. This is why we recommend that at the end of the configuration
procedure that you save the Configuration print out in a safe place for later reference.
Default Values
If when you load the Configuration screen and some of the number appears to be messed up, we
recommend that you press the F2-Defaults button at the bottom of the screen because this not only
provides a clean start, but will enter reset other values that cannot be seen on the screen.
You should now modify the default screen to the values for your scale. The best way to do that is to
pull out the last Configuration printout that you diligently saved the last time you went into
configuration.
Remember that it is dangerous to guess at values like scale capacity.
Entering Values
Start at the top of the list and work down. Use the ‘Tab’ key to move to the appropriate line, enter the
information and then press the ‘Tab’ or ‘Enter’ key to move to the next line. To move up - hold down
the ‘Shift’ key while pressing the ‘Tab’ key.
CD-4000 with Unit Train Configuration • 13

General Scale Configuration
Note: Four boxes are in orange. If you change the values of the first three, you will need to make the
same change in the digital weight indicator. If you change the Percentage Gate in Use to ‘WH’ or ‘LG’
you will have to recalibrate the gate.
Scale Name
Enter a name for the scale so that there is no confusion as to which scale it is. This name
will appear on the top left of the normal screen.
Weight Units (must also be set in digital weight indicator)
When the cursor is on this field press the Down Arrow on the keyboard and you will see the
choices of ‘Lbs’ for pounds, ‘Kgs’ for kilograms and ‘Tons’ for metric tons. Use the Up and
Down Arrows to select the one you want.
Scale Capacity (must also be set in digital weight indicator)

Enter the ‘water level’ capacity of the scale. This information is supplied by the scale
supplier. Typical sizes for new scales are between 1,000lb to 35,000lb range. Older scales
might be considerably larger than this.
Division Size (must also be set in digital weight indicator)

This is the increment between weights displayed by the indicator. For example if it is set to
10, then weights might show as 2000, 2010, 2020, whereas if the value is set to 5, the
weights would show as 2000, 2005, 2010, 2015 etc. Acceptable values are 1, 2 & 5 or ten
times larger or smaller than these three divisions (0.1, 0.2, 0.5, 1, 2, 5, 10, 20 & 50).
Important: For legal-for-trade weighing of grain, the regulations require at least 2,000
divisions while the maximum is determined by the NTEP Class III approval of the load cells
on your scale. The maximum divisions is normally 5,000. To determine the correct number
14 • Configuration CD-4000 with Unit Train

of divisions for your scale divide the Scale Capacity 2000 and also by the maximum allowed,
(e.g. 5,000). Let’s assume a 30,000 lb scale capacity. Dividing 30,000 by 2,000 = 15 and
30,000 by 5,000 = 6. The division size must be <= to 15 and >= to 6. The only division size
that would meet these criteria is 10. The scale would be set up as a 30,000 x 10 lb scale.
Updating the indicator

If you have made a change to any of the items in the orange boxes, (Weight Units, Scale
Capacity or Division Size), you will need to update the digital weight indicator. This is
achieved by pressing F5-More on the Process Screen and then F3-Cal DWI to run through
calibration.
Below is the message you will see when you make a change to one of these three fields.
Select ‘No’ if you do not want to make the change.
Standard Draft Size (important to understand this)

The draft size of the scale is the working capacity of the weigh hopper when loaded with 60
lb per bushel material (like Wheat). This is normally set to 90 - 95% of the scale capacity,
see above, (compare this to around 80% on a CD-3000). For example, if we have a scale
capacity of 30,000 lbs we might want to set the standard draft size at 27,000 to 28,500 lbs. It
is important to realize that if we are weighing light materials there will typically not be enough
space in the weigh hopper to reach this draft size. To eliminate the need for you to adjust the
draft size for differing test weights, we do this for you automatically. We will refer to the
product database for the commodity that you are weighing and compare the test weight
entered there to the ‘standard’ 60 lb/bushel wheat.
For example, if you enter the standard draft size (for 60 lb/bushel product) as 27,000 lbs,
when you weigh products with this Test Weight the CD-4000 will run drafts of 27,000 lbs. If
you are weighing lighter products, for example Yellow Corn, the CD-4000 will look at the Test
Weight that you have entered for Corn in the Product Database (for example, 55.4 lbs/bu)
and run draft sizes of 55.4/60 x 27,000 = 24,930 lbs. This conversion is completely automatic
and will ensure the maximum use of the scale whatever the test weight of the product.
Note: if your scale capacity is well above the standard draft size (for example you have a
150,000 lb weigh hopper but are only running 75,000 lb drafts) you may not want the
automatic adjustment to take place. If so please see Bypass Draft Size Optimizing on page
22 to turn this feature off.
Max Add to Draft Size

The additional amount of weight that can be added to the draft size for those occasions
where the CD-4000 can eliminate a draft from the order. Enter 0 if you do not want any over-
ride.
The CD-4000 is always trying to reduce the number of drafts required to complete an order.
Sometimes the math works out that two small drafts are required at the end of the order to
reach the required weight. To minimize this occurrence, we suggest that you enter an
additional amount that the draft size can be increased to, (just for these ‘special’ occasions).
It will depend on your scale but something around 5% of the scale capacity might make
sense (e.g. 500 lbs on a 10,000 lb scale or 1,000 on a 20,000 lb scale)

Tare Reset Range
This is the weight range on either side of the tare value (usually set to zero) that the system
can reset the tare value. This operation cannot be done while an order is in process.
Typical values are between 100 and 500.
WH Discharge Cutoff
Instead of waiting until the weigh hopper is completely empty before closing the gate, time
can be saved by starting to close the gate while there is still product in the scale. This offset
value is the weight in the scale at which time the gate will start to close. The idea is that by
the time the gate fully closes all the product in the scale has been discharged and none is
trapped in the scale. You should fine-tune this offset number to achieve this goal.
This offset value is used in both the Receive and Ship Mode.
You can enter a value between 0 and 9999. A typical value would be between 100 and
1000.
Percentage Gate In Use (requires calibration of gate)

If the scale has a gate on the lower garner or weigh hopper that can be set to a position other
than full open or full close (commonly called gate control), select the gate from the list. Do
this by pressing the Down Arrow on the keyboard and selecting ‘WH’ for Weigh Hopper or
‘LG’ for the Lower Garner gate. If there is no percent gate control on either of these two
gates select ‘None’. Do not confuse this with ‘Trim’, which refers to the Upper Garner Gate.
Please note: if you select the lower garner as having a percentage gate in use then LG
Gate Type in the Advanced section of Configuration will by default be set to automatic. You
may override this parameter to be a ‘Manual LG gate’ instead, which means that CD-4000
will not energize either close or open solenoids for the gate, but merely display its current
position on the screen next to the gate image. It will be left to the operator to open and close
the gate at the appropriate times.
Gate Pulse Time

This field is only available if there is a percentage gate above.
This time is only used when the position of the percent gate needs to be adjusted.
Jog Time represents the least amount of time a signal will be applied by the CD-4000
to the solenoid when jogging the percent gate open or close. The value is in tenths
of a second and the value can range from 0 to 99. Slower gates will need a larger
value. A typical jog time is between 5 and 20 (½ to 2 seconds).
Gate Dead Band

You can enter a value of 0 to 99. The value is the percent, plus or minus, from the
open position that the gate can drift and still be considered in position. Values
between 2 and 5 would be typical.
Jog Dead Band

When the gate moves to a partially open position it will attempt to do so in one
movement. If the gate moves very quickly, the gate may overshoot the desired
position and then attempt to correct itself and potentially overshoot the other way. If
it appears that this is happening on your system, enter a jog dead band (typically 5 or
10%). The gate will then stop this % of the gate movement before the desired
position and then jog itself into position. Jogging increases the wear on the gate
system, so try to minimize its use and the % number used.

LG Cleanout Time
This field is only available if the Lower Garner percentage gate has been selected.
There are two situations depending upon whether there is or is not a LG Low Level
Sensor Present (please see page 23 in Advanced Configuration).
1. If there is no LG low level sensor present then at the end of the order the
lower gate will fully open and close to remove any product that might be
resting on the gate. The LG Cleanout Time is the time in seconds, once the
Upper Level sensor in the lower garner is clear of product, before the lower
gate will fully open and then close. (This can be several seconds).
2. If the LG low level sensor is present then the function is the same as above
but the time starts when the LG Sensor clears. Since this sensor is right at
the bottom of the lower garner, the elapsed time can be much shorter than
above. (Perhaps just a second or two.)
WH Cleanout
If the Weigh Hopper has gate proportioning, you may want to select this option to
force the gate to open fully at the end of each order to ensure that there is no
material resting on top of the gate.
UG Trim In Use
If the upper gate has a trim limit switch, press the ‘Space Bar’ to change the gray box to
black, indicating ‘Yes’.
The trim limit switch is used on the last draft of each order to ensure that the amount weighed
through the scale very closely matches the amount requested. When the order is close to
completion, the upper gate is partially closed to the trim position, which is typically around
25% of full open. At this partial open position the flow rate is reduced (for example on a
60,000 bu./hr scale the flow might reduce from 1,000 lbs a second to 250-300 lbs a second)
providing better precision of when to close the gate at the end of the order.
Note: Once you have run a few orders through the scale, refer to Trim LS position on page
26 to see what percentage of full flow is actually passing through the scale at trim. You
should consider readjusting the trim limit switch if the number shown is NOT between 20%
and 30%.
UG Mid Level In Use

This level switch prevents the weigh hopper feed gate from opening until there is a certain
amount of product in the upper garner. The switch serves two purposes:
• When the upper garner is empty the weigh hopper is filled by grain coming directly
off the leg. The grain falls from the top of the upper garner to the bottom of the weigh
hopper. This is often more than a 20’ drop which can damage the grain and can
increase the wear on the hoppers. This level switch ensures that product is always
falling on top of product, thereby cushioning it.
• The accuracy of the CD-4000 comes from its ability to monitor the flow rate in ‘real
time’. If however the upper garner empties right at the time when the system is
planning to move to trim, the flow rate will dramatically change and thereby invalidate
the gate timings. With a correctly located mid level switch, we can ensure that the
upper garner does not empty out at a critical moment in the finish cycle.
Note: Leave grayed out if there is no mid-level contact or if the contact is ‘Normally Closed’.
If there is a mid-level and it is wired as ‘Normally Open’ click the box to black.
Over Capacity Manual Print

If Regulations permit an ‘over capacity’ print, you can press the ‘Space Bar’ to change the
box from gray to black. This will allow you in an over capacity condition to go to the Manual

Mode to print the scale weight and then open the weigh hopper to relieve the over capacity.
If regulations do not permit over capacity, leave the box in gray.
Extended Motion Time (important)

By default the CD-4000 captures the weight as soon as the digital weight indicator stops
transmitting the weight without the ‘motion’ bit. If there is a reason to believe that the scale is
moving back into motion after the stable weight has been obtained, you can press the ‘Space
Bar’ to change the gray box to black. Turning extended motion time on will definitely slow
down the operation because the controller will ensure that there is no motion in the scale for
a longer period of time. For this reason this option is rarely used except in Export Houses.
Fill Motion Delay Time

This option will only be available if you have placed a black box in the Extended
Motion Time above. You can enter a number between 1 and 9 that specifies the
duration for which the scale must be stable after filling the weigh hopper before a
grass weight is printed. A count of 1 is approximately 1 second. If the count starts
and the scale goes back into motion, the count will restart.
Dump Motion Delay Time

This option will only be available if you have placed a black box in the Extended
Motion Time above. You can enter a number between 1 and 9 that specifies the
duration in which the scale must be stable after dumping the weigh hopper before a
tare weight is printed. A count of 1 is approximately 1 second.
Draft Count Rollover

Scale Officials need to be assured that all scale drafts are accounted for. The draft count will
automatically increment by 1 until this Rollover number has been reached at which point it
will reset to zero and increment again. The number can be set to any number up to 9,999.
Drafts Per Subtotal

You can enter a number between 0 and 99. When the count reaches this number the system
will automatically print a subtotal, reset the sub-total draft counter and begin the count again.
If you select 1 to print the subtotal on every draft, the print layout will change to optimize
paper usage.
If you enter 0, the draft count will reset to 0 at the beginning of each order and increment by 1
for every draft in that order.
Available Transaction Types

The left hand box contains all the transaction types supported by the CD-4000. This list is
considerably larger than the actual transaction types that you will want to run on your system.
You should move from the left box to the right box only those transactions that you will be
running. Keep the list to a minimum to reduce operator confusion. Remember that you can
always move transactions from one side to the other, so if you are not going to be using a
transaction for some time you may want to move it back to the left hand side.
Moving Transactions
• To move a transaction from the left to the right use the ‘Tab’ key until the cursor is in
the left hand box. Now use the Up and Down keys to select the transaction that you
want to move. Press ‘Enter’ and that transaction will move over to the right hand
side.
• To move a transaction from the right to the left side, press the ‘Tab’ key until the
cursor in the right hand box and then using the Up and Down keys to select the
Transaction Type you want to remove. Now press ‘Enter’ and the Transaction will
move to the left hand side.

• To move all items from the left to right at one time use the double right chevron and
to remove all transactions press the double left chevron. Remember you must leave
at least one transaction on the right hand side.
Printer Configuration
For legal for trade weighing, all systems include an Audit Printer. The standard audit printer is the 80-
column serial Okidata printer which prints all the weights taken by the scale and changes in the
status of the scale. These events are time stamped so that an inspector can easily ensure that the
scale is meeting NTEP requirements.
As an option, a Remote Printer can be installed. This allows a person some distance from the scale
to view the printout from the scale. Note: you must configure the Remote printer same way as the
Audit printer.
The CD-4000 has limited capabilities to print reports. The least expensive method is to connect the
parallel cable (which is supplied with the printer) to the P1 – Ticket Printer on the back of the CD-
4000. The serial cable will continue to handle audit printing and the parallel cable will handle the
reports. Reports are not a part of the system and there will be a charge for supplying custom reports.
Note: although it is technically possible to share the printer between the CD-4000 and the GMS
computer, this does not work well because Microsoft Windows running on the GMS computer
expects to have exclusive use of the ports. The best solution is to purchase a second printer that is
connected only to the GMS computer that is used for running reports. The next best solution is to
obtain a printer switch box from CompuWeigh.
Use Wide Printout
If you are using an 80-column printer (the typical Xerox letter size) press the ‘Space Bar’.
This will change the gray button to black. If your printer is a 40-column printer (with paper
similar in width to a receipt from a gas station pump), leave the button gray.
Form Feed on Narrow Print

This only applies if you have placed a black box on ‘Use Wide Printout’. If despite
the fact that you have wide paper, you want to keep the print in 40-column format,
press the Space Bar to make the gray box turn to black.
Paper Length In Inches

This only applies if you have placed a black box on ‘Use Wide Printout’. If you are
NOT using continuous paper, enter the length of paper you are using in inches.
Typical lengths would be 5.5” or 11”.

Report printer
If this printer is present, place a black box on ‘Yes’. This will allow you to print reports at the
end of each Unit Train or print Weight Certificates (if enabled) while you are loading.
Print Certificates
This option is only available if the Report Printer is present. Enabling this option will instruct
CD-4000 to print a so-called Weight Certificate on the Report Printer at the end of each
order.
Print Custom Lines On

If you have entered header or signature lines (see Custom Ticket Format below), select
from the drop-down list which printer should print these extra lines. The choices are: None
(do not print anywhere), Audit Trail (print on Audit Printer), Certificate (print on Report Printer)
or Both.
Header Lines 1 & 2

This is typically used to enter the name of your Company. This information will appear on the
upper left hand side of the screen above the graphic display of the upper garner. It will print
on all hard copy records.
Signature Line
Press ‘Space Bar’ to change the box to black if you need to have signature lines on your print
out.
Signature Lines 1 & 2

These two lines are only available if the ‘Signature Line’ above is enabled. Whatever
you type in this field will be printed on the ticket with an underlined space above it for

something to be entered. A typical use would be to type in ‘Weighmaster’ on the first
signature line and Signature on the second. The ticket would show the following:
Weighmaster Signature
Custom Ticket Format

The State may require that you print so-called Weight Certificates in addition to the standard
tickets. Typically a Certificate will contain information about the facility, name of the scale,
operator and some legal information. To fit that data on the ticket printout you may have to
create your own custom ticket header and signature layout. Press the F7-Custom button to
display a Custom Ticket Header/Signature Line window (see the picture below), where you
can enter up to 7 separate lines of header information and up to 10 lines of ticket signature
data. Use the ‘Space Bar’ to enable each line and type in the information you need. Use the
‘Tab’ key to move between the fields. After entering all required data press the Esc-Close
button to return back to the Scale Configuration screen. Press the F3-Save button to save
this data together with the other Scale Configuration information.

Advanced Scale Configuration
This section includes some complex parameters that should not be changed unless you have
extensive knowledge of bulkweighing scales, even then you should be careful. All the parameters on
the right hand side of the screen are automatically calculated by the CD-4000 and unless there is
some reason to believe that the CD-4000 was unable to set them correctly you are best advised to
leave them as calculated.
To change this data you press F5-Edit Adv. and enter the special password that we only provide to
authorized CompuWeigh scale dealers.
Bypass Draft Size Optimizing

If ‘Yes’ is selected the CD-4000 will not optimize the draft size for the differing test weights of
products weighed by the scale. This option can be useful if you have a large volume weigh
hopper, which has plenty of room to hold light materials at the normal draft weight without the
risk of overfilling the scale.
Hydraulic Unit “Power ON”

Where CompuWeigh provides the bulkweighing scale the hydraulic unit output is wired to the
CD-4000 SmartTech opto box for monitoring purposes. This is a “positive” signal so that
when the hydraulic unit is running properly it will provide a signal. Should the signal
disappear, the CD-4000 will create a SmartTech alarm warning the operator about the
malfunction. If this is how your system is set up, select ‘Yes’. If you are not wiring the
hydraulic unit to SmartTech, or the hydraulic unit uses a “negative” signal so that a signal is
only given when the unit is malfunctioning, select ‘No’.

UG Close Solenoid Present
The Upper Garner gate that feeds the Weigh Hopper can either have a double acting
solenoid on it, (which allows for the scale to move to a partially open called the Trim position)
or has a single acting solenoid with a spring return, (so that the gate is either open or closed).
If the gate has a double acting solenoid check the ‘Yes’ box, otherwise leave the box gray.
Note: this parameter is automatically marked ‘Yes’, when you select the “UG Trim In Use”
parameter in the General Scale Configuration section.
WH Close Solenoid Present

Exactly the same as above, but refers to the Weigh Hopper discharge gate. This is an
unusual situation unless the scale does not have a lower garner.
LG Low Level Sensor Present

This sensor is used if the CD-4000 is connected to a GMS system that is running Super
SmartLoad that allows the draft from the weigh hopper to drop into the lower garner, even
before the operator has processed the order. Before doing so we must be sure that the lower
garner is empty and that the gate is closed. This is a Government requirement.
If this sensor is present it will also change the timing used in LG Cleanout Time on page 17.
LG Gate Type
The system needs to know if there is a gate on the lower garner. If there is no gate, select
“Disabled”. If the gate is to be controlled by the CD-4000 select “Automatic”. If the gate is to
be controlled by the operator outside of the CD-4000 select “Manual”. If Super SmartLoad
or LG percentage gate is being used, the gate can either be “Automatic” or “Manual” but in
either case the gate closed limit switch and the low level sensor must be wired to the
SmartTech Opto box.
Over capacity alarm range

The number of scale graduations over the scale capacity before CD-4000 controller signals
an over capacity zero alarm. This should be set fairly tight. One grad is normal.
Under zero alarm range

The number of scale graduations under zero before the CD-4000 controller signals an Under
Zero alarm. Around 20 grads is normal.
Deviation correction
As discussed under UG gate full motion time below, the scale gets better and better at
predicting when to close the upper gate. It does this by looking at the weight of each draft
and compares it with the target draft size. The Deviation correction is the % of that difference
that should be applied to correcting next gate closing. A value of 50% works well. Once the
system has been running for some time, a smaller % correction like 30% will give even better
results.
Note: As the equipment warms up during the day, the gates will move more quickly. The
CD-4000 will automatically adjust for these changes. When the equipment has been turned
off for some time (for example overnight) the equipment will cool down again. To ensure that
we do not overshoot the first few drafts using the timings of the night before, if the scale has
not been running for five hours or more we add a second to the closing time of the upper gate
and within a few drafts the gate timing will be exactly tracking the actual gate timing.
Maximum draft size

This sets the maximum percentage of the scale capacity that will be used for the draft size.
This includes the Max Add to Draft Size, please page 15 for more information on this.

On previous Compudraft controllers this maximum would be set around 80%. The CD-4000
with its much faster processing power can handle values as high as 95%. Remember that
the scale capacity is a water level measure. Before selecting a high % you need to be
certain this amount of product will actually fit into the scale without plugging it.
Auto-Test Parameters
This test must be run if any of the following have occurred:
1. The CD-4000 controller is being placed into service for the first time or the unit is
being replaced
2. Important scale characteristics have been changed (e.g. Scale Capacity or Division
Size)
3. A change has been made to the weigh hopper feed gate. For example the trim limit
switch position has been moved
4. The draft size of the scale has been materially changed.
Note 1: The CD-4000 will calculate these values. You do NOT have to guess at these
values unless there is some reason to believe that the CD-4000 was unable to calculate
them. Please refer to the Auto-Test Procedure on page 29 for how to perform the test.
Note 2: Note that Auto-Test can be run as part of an order so that any material used during
the test does not have to be returned to the ‘house’.
Note 3: Unlike the Self-Learning Parameters below, once these values are set they do not
change until Auto-Test is run again
Purpose of Auto-Test
During normal operation, the weigh hopper is being filled close to the draft size
selected in Configuration. On occasion it is necessary to run a smaller draft for
example when the operator wants to add more product to an order. The smallest
increment that can be added is set by “UG Gate Jog Time” below, however it would
be very time consuming and potentially damaging to the gate if jog was used for all
drafts less than full ones. The CD-4000 can use larger increments (for example
taking the upper gate to the Trim position (if trim limit switch is installed) wait there
and then close the gate. For even larger amounts the gate could go to the Full Open
position and close from there through Trim to fully closed in the normal fashion.
Auto-Test ascertains what these ranges are.
UG Gate Jog Time, 1/10 sec

This is the minimum time, measured in tenths of a second, that the upper garner gate
can be energized to get a repeatable small amount of product through the upper
gate.
The actual value will depend on how quickly your gates react. A value of 5 would jog
the gate for half a second (5/10ths of a second).
Minimum draft size

This amount represents the smallest amount of product that the operator can reliably
add to an order. It is based on the UG jog time above. The amount is measured as
a percentage of scale capacity. 2% is a typical value.
Jog Range
This is the percentage of scale capacity under which the upper garner gate does not
have time to go to the Trim position (if installed). To achieve values in this range the
upper gate may have to be jogged multiple times to reach the required amount.
Typical settings are around 5%.
Direct Trim Range

This is the percentage of scale capacity under which the upper garner gate has time
to go to the trim position but not enough time to go to the full open position. Anything
larger than this range will allow the gate to move to the fully open position and close
in the normal manner.
Typical settings are between 10 and 20%.
Self-Learning Parameters
Unlike Auto-Test above, this set of parameters is constantly being updated by the CD-4000
because scale performance is constantly changing. For example during the day the
hydraulic oil in the pump warms up and this causes the gates to operate faster which in turn
requires that we close the upper gate later to achieve the same amount of product in the
scale.
Normally, you should not be concerned with these parameters unless you notice that the
scale is not achieving relatively constant draft weights or there is a poor correlation between
the order size set and the actual amount of product weighed out by the scale.
Please contact CompuWeigh Technical Support before making any changes to these
parameters because erratic weighing may be pointing to a physical problem with the scale
and because improper modification of these parameters will negatively affect the scale’s
performance.
UG gate full motion time

The feed gate starts to close before the full draft size is reached, otherwise the scale
would overfill each time. This ‘preact’ is based on the flow rate x time it takes to
close the gate. For example if we have a flow rate of 1,000 lbs a second and it takes
2 seconds to close the gate, we might say that we should start to close the gate
2,000 lbs before we reach the draft size. This of course would be incorrect because
during those two seconds the gate would be moving from full open to full close, so on
average would be half open. We would probably therefore get nearer to 1,000 lbs
than 2,000 lbs through the gate while it was closing. This guestimate of ‘effective
time’ is automatically calculated by the CD-4000 on each draft and entered into this
box. As a default you can use 2 seconds. Do not be too concerned, because the
CD-4000 will automatically update this number as it runs the scale, making the scale
more and more accurate until it reaches the mechanical limitations of the scale.
UG gate 100 → trim time

When the CD-4000 is on the last draft of an order and the upper gate has a trim limit
switch, a point will be reached when the gate should move from the full open position
to the trim position. This ‘UG gate 100 → trim time’ is the time it takes for the gate to
move to trim, including the time it takes for the flow rate to stabilize at the slower flow
rate.
UG gate trim motion time

This is exactly the same concept as the one described above and relates to the time
it takes for the upper garner gate to move from the trim position to the fully closed
position.
A typical value is around a second. Again this is a self-learning number.
UG gate direct trim motion time

Same concept as the two above, but handles the situation where the operator has
added product to the order and to accomplish this, the feed gate will be opened to
the trim limit position. It is a different value to the UG gate trim motion time above
because in the first instance trim is reached from the full open position and therefore
there is likely to be some drift past the trim limit switch before the gate stopped. In
direct trim the gate is traveling from full closed to trim and would tend to drift past

the trim position, to a slightly more open position. Here you might want to start with a
value like 1.2 seconds.
Max Weight Thru UG Gate

In addition to monitoring the Upper Garner’s gate motion timings, the system will also
record the amount of material which passes through the Upper Garner gate while it’s
closing. This is necessary for a couple of reasons:
• When the operator places the scale in Stop Mode while in the fill cycle and then
presses the F2-Auto button again, the system must decide whether it has
enough time to fully open the Upper Garner gate and continue filling the scale
without the risk of over filling the scale. The difference between the current
weight on the scale and the draft target weight must be at least twice the value of
the “Max Weight Thru UG Gate” parameter, meaning that there is enough time to
open and close the UG gate before reaching the draft gross weight. Otherwise
the CD-4000 will take a short draft and continue to the discharge cycle.
• There are a few scales that show very uneven flow rates while filling. The CD-
4000 may see a large spike in the flow-rate and decide that it had better close
the gate early. This could result in a short draft. To prevent this situation, the
program compares the calculated cutoff weight with the value of this “Max
Weight thru UG Gate” parameter and will use the lesser value for the cutoff.
Trim LS position
When a scale is fitted with a trim limit switch on the feed gate there is a trade off
between the increase in accuracy that trim provides and the extra time that it takes to
complete the last draft.
From experience we have found that the best trade off is achieved when the trim limit
switch is positioned so that full flow is reduced from 100% to around 25%. This %
value is automatically displayed in this box.
We suggest that you periodically review this number and move the limit switch closer
to the closed position if the % shown is above 30% and move the limit switch further
out if the % shown is less than 20%. If set within this range we have found that the
last draft with trim takes no longer than a normal draft without trim.
SmartTech
SmartTech is the built-in diagnostics system that constantly monitors the operation of the scale. There are
34 situations that SmartTech will alert the operator to. These are in addition to the critical alarms like both
gates open during the weighing operation, that will automatically shut the scale down.
If there is a defective component on the scale, like a gate limit switch or a level probe, SmartTech will
constantly alarm the operator. This can become annoying for the operator. To overcome this, the particular
alarm can be temporarily turned off on the SmartTech screen. This does not mean that CompuWeigh is
saying that it is OK to run the scale with a defective component and it may well void the “legal for trade”
weighing status of the scale. It is merely a temporary fix while the component is being replaced and to make
sure that other alarms are not hidden by the constant flashing of this alarm.
Please review the screen on the next page for the list of SmartTech alarms.
Important: The customer takes on full responsibility for the scale and the weighing integrity of the
scale if any of these SmartTech alarms are turned off.

Clearing Memory and Re-Loading Configuration
If the memory in the CD-4000 has become corrupted it may be necessary to reconfigure the scale.
To do this press the F6-Clear Mem button in Configuration. You will see the message below, which
warns that if you press the “Yes” button you will lose all records in the Intransit List(s), Gate
calibration data if you have gate control and also the current configuration. You will however be able
to reload the last saved configuration of the scale (but not Intransit or gate information).
If you selected “Yes” above you will now be given the opportunity to load the last saved Configuration
or the CompuWeigh factory defaults. Normally you will want to select the last saved version because
this will require less modification than starting from scratch.

If you selected “Yes” you will see the screen below that tells you that you now have the last saved
values. You should review the configuration because there may be a number of values that were
reset.
If you selected “No” you will see the screen below that tells you that you now have the Factory
defaults. It is important that you edit this file because important values like scale capacity, division
size are not entered.
Printing out configuration

If you press F4-Print any changes that you have made will be saved to non-volatile memory and the
configuration will be printed out. This print out contains important information and should be saved in
a safe place.
Saving and Exiting from Configuration

Once you have completed entering the configuration data, press the F3-Save key to save the
information to non-volatile memory. The system will also print out the scale configuration on the Audit
Printer.
Important: Keep the configuration printout for future reference.
If you don’t want to save the changes press the ‘Esc’ key without previously pressing the F3-Save or
F4-Print buttons you will be warned that you are about to lose any changes that you may have made.
If you ignore the warning none of the changes will be saved.

Auto-Test Procedure
Every time you modify important scale parameters like Scale Capacity or Division Size, or if your physical
scale equipment changes (for example the Upper Garner gate cylinder is replaced or the Trim Limit Switch is
adjusted), you need to run the Auto-Test procedure. The CD-4000 will remind you to run Auto-Test every
time you begin a new order until the test has been completed.
Auto-Test performs a number of tests on the upper gate to optimize how it handles smaller than normal
drafts. If this test is not run, the CD-4000 will either take a long time to add these smaller drafts or overshoot
the desired weight.
The two nice things about Auto-Test are:

1. it is completely automatic
2. the grain used to run the test can be used as part of a shipping order, so the grain does not have to
be returned to the ‘house’.
IMPORTANT! Before starting Auto-Test you must make sure that the Upper Garner is full because we need
to make the calculations when there is maximum flow through the upper gate. Failure to do this will definitely
reduce the accuracy and speed of the scale.
Starting Auto-Test
Enter a new Outbound transaction. Please refer to the chapter called Operating Instructions on
page 33 for how to do this) and press F3-Single to bring it on the left-hand side of the screen.
Note 1: Auto-Test procedure is not available for Inbound (receiving) transactions.

Note 2: The transaction’s order weight must be sufficient to run at least 5 drafts otherwise the CD-
4000 will refuse to start Auto-Test because it is likely that it will reach the order weight before the test
would be complete.
Press F5-More and then F2-Auto Test to start the order in Auto-Test mode (see below).
CD-4000 with Unit Train Auto-Test Procedure • 29

Press to start
Auto-Test
The following message will appear on the screen to explain what Auto-Test is going to do and to give
you the ability to cancel the test if you wish. If you do cancel, the system will keep warning you at the
start of each order until the test has been run.
Press ‘Yes’ to begin the test. During the Auto-Test CD-4000 will perform a series of tests, which will
set up the different ranges of how to handle less than full drafts. Do not be alarmed when the CD-
4000 frequently opens and closes the Upper Garner gate. This is completely normal. By default, the
CD-4000 will display a graph on the right-hand side of the screen to show you the progression of the
Auto-Test (see the next picture).
Note: In the course of the Auto-Test the CD-4000 may need to discharge the scale once or twice, so
make sure that you have a rail car or truck below the scale to collect the product.
30 • Auto-Test Procedure CD-4000 with Unit Train

Pausing Auto-Test
While Auto-Test is in progress, you can press F1-Stop button to pause the scale, if required. To
resume the Auto-Test, press the F5-Resume button.
If the CD-4000 encounters a problem while running Auto-Test and is not able to get at least three
repetitive results for any one of the tests, it will display an error message and stop the test.
At this point the Auto-Test parameters in the Scale Configuration will be set to default values, which
will work OK for the most scales.
Note: We would suggest that you call CompuWeigh Technical Support or your scale dealer because
inconsistent readings on the upper gate will almost certainly lead to accuracy problems.
CD-4000 with Unit Train Auto-Test Procedure • 31

If the CD-4000 was able to complete the Auto-Test successfully, a message similar to the one below
will appear on the screen showing the calculated values.
Finishing Auto-Test
Press F2-Done button to continue running the order in Automatic mode. The CD-4000 keeps track of
the total amount of material that has passed through the scale while running the Auto-Test, so your
total order weight will correctly include this amount in the total order.
Note: if there was only one draft left before the order is complete, the CD-4000 may have interrupted
the Auto-Test and proceeded directly to Auto mode to ensure that the Order weight was met. In this
case you will have to run Auto-Test again.
Important: In rare instances Auto-Test may not be able to calculate one or more of the four
values. In these cases the CD-4000 will show the values that it could calculate and enter
default values for the others. If you know what you are doing, you can over write any of these
values.
32 • Auto-Test Procedure CD-4000 with Unit Train

Operating Instructions
Note: Depending on which program is installed, certain features, functions and descriptions may not apply.
When you press the F2-Start key in the Startup screen, the system loads the Main Screen and ‘Mode...Idle’ is
selected. This is the screen that will be used for most of the scale operations.
Screen Components
Scale Information Window
The picture of a bulkweigher on the left hand side of the screen is intended to show you
exactly what is happening with the scale. This includes information on the gate positions, the
level of product in the scale and whether the scale in filling, discharging or in motion.
Other important information is available on the left side of the screen including the size of the
order, how far the order has progressed and the average flow rate.
Menu Items
Transaction Window
Scale Information
In-Transit List
Function Keys
Intransit List
The Intransit list on the bottom half of the right hand side of the screen shows the transactions
(usually rail cars) that have been entered into the system but have not been completed. One
of these transactions is highlighted by the cursor and has a ‘>‘ on the left side of it. Detailed
information about this transaction is shown on the top right side of the screen.
Transaction Window
The transaction highlighted in the Intransit List is shown in full detail on the top right of the
screen. Please note that the color of the right hand side of the screen changes depending on
CD-4000 with Unit Train Operating Instructions • 33

screen. For instance Outbound Transactions have a slight tan color, whereas Inbound
Transactions have a green look to them. This change in color is a visual aid to help prevent
you from accidentally selecting the wrong transaction type.
If you move the cursor to a field and make a change this whole area will turn to a bright green
to warn you that you have made changes.
Function Keys
The Function keys, most of which are located at the bottom of the screen, are ‘action’ buttons
that cause something to happen. The Function keys relate to the keys at the top of the
keyboard numbered ‘F1’ through ‘F12’. For example, pressing the ‘F9’ button will start a ‘New’
transaction and allow you to enter information about this transaction. At this point the F9-New
key changes F9-Save to allow you to save your changes.
Menu Items
There are certain actions that do not occur that often, so they are not given a Function key.
These items are grouped in Menus, which are listed at the top of the screen. Typical menu
items include Data, Options, Scale, Statistics and Help. To reach a menu item do one of the
following:
1. Press the F10-Menu button to activate the Menu bar. The first drop-down menu list
Data will appear on the screen
Now you can use the cursor navigation keys (arrow keys on the keyboard) to move
across and down to select the desired menu item. Press ‘Enter’ to finish your
selection.
2. Alternatively, hold down the ‘Alt’ key (next to the ‘Space Bar’ on the keyboard) and
then the letter underlined. For example to select the Data, press and hold down the
‘Alt’ key and press the ‘d’ key. Then use the ↓key (down arrow key) to select the
desired menu item and press the ‘Enter’ key to select, (or press the underscored
letter, e.g. ‘b’ to select the ‘Bin List’ shown above)
Order Entry
Enter New Transaction
Pressing F9-New allows you to enter a new order. The middle right part of the screen will turn
from gray to green indicating that you are about to enter (or change) data. You will be
presented with a clean screen ready to accept your information. Type in the information.
When you have completed each field press the ‘Tab’ or the ‘Enter’ key to move to the next
field. When you land on fields like the Product and Bin fields you will be presented with a
browse list of choices. Use the up and down arrows on the keyboard to move to the correct
item and then press the ‘Enter’ key. Your item will be selected and the cursor will
automatically move to the next field. When you are done, press the F9-Save key to Save the
new order, or press ‘Esc’ key to cancel, if you do not want to save the information.
34 • Operating Instructions CD-4000 with Unit Train

Revise Existing Transaction
Select the desired transaction by moving the arrow keys up or down on the Intransit List. The
middle right part of the screen will show the details of the one highlighted. The cursor will be
on the first field. Press the ‘Tab’ key until you are on the field that needs to be changed. Type
in your change. Note that the top right part of the screen turns to green, to warn you that you
are changing data and should therefore be careful. If you want to make more changes press
the ‘Tab’ key enough times so that you are on the field that needs to be changed. Again type
in your changes. Press the F9-Save key to save the data or press the ‘Esc’ key if you decide
that you do not want to save the changes.
‘Sticky’ Fields
To reduce the amount of typing, certain fields retain the value of the previous transaction.
Items that typically fall into this category are Unit Train #, Product, Bin and Customer.
Typically only Rail Car id and Order Weight are all that is required to enter a rail car, once the
first transaction has been entered. To move back a field, hold down the ‘Shift’ key and press
the ‘Tab’ key.

Remove Transaction
To remove a transaction from the Intransit List you need to select the desired record in the
Intransit List by using the up and down arrows until you have the focus on that transaction.
You will see the details of the transaction on the top right hand side of the screen.
Now hold down the ‘Alt’ key (next to the Space Bar) and press the letter ‘o’ to select the
‘Options’ menu. Now press the letter ‘r’ to select ‘Remove Record’. The currently selected
transaction will be deleted. Be careful because there is no way to get this transaction
back again – you will have to re-enter all transaction’s data from the beginning.

Starting the Process
Orders in the Intransit List can be processed in two different ways:
F2-Group
If you are processing a string of cars that are in the correct order in the In-Transit List or you
are using the SmartRead RF tag system press F2-Group to run a group of transactions. In
this mode the transaction at the top of the Intransit List will be selected and when complete,
GMS will automatically select the next car on the list.
F3-Single
If you wish to work on an individual transaction, move the ‘>‘ arrow on the Intransit List to the
required transaction and press the F3-Single key. When this transaction has been completed
no additional transaction will be moved over to the left hand side of the screen.
Push to process a single

Press to process a railcar or truck
group of cars
Other keys on the left side of the screen:
F4-Tare Set
Press the F4-Tare Set key if you wish to re-zero the scale. For more details on this please
see F4-Tare Set on page 46.
F5-More
Sometimes there are more scale actions than function keys available on the screen. When
this happens you will see the F5-More function key, which allows you to switch to a new set of
function keys. Pressing the F5-More multiple times will return you to the original set of keys.
F2-Test
Press the F2-Test key if you wish to perform a scale test. For more details on this please see
Build-up Test on page 42.
F3-Cal DWI
Press the F3-Cal DWI key if you wish to reconfigure the digital weight indicator. For more
details on this topic please see DWI Calibration on page 85.
F4-Cal Gate
Press the F4-Cal Gate key if you wish to recalibrate the percentage gate (this button is
accessible only if percentage gate is selected in the Scale Configuration). For more details on
this topic please see Gate Calibration on page 63.

Running in Auto or Manual
The bulkweigher is normally run in Automatic Mode, whereby the controller makes all the decisions
about when to open and close the gates. The scale can also be run in Manual Mode, where you get to
decide when to open and close the gates.
Note: even in Manual Mode the system will still perform legal-for-trade weighing because the system
will force a print of the tare and gross weights, when you alternate the opening and closing of the
upper and lower gates.
Processing Processing
transactions in transactions in manual
automatic mode mode
Press F2-Auto key to select Automatic processing. Press F3-Manual to select Manual
processing.
Once the order has been started the function keys will change allowing you to control the
scale while in Auto Mode.
Stops the scale,
when running in
Automatic mode
F1-Stop
Stops the automatic scale operation, closes both the upper garner and weigh hopper gates
and changes the Scale Mode to Stop.
F2-Cutoff
Allows the upper gate to be closed before the normal gross weight is reached or to close the
scale gate before the scale is empty. This is rare situation but can happen when for example:
• You are receiving product and the there is no more product to reach the draft weight.
• If the upper garner high level switch turns on due to excess material in the upper
garner level, one way to relieve this situation is to take a high tare (in other words take
the draft tare weight sooner than usual) and thus allow the feed gate to the scale to
open sooner and thereby take material out of the upper garner.
F3-Manual
Allows you to switch into the Manual processing mode should this need occur. Please see
Manual on page 41

F4-Finish
Will complete an outbound transaction before the order weight has been reached or complete
an inbound transaction that typically does not have an order weight because typically you will
want to receive whatever is in the vessel that is being emptied.
Once the order weight for outbound transaction has been reached the scale stops and waits for your
next action.
F2-Add
You now have three choices:
• Add more weight to the order (F2-Add button), see below
• Switch to Manual mode (F3-Manual button), see page 24 for more information.
• Finish processing the order (F4-Finish button), see below.

Scale is stopped
while in Ship Add
mode
Use F2-Add to add Use F4-Finish to

more product to the finish the current
current order order as is
If you choose F2-Add to add more weight then you are prompted to provide the additional
weight amount. When you press OK button the scale starts in the Automatic mode again and
will add the additional weight that was requested. The scale will again stop once it reaches
the new target weight. Note if you add a very small amount the scale may not let you process
it, because the gates cannot be properly controlled for such a small order.
Press F4-Finish when you finally want to finish the order.

The scale’s behavior then depends on whether you previously selected F2-Group or F3-
Single processing modes – unit train or a single car. If you were running from F2-Group, the
next railcar in the sequence will automatically come across to the left hand side of the screen
allowing you to start it by pressing the F2-Auto button.
If you had previously selected F3-Single, no transaction will be brought over to the scale and
the system will wait for your next instruction.

Manual
Although running the scale in automatic mode is much easier, the scale can be run at any time in
manual mode.
If the order has not been started, selecting F2-Group or F3-Single and then press F3-Manual to enter
Manual processing mode. If the scale has been started press F1-Stop and then select F3-Manual.
Return to Stop mode Open Upper Record Gross or Change to the next
(exit from Manual) Garner gate Tare Weight available key set
To process an order will require that you press the F3-Open UG (upper garner) until the desired draft
weight is reached. At this point you should press F3-Close to stop the flow of material. At this point
you can press the F3-Open UG again if you want a bit more material in the scale.
Close the gate Take weight

and print
When you have enough material in the scale, press the F4-Print button. This will take the Gross
weight. Notice that the F3-Open WH key will now control the weigh hopper gate, allowing you to
discharge material from the scale. When the scale is empty press the F4-Print button, the tare weight
will be taken and the F3-Open UG key will now control the upper garner gate again.

When you are close to finishing the order you can press the F2-Trim button, which will partially close
the upper gate to the Trim position. This will slow the flow of material into the weigh hopper allowing
you to close the gate at the correct time. Use the F3-Jog key if you are already near to the target
weight and need a little more material in the weigh hopper. The Jog Time set in Configuration
determines the amount of time that the upper gate will remain open. Please see Configuration on
page 13.
Note now controlling the weigh hopper not

the upper garner
When you have finished the order or want to exit from Manual Mode press on F2-Done.
You can now press F4-Finish to complete the order or select any other action available.
Build-up Test
Press F5-More then F2-Test when you want to run an official scale build-up test. The scale mode will
change to ‘Test’ and print the following message to the system printer:

LOCAL MODE TEST TIME
The display will show you a new group of active soft-keys. The selections available under Test are
shown on the picture below:
1. Press F4-Print
2. Press F2-Raise Wt
Press F4-Print to record the empty weight and then lift the test weights by pressing F2-Raise Wt and
ensure that the increase in weight matches the test weights (in this example we are using four 1,000
lbs weights so the weight should register 4,000 lbs). If so continue to the next step.
2. Press F2-Lower Wt 1. Press F4-Print
Now print the weight and then lower the Test Weights by pressing F2-Lower Wt. The empty weight
should return to the weight before the test weights were raised.
Now press F3-Open UG and allow grain to fill the weigh hopper until the weight is slightly less than the
weight of the test weights plus the empty weight of the scale. In this example you would be trying to
get the weight to slightly less than 4,000 lbs.
Now press F4-Print to take the high tare (you could also press the F3-Close and then F4-Print – but
F4-Print will also close the gate).

F4-Print will close the gate
and take new high tare
weight
Now press F2-Raise Wt to lift the Test Weights and press F4-Print. The weight should increase
exactly by the value of the test weights.
F2-Lower Wt will drop

test weights
Now lower the Test Weights by pressing F2-Lower Wt again. Again the weight should return to the
previous weight (in our example 3,970). Now press F3-Open UG and allow grain to fill the weigh
hopper until the weight is slightly less than the weight with the test weights raised, in our example
slightly less than 7,970). Press F4-Print to record the weight.
The procedure now repeats itself. You will keep lifting the test weights to ensure that the weight
increases by exactly the weight of the test weights. You will then drop the test weights and add more
material to the scale to match the test weights. Continue this procedure up to the scale capacity of the
scale.
Note: The inspector may also ask you to print the weight on the scale, immediately after the test
weights have been lowered, to confirm that the weight precisely matches the weight before the
weights were lifted. Do not volunteer this print because the load cells do not always immediately
return to their original weight.
To discharge the scale after the test is done, press F5-More twice to select the next set of function
keys and then press F3-Open WH.

F3-Open WH will empty
the scale
Press F2-Done button to exit Test.
Press F2-Done to finish

the Build-up test
Daily Two Point Test

Finish any weighing transaction that you are running, and then press F5-More then F2-Test.
Press F2-Test to start

test
Press F4-Print to record the empty weight
2. Press F2-Raise Wt 1. Press F4-Print
Lift the test weights by pressing F2-Raise Wt button and ensure that the increase in weight matches
the test weights. If so continue to the next step.

1. Press F4-Print
2. Press F2-Lower Wt
Lower the test weights and fill the scale to approximately 70% of capacity (or to an amount that will not
cause the scale to go to ‘over capacity’ with the test weights lifted). Make a note of the weight.
Now press F2-Raise Wt to lift the weights and check that the previous weight has increased by the
test weights. (In this example the four test weights of 1,000 lbs each).
If everything is in order, drop the weights and empty the scale. You are now ready to use the scale.
Tare Set
Pressing the F4 -Tare Set, when the Scale Mode is ‘Idle’, will reset the weight shown on the indicator
to zero. Tare Set operation compensates for any build up on the weigh hopper. Should the build-up
fall off the hopper the tare weight may show a negative weight. You will want to use the Tare Set
button again. Remember you cannot use this button in the middle of an order because this would
affect the integrity of the weighing.
Note: in the scale Configuration window (please see page 16) you have a parameter called ‘Tare
Reset Range’, which sets the weight range on the scale within which you are allowed to set the tare
weight of the scale back to zero. If your scale’s weight is out of this range (say, the range is set to 300
lbs and current weight on the ‘empty’ scale is 800 lbs), then the system will not allow you to set the
tare back to zero point, therefore preventing you from setting up a wrong tare value when there is
actually material in Weigh Hopper.

Transaction Sorting
Introduction
The transactions are not always entered in the order that they need to be processed. For example a
complete unit train of rail cars may be entered but when the cars are broken into tracks, the cars may
no longer be in the correct order. The CD-4000 offers three ways of getting the transactions into the
correct order.
The first step is to press the F12-Sort key. At this point you will notice a comprehensive Help menu to
walk you through the three methods.
Press F12-Sort to begin

re-sorting process
CD-4000 with Unit Train Transaction Sorting • 47

Re-ordering one transaction
Move the ‘>‘cursor in the In-Transit List to the transaction you want to reorder using the up and down
arrows.
Now press the ‘Enter’ key. At this point a box will appear. Enter the sort number that you want to
move the car to.
Please note that if another transaction already has that number, these transactions will be positioned
in the alphabetical order but with the same number. In our example when we enter the number 2 and
since 2 already exists, our transaction will be positioned above it and when we press F12-Finish, will
be sorted into position 2. To fine tune the order please see the Drag and Drop method below.
48 • Transaction Sorting CD-4000 with Unit Train

Re-ordering several transactions
Move the ‘>‘cursor to the first transaction that needs to be moved and either hit the Insert key or the
‘Space Bar’ to mark that transaction. You will notice that the transaction background changes to a
darker color. Now use the up and down arrows to move to the next transaction. Again press the
‘Space Bar’ or the Insert key to mark this transaction. When you have completed all your selections
press the ‘Enter’ key and enter the sort number to apply to all of these transactions.

You will notice that the two selected transactions have been given the same number 3 sort order.
When you press the F12-Finish key the cars will be sequentially ordered.
‘Drag’ and ‘Drop’

The third way to re-sort a transaction is to select the transaction by using the up and down arrows and
then hold down the ‘Alt’ key while using the up and down arrows to move the transaction up or down
the list.

Completing the sort
When you have positioned the records in the correct order, press the F12-Sort key. The transactions
will now be sequentially numbered starting with the smallest number that existed prior to the sort. In
our example “2”.
Changing the Starting Sort Number

If you do not want the sort to start at the existing number, hold down the ‘Alt’ key and press the letter
‘o’, to bring up the ‘Options’ and then press ‘s’ to select ‘Reset Track Sort’.

Now type in the start number. In our example we will type in the number 30.
Notice how the sort number now starts at 30.

Lists
Introduction
What is a List?
In previous Compudraft controllers you had to type in all the information about a transaction
each time. This was time consuming and led to typing errors. On the CD-4000, lists of the
commonly used products and bins are maintained by the system. Now you are able to select
an item from the list rather than have to type it in.
The CD-4000 is delivered with sample products and bins lists. These lists should be adjusted
to your actual facility.
Note: If you do not want the see the automatic lists as you enter transactions, hold down the ‘Alt’ key
and press the letter ‘o’, to bring up the ‘Options’ and then press the space bar on Automatic Lists so
the black box next to it disappears.
Products List
Accessing the Product List
To access the Product list hold down the ‘Alt’ key and press the ‘d’ key. This will activate the
‘Data’ Menu item at the top of the screen. Now either press the ‘p’ key to select ‘Products’ or
use the Down Arrow (↓) to move the cursor over ‘Products’ and then press the ‘Enter’ key.
You will then see a list similar to the one below.
CD-4000 with Unit Train Lists • 53

Editing an existing Product
If the product you want is already on the list, but you want to change something about it, just
press the Down Arrow (↓) until the cursor is on that item. Then press the ‘Enter’ key (or hold
down the ‘Alt’ key and press ‘d’) to move to the Details Tab. You will now see the Detail
screen for that Product. For example:
You can now update Product Code, the Description and Test Weight. Normal Draft Size is a
calculated field and is Read Only.
Test Weight
Enter in this field the typical test weight of the product you are handling (not
necessarily the official test weight). For example if this year yellow corn is light and
typically is only 53 lbs/bushel you would want to enter 53 (not the official weight of 56).
Normal Draft Size is automatically calculated by taking this test weight that you
entered above and dividing it by 60 and multiplying the result by the Standard Draft
Size entered in Configuration. Please see Configuration on page 13. This calculation
ensures that the volume of grain in the scale is consistent, whatever the test weight of
the product is. Clearly we can get a lot less weight of oats into the weigh hopper
compared to wheat, but we still want to fill the scale to the same height, whatever the
product.
When everything is correct and you wish to save the changes, press the F9 function
key, which corresponds to the F9-Save message on the screen. If you do not want to
save the changes press the ‘Esc’ key (top left on the keyboard), which corresponds to
the Esc-Cancel message on the screen.
If you want to edit another Product hold down the ‘Alt’ key and press the ‘L’ key to
select the List. Now repeat the process again.
54 • Lists CD-4000 with Unit Train

Add a New Product
To create a new product press F9-New key. The screen will look like this:
Start entering the product information. Press ‘Enter’ or ‘Tab’ key to move to the next field.
After you finish entering data you can save this product to the list by pressing F9-Save key. If
you decide not to save this new product press Esc-Cancel key instead. Again pressing the
‘Alt’ key in conjunction with the ‘L’ key will take you back to the main Product list.
Note: see the note above on setting the test weight value
Remove an existing Product

To remove a product, select the product using cursor moving keys and press F8-Delete key.
You will have to confirm the deletion before the product will be actually removed. Warning:
once a product is removed, it cannot be restored.

Print List of Products
To print a list of the products press the F7-Print key. This operation will format and print a list
of available products along with their information.
Removing all Products

To remove products, press F6-Clear button. A warning message will appear on the screen to
confirm the action.
Note 1: you must have at least one product left in the list otherwise the system will not let you
enter any new records into the Intransit List, as Product is a required item.
Note 2: if the database of products became corrupted, it may contain incorrect or ‘garbled’
data. In this happens, use F6-Clear to remove all products and then re-enter them.
Bins List
Accessing the Bin List
The Bin database uses information from the Product List. It is therefore recommended that
you complete the Product list before updating the Bin List.
To access the Bin list hold down the ‘Alt’ key and press the ‘d’ key. This will activate the ‘Data’
Menu item at the top of the screen. Now either press the ‘b’ key to select ‘Bins’ or use the
Down Arrow (↓) to move the cursor over Bins and then press the ‘Enter’ key. You will then
see a list similar to the one below.
Editing an existing Bin

If you want to change information about an existing bin, just press the Down Arrow (↓) until the
cursor is on that item. Then press the ‘Enter’ key (or hold down the ‘Alt’ key and press ‘d’) to
move to the Details Tab. You will now see the Detail screen for that Bin.

You can now change anything on this screen. Maybe you want to change the Bin Code to Bin
95. Type it in and press the ‘Enter’ key and the cursor will automatically drop down to
Description. Make any changes needed to Description and then press ‘Enter’ again and the
cursor will now be on Product Code.
You will now see the Products List (see below). Using the arrow keys move to the Product
that will be or is already in this bin. (If the product is not on the list, then you should escape
out of the Bin List and update the Product List). Press ‘Enter’ when you have selected the
correct Product Code.
The Comments field is completely optional and is just for your own use. Perhaps you want to
remind yourself of some characteristic of the bin or the quality of the product in the bin.
Add a New Bin

To create a new bin press F9-New key.

Start by entering the Bin Code. This is usually a short set of letters and numbers that help you
select the correct bin. . Press the ‘Enter’ button when you have entered the Bin Code and
then enter a longer description that you will find helpful. Press ‘Enter’ again and the cursor
moves down to the Product Code.
Note: the bin list shown while entering transactions is in the alphabetical order of Bin Code.
You will now see the Products List. Using the arrow keys move to the Product that will be or is
already in this bin. (If the product is not on the list, then you should escape out of the Bin List
and first correct the Product List). Press ‘Enter’ when you have selected the correct Product
Code.
The Comments field is completely optional and is for your own use. Perhaps you want to
remind yourself of some characteristic of the bin or the quality of the commodity in the bin.
Remove a Bin
Select the bin using cursor moving keys and press F8-Delete key. You will have to confirm
the deletion before the bin will be actually removed. Warning: once a bin is removed it cannot
be restored.
Print List of Bins

To print a list of the bins press the F7-Print key. This operation will format and print a list of
available bins.
Removing all Bins

To remove all bins, press the F6-Clear button. A warning message will appear on the screen
to confirm the action.
Note #1: before leaving the Bin Inventory system you will need to have at least one bin in the
list because most transaction types require a bin selection.
Note #2: if the Bin database has become corrupted, it may contain incorrect or incorrectly
formatted data. If this happens, you should press F6-Clear to remove all products and then
re-enter them.

SmartTech
Introduction
The continuing trend is towards higher output using fewer personnel. This trend has been intensified
by the bonuses offered by the Rail Companies. A $10,000 bonus for loading 110 cars in 15 hours is a
reward that few elevators can afford to give up. For this reason reliable equipment is more important
than ever. SmartTech is a unique product that automatically tells you when there is a problem with
the scale, where the problem is located and how to fix it.
In many cases you can fix the problem yourself and get quickly back to using the scale. For more
difficult problems (e.g. faulty solenoid), you may not be able to fix the problem yourself but can provide
the scale serviceman with an exact description of what component is broken so the serviceman can
bring exactly the right part to get the scale back into service as quickly as possible.
Opto Screen
At any time, even when the scale is running, you can press the F11-Opto key, and see a
representation of the Opto Board that is in the SmartTech enclosure. It shows you which lights are
on.
You will notice that those inputs from the scale (yellow modules) and the output instructions from the
controller to the scale (black modules) that are active have red lights lit and the description is also in
CD-4000 with Unit Train SmartTech • 59

red. For personnel that have a good understanding of how bulkweighing scales work, will find this
information very informative. If SmartTech has identified a problem, the orange box below the Opto
Board will have information in it. At this point it is best to press the F11-SmartTech key again to see
more information (please see below).
SmartTech Screen
During normal scale operation the SmartTech screen is not visible. To see the screen:
1. Select the Options Menu at the top of the screen by holding down the ‘Alt’ key and
pressing the ‘o’ key. Now either use the down arrow or press the ‘s’ key, select
SmartTech Screen.
2. Press the ‘F11’ function key once to get to the Opto Board screen and then a second
time to see the full SmartTech screen
The advantage of the full screen is that if SmartTech has identified a problem with the scale there will
be a red circle next to the faulty equipment and the message box below will tell you what equipment
needs to be checked. In our example SmartTech has identified a problem with the Weigh Hopper
Gate Limit Switch and a red circle marks the location of the problem. Press F1 for more help.
SmartTech detected a
faulty limit switch
Press F1-Help to get more

detailed information about
the problem
Brief explanation of the

problem
SmartTech is an excellent diagnostic tool. On previous Compudraft systems the normal way for
CompuWeigh technicians to diagnose a scale problem was to ask you to open up the Opto box and
tell us what lights are on at certain times in the weighing cycle. With SmartTech those lights can be
seen right on the screen.
Where possible SmartTech will single out a single problem with the scale. In other cases there may
be two or three items that would cause this problem. It may therefore require you to go up and take a
look at the scale. In all cases you are directed to a specific area of the scale and the items shown in
the Help menu reflect the order you should check for faults.
60 • SmartTech CD-4000 with Unit Train

Important: Please use extreme care when troubleshooting the actual scale. For example removing a
piece of wood that was preventing a gate from closing may allow the gate to close cutting through
anything in its path. Climbing into any of the hoppers is extremely dangerous. Always place the scale
in Stop mode, which ensures a safe condition before trying to make a fix.
Currently there are 34 different scale problems that SmartTech can detect and analyze.
CD-4000 with Unit Train SmartTech • 61

Gate Control (optional)
Some bulkweighing scales have a gate on the lower garner that has a proportioning mechanism to allow the
gate to be opened to a partial position. (For scales with no lower garner the proportioning gate may be on the
weigh hopper).
If your scale has gate proportioning select Percentage Gate In Use (requires calibration of gate)and select the
appropriate gate (see page 16 for more details).
Note: please do not confuse gate control with a simple open/close gate on the lower garner or the weigh
hopper feed gate that commonly has trim on it.
Gate Calibration
When the gate proportioning is selected, the internal CD-4000 Gate Control A/D channel must be calibrated
for the gate’s full motion span before you can use the gate. Please follow the instructions below to calibrate
the gate.
First of all make sure that the hopper with the gate proportioning on it is empty because the gate will have to
be opened at least once.
Press F5-More button and then press F4-Cal Gate button to start the gate calibration process. In the
Parameters box the current value of the gate A/D count is displayed.
Press to start gate Current value of

calibration process the gate A/D
After providing the admin password to access the calibration you will see the following dialog message.
If you want to interrupt the calibration process, press the ‘Abort’ button and the following message will appear
on the screen. The gate will not be calibrated.
CD-4000 with Unit Train Gate Control (optional) • 63

If instead of ‘Abort’ you press ‘Continue’ the CD-4000 will try to close the gate first and, when the gate limit
switch indicates the close condition, the message below will be displayed.
Note 1: please verify that gate’s A/D counts are decreasing while the gate is closing.
Note 2: if the gate did not close within 30 seconds, a time-out error will occur and the message below will
appear. Calibration will terminate.
Assuming everything was successful, press the ‘Continue’ button to proceed with the calibration. The CD-
4000 will begin to open the gate. Pay attention to the gate’s A/D counts in the lower right corner of the scale
screen. It is imperative that the value INCREASE gradually. Once the gate has fully opened, this value will
stop increasing and may fluctuate slightly. When you reach this point, press the ‘Continue’ button to proceed.
Note: the gate control A/D has a full span of 0 – 4096 counts. In reality, due to the gearing limitations of your
gate, it may not employ the full A/D span, but just a component of it. When the gate is closed, the A/D must
read a lower value than when the gate is fully opened. The A/D range of the gate needs to be at least 20% of
the full A/D span, so we need 819 counts or more. If this difference is less than 819 counts, the following
message will appear and calibration process will be aborted.
It is unusual for there to be insufficient number of counts. We recommend a 2K Ohm pot, but most will work.
If there are insufficient counts, watch how the counts move up and down as the gate is opened and closed to
see if there is an uneven change in the counts, indicating that the pot should be replaced.
(If there has been some electrical damage to the CD-4000 it is possible that the gate control card in the CD-
4000 needs to be replaced).
The last stage of the gate calibration is to close the gate again. Press ‘Continue.
64 • Gate Control (optional) CD-4000 with Unit Train

After the gate has closed the calibration process is over.
Note: the default gate setting after the calibration is set at 100%. Please use the ‘Change Gate Setting’ item
from the ‘Scale’ menu list to change the gate setting value. Valid values for the gate setting include 0%, which
will cause the gate to close completely or any number in the 10 to 100% range.
Checking Gate Operation

Perform the following steps after you have completed the gate calibration:
• Go to the Build-up Test (please see details on page 42).
• Try setting different gate positions between 10 and 100% and verify that CD-4000 stops the gate
within the dead band of the required position (if this is the Weigh Hopper gate, use F3-Open WH
button to move the gate; if it is the Lower Garner gate simply change the gate setting to move the
gate).
• In case of the Weigh Hopper gate control, try changing the preset gate position while the gate is open
and verify that it moves to that position + or – of course the gate dead band
• If the gate is constantly jerking around the preset position, you have three parameters that you can
adjust. Our recommendation is that you start by:
o increasing the Gate Dead Band, normally around 2-5%, (please see 16 for more information),
if this does not help
o increase the Jog Dead Band. It be should be around 5-10%, and finally
o reduce the Gate Pulse Time, normally around 5-20 counts (10 counts to a second)
CD-4000 with Unit Train Gate Control (optional) • 65

• If you have to set a wide gate dead band to avoid frequent gate pulsing, this may indicate that the gate
control pot is not geared to the gate properly resulting into a very narrow A/D range for the full gate
stroke and this is what is making the gate so sensitive.
• Finally make sure to try the 0% gate setting to verify that the gate closes completely. For Automatic
Lower Garner gates also check that CD-4000 turns the gate close output off, once the gate close limit
switch is made.
66 • Gate Control (optional) CD-4000 with Unit Train

Reports
Introduction
There are a number of reports that can be run when the scale is not actually weighing. These reports
are reached from the Start-Up Screen (the one with the picture of the elevator on it). If you are on the
Process Screen, press the Esc-Exit button to return to the Start-Up Screen.
To select a report hold down the ‘Alt’ key and press ‘R’ key. You will now see a list of reports similar to
the list below. Either use the down arrow key to move to the report you want and press the ‘Enter’ key
or type in the letter that is underlined for that report.
For some reports you will be asked to provide a date. Enter the date for which you want the report
run. This is usually Today’s date.
Important: Remember days, months and years each need to have two numbers to them so
February would be ‘02’ not ‘2’. Please see below.
Some reports provide a range of dates, in which case you should enter the starting and ending dates.
CD-4000 with Unit Train Reports • 67

In a few seconds the report will appear on the screen
If you would like to print out the report press the F4-Print button and if your Report printer is online you
will receive a hard copy of the report.
Ticket Reprint
A special type of report is Ticket Reprint. This allows you to reprint the ticket for a transaction that was
previously completed. A typical reason to run this report is if you experience problems with the Audit
printer and the original ticket did not print properly.
You will need to enter the ticket number. If it never printed you may have to figure out the number
from the ticket that printed before or after it.
68 • Reports CD-4000 with Unit Train

Please see below for a typical ticket reprint.
If you would like to print out what is on the screen press the F4-Print button and if your Report printer
is online you will receive a hard copy of the ticket.
You need to take care when entering your selection because if you enter something that the CD-4000
cannot find you will get the message below. For example, pay attention to small details like entering
leading zeros on dates.
CD-4000 with Unit Train Reports • 69

Administrative Tools
Introduction
Administrative tools are designed to keep the GMS system running smoothly and to remove records
that are no longer required. Be careful - these are powerful tools because once you run them you
cannot undo them.
To use any of the items on the list Exit from the Process Screen to the Start-Up Screen (the one with
the picture in the center) and hold down the ‘Alt’ key and press ‘A’ to display the ‘Administrative Tools’
menu list. Now use the down arrow to move to the appropriate item and then press the Enter key or
enter the letter of the alphabet underlined (for example the letter ‘m’ to select Clear Memory. You will
be asked to enter the Administrative Password before being able to run the utility.
Re-Build Intransit
Select this function if the data in the Intransit List is not displaying correctly. This is the only utility that
does not require a password to operate.
Clear Intransit
Clear Intransit removes records from the Intransit List that are no longer required.
Enter in your password and when you see the menu below, press the down arrow and select the
transaction you wish to remove. Select ‘All Transactions’ if you wish to clear all lists. If you do, you
will the following message.
CD-4000 with Unit Train Administrative Tools • 71

If you select a particular transaction type to remove, you will see a screen similar to the one below
Once you have made your selection the CD-4000 will tell you how many transactions will be deleted.
If that is correct or you are not concerned about the number of transactions that will be deleted press
the ‘Yes’ button
You will then be informed that those records have been removed.
Clear Order in Progress

Selecting this utility will remove the transaction that is in currently present in non-volatile memory (this
may happen if the CD-4000 was restarted while running an order).
Clear Database
This utility removes all the completed transactions from memory. This utility should to be run after
about 500 transactions to provide memory for new ones. Once you remove these old transactions
they will not be accessible again, so print out any reports that you need on this old data before running
this utility.
72 • Administrative Tools CD-4000 with Unit Train

Clear All System Files
This utility should only be run if the following message appears on the screen at start-up time. It will
remove all dynamically created system files including the database of the completed transactions, any
collected statistical data, system errors and communication log files etc.
You will be asked to confirm your action by the following message. Press OK if you are sure.

Change Time/Date
This utility allows the administrator to reset the clock and calendar. Note that the CD-4000 uses a 24-
hour clock, so if the current time is after mid-day add 12 to the hour, also you should enter the leading
‘0’ for the month and day when either is less than 10. For example if it is 6 o’clock in the evening, you
would enter ‘18’ in the Hour field and ‘03’ for March.
Allow Inbound Order Weight

Normally on Inbound transactions there is no target weight because typically you will want to accept
all the contents of the vessel that is being unloaded. This option over-rides this and allows a target
order weight to be entered. Once the target weight has been reached, the scale will stop and the
operator will be able to add more material or complete the order.
Note: Even if this option was selected, but a zero weight is entered for an Inbound transaction then
CD-4000 will not stop receiving material until the operator presses the Finish button.
Connect to CompuWeigh
This utility allows CompuWeigh to provide you with software updates over the phone line as well as
allowing CompuWeigh technicians to diagnose problems with your system.
Setting up the Modem

Perform the following steps to ensure that the modem if properly set up.
1. Check that there is a telephone cable connected to the back of the modem. Check that
this cable is connected to an analog phone line (the same type used by a fax machine. In
fact, if you have a fax machine nearby, you can use that connection).
2. For a standalone CD-4000 ensure that the thicker black cable on the back of the modem
is connected to the ‘J9’ Remote Printer connector on the back of the CD-4000. If your
system is equipped with a Remote printer you will have to remove that cable from J9 first.
For a GMS-4000 system ensure that the A/B switch box that shares the modem between
the CD-4000 and GMS Computer is in the position labeled “CD-4000”.
3. Ensure that the modem is plugged into a power outlet and then turn on the switch at the
back of the modem to ‘On’ position. At which point the Power light will appear on the front
of the modem.
74 • Administrative Tools CD-4000 with Unit Train

Running the Utility
Select the ‘Connect to CompuWeigh’ menu item
Enter the Administrative Password, the screen will blank for a second and the screen below
should appear.
When the CompuWeigh technician calls, the word ‘OK’ will change to the word ‘Ring’ and
once communication has been established you will see a screen similar to the one below.
Once the technician logs in the CD-4000, the screen will turn blank and will stay blank until the
technician has updated the system. Once the update has been made you will see the screen
below.
At this point the CD-4000 will restart and you will be able to run the system. If there are
problems with the system, you can press the reset switch on the back right of the CD-4000.
This will restart the CD-4000 in the normal manner.

Statistics
Introduction
For 90% of all CD-4000 installations, there is never a need to fully understand the dynamics of the scale. The
normal setup procedure of running Auto-Test (please see page 29) and allowing the Self-Learning to
continually fine-tune the system (please see page 25) noramlly provides excellent results.
There are however a few scales that do not have predictable flow characteristics or have physical problems
with the scale (e.g. a malfunctioning load cell or inconsistent gate movement) that turning on Statistics can
provide CompuWeigh with the information needed to fully analyze the scale.
Configure
To turn on Statistics please do the following:
1. On the Process Screen hold down the ‘Alt’ key and press the ‘t’ key
2. Then hit the Enter key to select ‘Configure’ or press the letter ‘c’.
3. Your screen should look like the picture below.
4. Use the Tab key to select ‘Save Statistics to disk’ and press Enter key to select it, so that there is a
black box next to the message. You will be given a warning that Statistics should only be left on for
a relatively short period of time because it consumes a lot of memory. The CD-4000 will
automatically turn off statistics after 30 drafts, if you do not turn it off before then.
CD-4000 with Unit Train Statistics • 77

5. Press the ‘Tab’ key again and hit the ‘Enter’ key on the OK button to close the window. You will then
see the following warning sign on the top right of the Process Screen, reminding you that you are
writing data to disk.
Now run one or two transactions through the scale. The data will automatically be collected and saved to the
flash disk. Data is being recorded 60 times a second so the file quickly becomes quite large and will
automatically stop collecting data after 30 drafts. This is enough data for CompuWeigh to analyze the
performance of your scale. By modem connection CompuWeigh will download this information and provide
you with feedback on the scale and suggest what parameters need to be changed or what physical problems
exist with the scale.
Setup Printout
In the Statistics section you can run graphs that display on the screen. You can also print these graphs on
your printer. We need to know the width of the paper which is normally 8½ “. After allowing for the margins,
you would typically enter 8”. Use this number whether you want to print in Portrait or Landscape
(recommended) mode.
‘Normal’ provides the best quality but takes the longest to print. Other options are Draft and Semi-draft, which
will print faster but with less definition. There is also a Condensed mode which prints the graph smaller. In
general it is best to select the defaults of 8”, Landscape and Normal.
78 • Statistics CD-4000 with Unit Train

Manage Data
This section handles the maintenance of the databases created by the CD-4000 after collecting the statistical
data.
Backup Statistics
You should run this procedure after running the CD-4000 with the Statistics turned on
because this takes the data that has been stored in memory and writes it out in a format that
can be transferred to CompuWeigh.
Note: Unless you have already turned off ‘collecting statistics’, the CD-4000 will stop saving
data after 30 drafts and will run the backup process automatically. You only need to start the
backup process manually if you for disabled collecting statistics yourself before the 30 drafts
had occurred.
You will see the following screen. Press ‘Yes’ to continue
If everything was saved correctly you will see the message below. Please make a note of the
Backup number.
Restore Statistics
This utility allows you to review graphs of previously backed up data. As noted in the box
below you need to store any unsaved data first. Press ‘Yes’ to continue.

Now select the backup that you wish to restore. Use the Down arrow to show the full list of
previously stored backups. Press the Enter key on the backup that you wish to review and hit
‘OK’ to start the restore utility.
When the data has been restored you will see the message below. Press the Enter key to
continue.
Erase Statistics
This procedure will remove transactions that have been saved to flash memory. Remember
this is the temporary memory used before you save it to Backup. Therefore do NOT run this
utility until you have made a backup as described above.
This utility will also remove from memory any data that you have ‘Restored’ using that utility
above. It does not erase the restored file from the Backup file but removes it from memory.
The file can be restored again if you need to review it at a later time.
Press ‘Yes’ to continue. The data will be instantly removed.

Drafts Data Analysis
This utility allows you to review graphs of previously saved and restored data.
On the screen below, you can select based on either Order ID or Draft Count Number.
Select by Order ID
• Press the Tab key to move the cursor to the first white box and then hit the Down key to
display all the cars. In the last column of each record you will see the difference between the
Order Weight and the Target Weight. This is to help you identify orders that may require
investigation.
• Once you have selected the order, select the draft that you want to review, in the second white
box by using the down arrow to reveal the individual drafts.
• Press the OK button when you have made your selection and you will see a message stating
that the data is being loaded from flash. In a second or two you will be see a screen similar to
the one shown on the next page.
Select by Draft Count #

• If you know the draft count number, which is available from the audit printer, it may be more
convenient to select by draft count number. If so, use the down arrow so the black circle is on
Draft count # rather than Order ID
• Now press the Tab key to move to the bottom white box and then press the Down arrow to
display the available drafts.
• Press the OK button when you have made your selection and you will see a message appear,
stating that the data is being loaded from flash. In a second or two you will be able to see a
graph similar to the one on the next page.

Making Sense of the Graphs
Scale Weight
• On the top graph, the top horizontal line (red) is the legal capacity of the scale. Please
note that these graphs are for the last draft of an order so that we can demonstrate ‘trim’.
• The next horizontal line (blue) is the weight that is being targeted. Note that it starts as a
nominal amount but once an accurate flow rate is calculated it drops to the weight needed
before the gate moves to trim. Once we get to trim, which is the first vertical line (green),
the target weight moves to the desired weight for the final draft.
• The line that starts at zero and moves diagonally up (brown) is the total weight in the
weigh hopper. When the feed gate first opens there will be no weight because the grain is
in flight but then you should see a nice clean line up to the cutoff weight. If this is not the
case you do not have an optimum scale.
• The second vertical line (brown), is only shown on the last draft of an order and is the
time when the gate is instructed to move from the trim position to the closed position. In
our example you can see that that it takes 3.1 seconds from the time that the gate moves
from full open position (first vertical line) to trim (second vertical line) and register a stable
flow rate. Two to three seconds is ideal. If the time is significantly longer than this, then
time is being wasted on each order. If the time is less than two seconds there is a chance
that the scale will not get a good reading at trim and you are likely to see target weights
that are not very close to the Order Weight.
• Call CompuWeigh if this trim time is not around 2-3 seconds. It may suggest that you
have a scale problem.

Flow Rate
• On the bottom graph on the previous page, there are two lines that follow each other. The
brown line shows the instantaneous flow rate and jumps around quite a lot.
• The blue line, which is the average flow rate provides a smoother flow. You will notice
that there is zero flow initially while the grain is in the air and then a surge in flow rate
when the grain first strikes the bottom of the weigh hopper. The flow rate should then
recover and show a reasonably consistent flow rate. If you see a very inconsistent flow
rate this is an indicator of design problems with the scale, including oversized gates. If the
flow rate does not stabilize by time the time the weigh hopper is half full, the CD-4000 is
going to find it very difficult to provide accurate cutoffs. Please call CompuWeigh if you
are experiencing these kinds of problems.
• Please refer to Scale Weight above, for information on the two vertical lines on the graph.
Zooming Graphs
If you wish to see a larger picture or wish to print of one of these two graphs, press F7 for the
Weight graph or F8 for the Flow Rate graph.
Press Esc when you have finished with a zoomed picture and you can then zoom the other
one if you wish.
Printing Graphs
• Make sure that you have set up the printer specifications in Setup Printout on page 78, so
that the printer knows how to print the graph.
• Zoom the Graph you want to print and then press F7-Print. If this key is dimmed you do
not have a Report Printer attached. If you in fact do have a Report printer you will need to

go to the Printer Tab in the Scale Configuration and click on the Report Printer ‘Present’
button.

DWI Calibration
Introduction
One of the problems of all digital weight indicators is that they do not have a full keyboard or monitor.
This makes them awkward to setup. The CD-4000 eliminates this problem by allowing the indicator to
be setup and calibrated from the CD-4000.
Ensure that Configuration is correct

Before calibrating the indicator you must first enter the Weight Units, Scale Capacity and Division Size
in Configuration. Please see Configuration on page 13.
Once that is done, press the F5-More on the Process Screen.
Now press F3-Cal DWI to select Calibrate Digital Weight Indicator. You will be asked to enter the
Administrative password. Enter this password.
You will now notice that the Scale Mode on the top left of the screen changes from Idle to Calibrate.
You will now be shown the Scale Configuration items discussed above. Please verify that they are
correct. (Note: Decimal Points is on this list but is actually established automatically by the CD-4000
once you have selected Division Size).
Press ‘Yes’ if these settings are correct. Press ‘No’ if they are not correct and go to Configuration to
update the scale settings. Please see Configuration on page 13 on how to do this.
CD-4000 with Unit Train DWI Calibration • 85

Starting the Calibration Process
Before you start this process, quickly scan down the boxes on the left side to make sure that you can
answer ‘Yes’ to all of them, otherwise you will get half way through the process and then have to start
again.
It is important that the scale is empty so we can set the zero point of the calibration. Press ‘Yes’ if the
scale in empty..
Press F3-BuildUp and open the discharge gate
If
until the hopper is empty.
No
-!
As a reminder we ask you to check that the test weight linkage is installed and hanging free.
Remember that the linkage is part of the net weight of the scale. A very common problem is to have
the test weight chain is resting on the test weights. The chain should be hanging free passing through
the test weight handles but not touching the test weights if possible. In other words, when lifting the
test weights the only additional weight that should be lifted is the test weights themselves.
Go and make sure that linkage is hanging free.
If
No
-!
You need to remove any build up of dirt that is sitting on the test weights. Remember that any
additional weight is multiplied by a factor of 10 because typically the test weights only represent 10% of
the scale capacity. For example ½ lb of dust on each the test weight would result in a 150lb error on
the scale.
Clean the dust off the test weights

If
No
-!
As part of the calibration process we will be storing information in the digital weight indicator. To do
this jumper E4 on the main GSE 460 board must be moved from ‘No’ to ‘Yes’. This requires that you
remove two screws on the back of the indicator. This will require breaking the Government seal if one
has been applied to the indicator.
86 • DWI Calibration CD-4000 with Unit Train

The E4 jumper is approximately in the center
of the GSE 460 board (just below the LCD
display). The schematic on the right side
shows the position of the jumper.
(Remember that the jumper will need to be
moved back to the ‘No’ position before the
indicator can be used). There are three
prongs you should move the jumper so that it
connects to the one nearest the word ‘E4’
and the center prong.
Open the back and move jumper to the ‘Yes’.

If
No
-!
If you have done everything correctly the Scale Weight box at the bottom will show the words ‘CALIBR’
as shown below
Now that the scale is empty, we need to press the Zero button to establish the empty or zero weight
If you don’t wish to continue with Calibration
If
now is a good time to exit
No
-!
We now need to lift the test weights. If you have automatic test weight lifting equipment the weights
will be lifted. If you have manual lifting now is the time to get ‘cranking’ and lift up the weights.
If you press ‘No’ Calibration is aborted.
If
No
-!

Press the Continue key once the weights have been lifted.
If
No
-!
Now enter the TOTAL weight of the test weights lifted (all corners)
If
No
-!
Look at the weight on the indicator and ensure that it matches what you entered. If the display does
not match what you entered you should restart the procedure. If this again fails, you should call us.
If
No
-!
Check that the weight display still shows the correct weight.
We now need to lower the test weights. If you have automatic test weight lifting equipment we will drop
the weights when you press OK. If you have manual lifting, now is the time to put the weights down.
It is important that the weight display now reads zero. If it does not you should check that the weights
are properly down and nothing is hanging up and that the chains are loose again.
88 • DWI Calibration CD-4000 with Unit Train

If
No
-!
Now we are going to repeat the process to make sure that we get consistent results.
If
No
-!
Same as above
If
No
-!
Same as above
If
No
-!
Congratulations you have configured the digital weight indicator. IMPORTANT: You should now move
the jumper back to the ‘No’ position so that the indicator will work properly.

Alarms and Warnings
There are several alarms that will be displayed on the lower left hand side of the screen (just above the
parameters field in a red square block). Some of them are important enough to stop the scale; others just
cause a temporary delay however even these temporary delays can chew up a serious amounts of time if they
are re-occuring. If you are using a GMS-4000 system, we recommend that you review the Analysis Chapter
and run the Scale Alarms Report. You may be surprised just how much time is being wasted and it will point
you in the right direction on how to speed up your operation.
Below is an explanation of each of the alarms.
Data Error
A data error occurs when the configuration stored in the CD-4000 memory has become corrupted.
Should this error appear, load General Scale Configuration as described on page 14 data. The action
of loading Configuration will force the CD-4000 to load the last saved configuration. Please check
each item to ensure that everything is correct and then press F3-Save to store.
No weighing is permitted until this problem has been eliminated.
Over Capacity
Over capacity occurs when the capacity set in General Scale Configuration on page 14 data and the
digital weight indicator has been exceeded. Should this alarm occur, no weighing is allowed until the
over capacity condition is cleared. This may require that product be manually removed from the scale.
Under Zero
An under zero alarm occurs when the weight indicator is showing a negative weight that exceeds the
Under Zero alarm range set in the Advanced Scale Configuration section. For example if the grads
set in the alarm range is 20 grads and the Division Size is 10 lbs then the alarm will occur at minus
200 lbs. This alarm can be caused by pressing F5-Tare Set (which resets the empty weight of the
scale) when there was a large buildup of foreign material on the discharge gates. If this buildup
suddenly falls off, the empty weight of the scale may be outside the allowable limits. For this reason,
the Under Zero alarm range should be set beyond the weight of any build up. No weighing is
permitted by the system while this alarm is active.
Audit Printer Error

This alarm appears when the printer is disconnected, out of paper, de-selected or power is off. No
weighing or operation of the scale is permitted until the error is cleared.
Remote Printer Error

This alarm appear when the remote printer (if it exists) is disconnected, out of paper, de-selected or
power is off. No weighing or operation of the scale is permitted until the error is cleared.
Scale in Motion
Scale in motion is not normally an alarm but just a temporary state that the scale is in prior to taking
the gross or tare weight. The message appears on the scale picture just under the weigh hopper
CD-4000 with Unit Train Alarms and Warnings • 91

graphics. Once the motion stops, the weight will be recorded. If the scale is in motion for a long time
you may have inadvertently set the Extended Motion Time box in Scale Configuration to ‘Yes’ (please
see page 18). Unless required by F.G.I.S. you should set this to ‘No’. Alternatively it may indicate a
problem with one of the load cells, possible structural problems or wind that is rocking the weigh
hopper.
Interlock Error
This error occurs when the CD-4000 is receiving an indication that both the weigh hopper feed AND
discharge gates are open at the same time. This is a big ‘NO-NO!’ The alarm will print on the printer
and stop any weigh cycle in progress. SmartTech will help you determine what is wrong with the
scale. Please see SmartTech on page 59.
Lower Garner Full

The ‘Lower Garner Full’ alarm occurs when the weigh hopper is ready to discharge and the lower
garner bin level detector is on. The weigh hopper gate will not open because there is not enough
space in the lower hopper for the contents of the weigh hopper. (Releasing the grain would possibly
cause the grain to push up on the weigh hopper discharge gate and therefore affect the weight).
This is not a serious alarm and as soon as the lower garner empties, the alarm will turn off and the
Weigh Hopper discharge gate will automatically open. If this alarm is a common occurance you may
want to take a look at resizing the equipment below the scale.
Weigh Hopper Full

The ‘Weigh Hopper Full’ alarm occurs when the contents of the weigh hopper reach the bin level
detector. The alarm is displayed within the graphics of the weigh hopper and is also printed. If the
system is operating in the Auto Mode, the cycle will stop and wait for your action. At this time, you
would discharge the weigh hopper.
Upper Garner Full

The ‘Upper Garner Full’ alarm occurs when the contents of the upper garner reaches the level
detector. The alarm is displayed within the graphics of the upper garner and is also printed on the
audit printer.
Although no action is taken by the CD-4000, the customer will normally tie this sensor to an audible
alarm and/or have it tied directly into the control equipment of the facility. This is not the responsibility
of CompuWeigh we provided the PLC/HMI automation system. The alarm will clear when the contents
of the upper garner drop below the upper garner bin level switch.
This is a normal alarm between strings of rail cars, however if this happens between every car, you
may want to consider upgrading to the GMS-4000 with Super SmartLoad that automatically weighs
up two drafts for the next car before it is in position. Not only does this speed up loading it relieves the
upper garner of two drafts and therefore allows the scale to run for another 45 seconds.
UG Gate Open/WH Gate Open

These are information messages rather than alarms and appear below the scale picture on the left
side of the screen during the period when either gate is actually closing. If the gate fails to close within
5 seconds, a Gate Error alarm is generated.
Gate Error
This alarm will appear on the screen if the system has being trying to close one of the gates for 5
seconds without success. This alarm can also occur if you are running the system from the GMS
92 • Alarms and Warnings CD-4000 with Unit Train

computer (GMS-4000 version only) with Super SmartLoad enabled and the system cannot close the
Lower Garner gate and is therefore being prevented from dumping the first draft into the Lower
Garner.
Reports Printer Error

This alarm appears when the Reports printer is disconnected, is out of paper, de-selected or power is
off. Unlike the Audit printer alarm, this error does not prevent you from continuing to run the scale and
is just for information.
Gate Not Calibrated

Gate control is an option on the CD-4000. This control is normally on the Lower Garner gate (if there
is one) or sometimes on the Weigh Hopper discharge gate if there isn’t a Lower Garner. Gate control
allows the gate to be open to a partial position, which is useful if there is a restriction below the scale
like a sampler or conveyor that cannot handle the product at full speed. The alarm appears if the gate
has not been calibrated and therefore the CD-4000 does not know how to position the gate.
Link Error/Link Offline/Link Shutdown

These alarms can only occur when the CD-4000 is being controlled by another machine and there is a
problem with the communications between the two. Typically the controlling machine will be a GMS-
4000 but may also be a PLC or other device capable of communicating over the Modbus protocol.
DWI Timeout
This alarm occurs if the CD-4000 is not receiving proper communications from the digital weight
indicator. Problems include loose or broken cable connection to the indicator and a faulty DWI.
DWI Jumper Err

This alarm indicates that the E4 jumper on the indicator has not been placed back in the Program ‘No’
position after calibration. You MUST set the jumper to the ‘No’ position prior to running the scale.
DWI Config Err

This alarm occurs if the CD-4000 discovers an inconsistency between its own configuration and the
Digital Weight Indicator’s configuration. A message appears on the screen showing the difference
between the configurations.
LG Not Empty
This alarm will only occur when the CD-4000 is being controlled from GMS and the Super SmartLoad
feature is enabled. This alarm means that the CD-4000 cannot discharge the first draft of the order
into Weigh Hopper because Lower Garner is not completely empty (see the SmartLoad section in the
GMS Manual).
SmartTech Alarm
This alarm occurs if SmartTech detects a malfunction in one of the 34 items that it monitors, (for
example a broken limit switch or a blown opto fuse). SmartTech alarms will not stop the scale unless
CD-4000 with Unit Train Alarms and Warnings • 93

it is because of a serious alarm (like both gates open at the same time), which will cause the scale to
stop. Please see page 26 for information about the alarms that SmartTech monitors for.
To get more detailed explanation about a message, go to SmartTech screen by selecting ‘SmartTech
Screen’ item from the ‘Options’ menu or pressing the F11 key twice. Please refer to page 59 for an
explanation on how to use the SmartTech module.
94 • Alarms and Warnings CD-4000 with Unit Train

Options
Remote Display
The remote display option requires an additional interface module to support the device and a second
monitor. This second monitor allows for monitoring (but not control) of the scale from a remote
location. These displays are often used for FGIS personnel.
Remote Operating System

A Remote Operating Station for the Compudraft CD-4000 can be provided if remote control rather
than just monitoring is required. The ROS includes an additional keyboard and monitor. This
station operates the CD-4000 exactly in the same manner as the local system. Control is shifted from
local to remote and back by the use of a key operated switch located on the Compudraft CD-4000.
This station is useful for situations where the CD-4000 is not located near the loading station or the
scale needs to be operated from two places (for example in the Head House and perhaps at a Truck
Dump).
Gate Control
This control is normally on the Lower Garner gate (if there is one) or sometimes on the Weigh Hopper
discharge gate if there isn’t a Lower Garner. Gate control allows the gate to be open to a number of
partially open positions. This is useful if the volume of product leaving the scale must to be restricted,
(for example if there is a sampler or a conveyor that cannot handle the product at full speed).
Gate control requires double acting solenoids on the gate, an additional interface module and a gate
position translator that senses the weigh hopper gate position. If you have a GMS-4000 and the gate
control is on the lower garner, we would suggest that you also install an empty level switch so you
can run Super SmartLoad that will potentially save 45 minutes on a unit train.
Remote Start and Stop

For operations such as rail loading, the weighing sequence can be stopped and started remotely by a
manually operated pendant switch. This may allow the operator to handle the whole operation from
outside of the control room.
Printers
The CD-4000 can print to either a Star 40-column serial printer or the standard 80-column serial
Okidata Turbo 320.
GMS Package
The CD-4000 system can be upgraded to GMS-4000. This will still use the CD-4000 controller but
will also have an industrial computer running the GMS software. The upgrade requireds updated
software for the CD-4000, a KVM switching module and the CompuWeigh Industrial Computer.
Benefits include faster loading, integration to accounting, automatic identification of the rail cars and
management reporting and analysis.
CD-4000 with Unit Train Options • 95

PLC Communication
The CD-4000 may be equipped with an add-on card and special software allowing remote
communication to PLCs via Modbus protocol. This system is currently being expanded to Modbus
via Ethernet at which point all major PLC systems will be able to monitor and control the CD-4000.
96 •Index CD-4000 with Unit Train

Interface Drawings
CD-4000 Back Panel Layout

The CD-4000 has been designed for easy integration to other CompuWeigh products and to third
party products. For example the SmartNet Option allows the CD-4000 to connect to PLC systems
using the industry standard Modbus protocol on either serial or TCP/IP.
Reset 5 VDC fuse for Opto Connector Digital 40 or 80

Switch Control Power to monitor Weight column serial
Indicator audit printer
S m a rtN e t
R e set 5 V F u se E xp a n sio n V 1 - M o n ito r J7 - D .W .I. GM S - KVM
Parallel printer for E 1 - E th e rn et H D 15
F em ale
DB9
M ale
Power tickets P 1 - T icke t P rin te r J8 - A u d it T ra il P rinte r

D B 25 DB9
F e m ale M a le
J3 - S ca le I/O M 1 - M o u se J9 - R e m o te P rin te r
D B 37 6 P in DB9
F e m ale M in i D in M ale
DB37 to J4 - S ca le I/O K 1 - K e yb o a rd J10 - G M S C o n tro l
SmartTech DB37
F e m a le
6 P in
M ini D in
DB9
M ale
Optional Optional connectors

AC Plug and PLC Keyboard Serial to GMS for GMS mouse and
On/Off switch Control connector computer keyboard
SmartTech Opto Wiring

The connection description on the next page is also found on the inside door of the SmartTech Opto
box.
The top left section shows the field wiring from the Opto box to the physical scale. These connections
are typically 110 VAC and normally require 16 AWG wire.
On the top right hand side of the screen is a layout drawing of the standard SmartTech Opto board.
Depending on your configuration, some optos modules may not be installed and therefore the
associated field wiring will not be required.
At the bottom of the screen is the control wiring from the SmartTech Opto Box back to the CD-4000.
The SmartTech Opto box is normally shipped pre-wired with 10’ of opto cable so that connection is as
easy as plugging the 37D connector into the J3 Scale I/O connector on the back of the CD-4000.
CD-4000 with Unit Train Interface Drawings • 97

SmartTech Opto to field wiring
Below is a typical wiring layout, but you should not assume that your system is exactly the same.
Please call the original scale manufacturer for the exact details on your system.
CD-4000 with Unit Train Interface Drawings • 99

Wiring and Connection
Load Cell Connection Notes

1. Load cell wiring must be in a separate conduit containing only signal cables.
2. Load cell wiring color codes are for ARTECH S-Type load cells. Please consult the
load cell specification sheet if a different load cell manufacturer is used.
3. The shielding for the load cell cable from the load cell summing junction board to the
D.W.I. should be terminated at the summing junction board only. The shield at the
D.W.I. end should be cut and taped to isolate it.
4. Manufacturers P/N's:
• Load Cell Cable - Alpha 25166
• Load Cell Connector on D.W.I. side of cable - Amphenol 97-3101E w/14S-6P
insert
• Load Cell Connector on Scale side of cable - Amphenol 97-3106E w/14S-6S
insert

Index
advanced select by draft count ........................................................ 81

scale configuration ..........................................................22 select by order................................................................. 81
alarm data error ............................................................................. 91
over capacity ...................................................................23 dead band............................................................................. 16
under zero........................................................................23 default values ....................................................................... 13
alarms, data error.................................................................91 delay
alarms, interlock error..........................................................92 dump motion ................................................................... 18
alarms, over capacity......................................................91, 92 fill motion........................................................................ 18
alarms, printer error.......................................................91, 93 deviation
alarms, scale in motion.........................................................91 correction........................................................................ 23
alarms, SmartTech................................................................93 digital weight indicator ........................................................ 11
alarms, under zero ................................................................91 direct trim range .................................................................. 23
alarms, upper garner full......................................................92 division size .......................................................................... 14
alarms, weigh and upper garner open ..................................92 double acting solenoids........................................................ 95
alarms, weigh hopper full .....................................................92 draft
alter test wts..........................................................................56 standard size ................................................................... 15
auto-test ................................................................................29 draft count
build-up test ..........................................................................42 rollover ........................................................................... 18
calibration selecting data .................................................................. 81
gate..................................................................................63 draft count subtotal .............................................................. 18
indicator ..........................................................................85 draft size
jumper .............................................................................87 maximum......................................................................... 23
start .................................................................................86 minimum ........................................................................ 24
two point..........................................................................45 dump
capacity motion delay.................................................................... 18
scale.................................................................................14 DWI
certificate calibration....................................................................... 85
weight ..............................................................................21 Ethernet connector ................................................................. 8
change cutoffs .....................................................55, 56, 57, 58 extended motion time............................................................ 17
checklist ................................................................................11 F9-New ................................................................................ 34
clearing fill
memory ............................................................................27 motion delay.................................................................... 18
configuration ........................................................................13 flow rate ............................................................................... 83
advanced..........................................................................22 foreign material.................................................................... 91
general.............................................................................14 function keys........................................................................... 8
printer..............................................................................18 fuse ......................................................................................... 7
printing ............................................................................28 slow-blow .......................................................................... 7
reload ..............................................................................27 gate
retaining ..........................................................................13 calibration....................................................................... 63
connector checking operation.......................................................... 65
Ethernet .............................................................................8 close time ........................................................................ 16
I/O .....................................................................................8 control............................................................................. 63
control dead band........................................................................ 16
gate..................................................................................63 percentage................................................................. 16, 63
GMS...................................................................................8 gate position translator ........................................................ 95
controls and hardware............................................................7 GMS control ........................................................................... 8
copyright.................................................................................2 graph
custom flow rate .......................................................................... 83
ticket ................................................................................21 printing ........................................................................... 83
cutoff scale weight..................................................................... 82
weigh hopper ...................................................................16 zoom................................................................................ 83
data graphs
backup data .....................................................................79 understanding ................................................................. 82
erase data ........................................................................80 header lines .......................................................................... 20
graph interpretation ........................................................82 I/O connector ......................................................................... 8
manage ............................................................................79 i/o input ................................................................................ 11
restore data .....................................................................79 indicator
review ..............................................................................81 updating .......................................................................... 15
CD-4000 with Unit Train Index • 101

interlock error ......................................................................92 SmartTech ........................................................................ 9, 26
jog SmartTech alarm.................................................................. 93
dead band ........................................................................16 solenoid ................................................................................ 16
range ...............................................................................24 low level.......................................................................... 23
time..................................................................................16 standard draft size................................................................ 15
jumper...................................................................................87 start up procedure ................................................................ 11
keys statistics................................................................................ 77
special ...............................................................................9 backup data..................................................................... 79
level erase data........................................................................ 80
mid...................................................................................17 printing ........................................................................... 78
lower garner restore data..................................................................... 79
cleanout ...........................................................................16 reviewing data ................................................................ 81
gate type ..........................................................................23 switch
low level sensor ...............................................................23 reset .................................................................................. 8
lower garner full...................................................................92 tare reset value..................................................................... 15
maximum draft size...............................................................23 tare set.................................................................................. 46
memory test
clear ................................................................................27 Auto-Test......................................................................... 29
mode idle ..............................................................................33 Build-up .......................................................................... 42
modem two point ......................................................................... 45
external............................................................................11 ticket
mouse custom............................................................................. 21
not required .......................................................................8 time
name dump motion ................................................................... 18
scale ................................................................................14 extended motion .............................................................. 17
negative weights ...................................................................91 fill motion........................................................................ 18
options ..................................................................................95 lower garner clean out.................................................... 16
options - remote display .......................................................95 weigh hopper clean out................................................... 17
options - remote operating station........................................95 transaction, new ............................................................. 34, 53
options - remote start and stop .............................................95 transaction, remove.............................................................. 36
opto box ..................................................................................9 transaction, revise ................................................................ 35
opto isolation ..........................................................................5 transactions
order available ......................................................................... 18
selecting data ..................................................................81 trim
over capacity ..................................................................17, 91 direct range............................................................... 23, 24
alarm ...............................................................................23 in use............................................................................... 17
paper trouble shooting
length...............................................................................19 gate ................................................................................. 65
password...............................................................................13 SmartTech ....................................................................... 26
percentage gate ..............................................................16, 63 two point test ........................................................................ 45
power up procedure............................................11, 34, 37, 38 under zero ...................................................................... 23, 91
printer units...................................................................................... 14
configuration .............................................................18, 28 unpacking............................................................................... 5
connectors .........................................................................8 updating indicator................................................................ 15
double print .....................................................................19 upper garner
narrow print ....................................................................19 close solenoid.................................................................. 23
printer error....................................................................91, 93 mid level.......................................................................... 17
printers ...........................................................................11, 95 trim in use ....................................................................... 17
printing upper garner full .................................................................. 92
graphs..............................................................................83 upper gate
statistics...........................................................................78 trim motion time.............................................................. 25
range warning
reset.................................................................................15 needs expert .................................................................... 13
reloading configuration ........................................................27 packing inside CD-4000 ................................................... 5
reset switch .............................................................................8 warnings................................................................................. 5
rollover weigh and upper garner open .............................................. 92
draft count .......................................................................18 weigh hopper
scale cleanout .......................................................................... 17
capacity ...........................................................................14 close solenoid.................................................................. 23
name ................................................................................14 cutoff ............................................................................... 16
scale in motion......................................................................91 weigh hopper full ................................................................. 92
scale weight weight certificates ................................................................ 21
graph ...............................................................................82 weight units .......................................................................... 14
signature lines ......................................................................20 zoom
size graphs ............................................................................. 83
division ............................................................................14

CD-4000 with Unit Train Index • 103

CD-4000 Manual, v300

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CompuWeigh Corporation

Version 3.00, April 2003

Copyright © 2002 CompuWeigh Corp., All rights reserved.

If you find errors or have suggestions to make, please email us at sales@compuweigh.com.

CD-4000 with Unit Train

Controls and Hardware 7

Gate Control (optional) 63

Alarms and Warnings 91

CD-4000 with Unit Train Introduction • 5

P ow er P 1 - T icke t P rin ter J8 - A udit Trail P rinter

J3 - S cale I/O M 1 - M ouse J9 - R e m ote P rinter

J4 - S ca le I/O K 1 - K eyboard J10 - G M S C ontro l

CD-4000 with Unit Train Controls and Hardware • 7

8 • Controls and Hardware CD-4000 with Unit Train

Digital Weight Indicator

CD-4000 with Unit Train Controls and Hardware • 9

10 • Controls and Hardware CD-4000 with Unit Train

Connections for Power and Peripherals

Digital Weight Indicator

CD-4000 with Unit Train Start up Procedure • 11

From this screen you can do any of the following:

12 • Start up Procedure CD-4000 with Unit Train

CD-4000 with Unit Train Configuration • 13

Weight Units (must also be set in digital weight indicator)

Scale Capacity (must also be set in digital weight indicator)

Division Size (must also be set in digital weight indicator)

14 • Configuration CD-4000 with Unit Train

Updating the indicator

Standard Draft Size (important to understand this)

Max Add to Draft Size

CD-4000 with Unit Train Configuration • 15

Percentage Gate In Use (requires calibration of gate)

Gate Pulse Time

Gate Dead Band

Jog Dead Band

16 • Configuration CD-4000 with Unit Train

UG Mid Level In Use

Over Capacity Manual Print

CD-4000 with Unit Train Configuration • 17

Extended Motion Time (important)

Fill Motion Delay Time

Dump Motion Delay Time

Draft Count Rollover

Drafts Per Subtotal

Available Transaction Types

18 • Configuration CD-4000 with Unit Train

Use Wide Printout

Form Feed on Narrow Print

Paper Length In Inches

CD-4000 with Unit Train Configuration • 19

Print Custom Lines On

Header Lines 1 & 2

Signature Lines 1 & 2

20 • Configuration CD-4000 with Unit Train

Custom Ticket Format

CD-4000 with Unit Train Configuration • 21

Bypass Draft Size Optimizing

Hydraulic Unit “Power ON”

22 • Configuration CD-4000 with Unit Train

WH Close Solenoid Present

LG Low Level Sensor Present

Over capacity alarm range

Under zero alarm range

Maximum draft size