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User Guide
CUC (Crisplant Universal Controller)
USER GUIDE
CUC (CRISPLANT UNIVERSAL CONTROLLER)
ADJUSTMENT SCALE (AS05)
Journal: 1028950
Date: 17 Sep 2013
Revision: R01
Pages: 64
Initials: bgm
Software: FIL04uk30316
© Kosan Crisplant 2013

17 Sep 2013 Adjustment Scale (AS05)
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CONTENTS
1. USER GUIDE ................................................................................................................................. 5

1.1 GENERAL DESCRIPTION ....................................................................................................... 5
1.2 FUNCTIONALITIES .................................................................................................................. 7
1.3 OTHER FEATURES AVAILABLE: ........................................................................................... 8
1.4 HOW TO GET STARTED ......................................................................................................... 9
2. PASSWORDS .............................................................................................................................. 11
2.1 PASSWORDS FOR SET-UP AND FORCE OF OUTPUTS ................................................... 11
3. BASIC SET-UP ............................................................................................................................ 12

3.1 SET-UP OF FUNCTIONALITY ADJUSTMENT SCALE (AS05) ............................................ 12
3.2 DESCRIPTION OF FUNCTIONALITY FOR ADJUSTMENT SCALE (AS05) ........................ 13
4. I/O-LIST FOR ADJUSTMENT SCALE (AS05) ............................................................................ 14

4.1 MACHINE LAYOUT ................................................................................................................ 14
4.2 INPUT LIST ............................................................................................................................ 15
4.3 OUTPUT LIST ........................................................................................................................ 16
4.4 ABBREVIATIONS FOR MODULES: ...................................................................................... 17
4.5 ABBREVIATIONS: .................................................................................................................. 18
5. MACHINE SET-UP ...................................................................................................................... 19

5.1 ENTER MACHINE SET-UP .................................................................................................... 19
5.1.1 NET ADDR ...................................................................................................................... 20
5.1.2 LIGHT .............................................................................................................................. 21
5.1.3 EXT DATA IN .................................................................................................................. 21
5.1.4 DQ SIZE [cyl] ................................................................................................................... 22
5.1.5 DQ DIR ............................................................................................................................ 22
5.1.6 REACTION TIME ............................................................................................................ 23
5.1.7 ENABLE EVACUATION .................................................................................................. 24
5.1.8 LIFT TMR1 ...................................................................................................................... 24
5.1.9 LIFT TMR2 ...................................................................................................................... 24
5.1.10 START LIMIT ............................................................................................................... 25
5.1.11 NEGATIVE TARE ........................................................................................................ 25
5.1.12 DISCONN.TMR............................................................................................................ 25
5.1.13 MAX DOSING TIME .................................................................................................... 26
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5.1.14 MIN FLOW ................................................................................................................... 26

5.1.15 MIN DOSING ............................................................................................................... 26
5.1.16 EVA DMDT [g/s]........................................................................................................... 27
5.1.17 POSITIVE TARE .......................................................................................................... 27
5.1.18 PUSHER DLY 1 ........................................................................................................... 27
5.1.19 ACC TIMER ................................................................................................................. 28
6. CYLINDER SET-UP ..................................................................................................................... 29

6.1 ENTER CYLINDER SET-UP .................................................................................................. 29
6.1.1 ENTER NET .................................................................................................................... 29
6.1.2 ENTER FIX TARE ........................................................................................................... 30
6.1.3 ENTER TARE OFFSET .................................................................................................. 30
6.1.4 ENTER TARE MIN .......................................................................................................... 30
6.1.5 ENTER TARE MAX ......................................................................................................... 31
6.1.6 ENTER ENC MODE ........................................................................................................ 31
6.1.7 ENTER Q-ENC ................................................................................................................ 31
6.1.8 ENC DECI PNT POS ...................................................................................................... 32
6.1.9 REMOTE TARE OFFSET ............................................................................................... 32
6.1.10 REM DECI PNT POS .................................................................................................. 33
6.1.11 ENTER OPER MODE .................................................................................................. 33
6.1.12 ENTER CS HIGH LIMIT .............................................................................................. 34
6.1.13 ENTER CS LOW LIMIT ............................................................................................... 34
6.1.14 ENTER LIFT TIMER .................................................................................................... 35
7. MACHINE FUNCTIONS .............................................................................................................. 36

7.1 POWER ON AND INITIATION ............................................................................................... 36
7.2 START/STOP ......................................................................................................................... 37
7.3 PROCESS AND BYPASS MODE .......................................................................................... 37
7.3.1 Process Mode.................................................................................................................. 38
7.3.2 Bypass Mode ................................................................................................................... 38
7.4 PROCESS ERRORS .............................................................................................................. 39
7.4.1 Errors ............................................................................................................................... 39
7.5 SERVICE & MAINTENANCE ................................................................................................. 41
7.6 PROCESS MODE .................................................................................................................. 41
7.6.1 Start/Stop of Filling Equipment ........................................................................................ 41
7.6.2 Auto zero for filling scale ................................................................................................. 41
7.6.3 Process status for filling / evacuation .............................................................................. 41
7.6.4 Process error ................................................................................................................... 44
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7.7 BYPASS / STARTUP MODE .................................................................................................. 46
8. ENCODING FUNCTIONS ............................................................................................................ 47

8.1 ENCODING IN GENERAL ..................................................................................................... 47
8.2 FUNCTION KEYS................................................................................................................... 48
8.2.1 Reset key......................................................................................................................... 48
8.2.2 Zero key........................................................................................................................... 48
8.2.3 Cylinder key ..................................................................................................................... 48
8.2.4 Decimal Point Cylinder Key ............................................................................................. 49
8.2.5 Type and owner during process ...................................................................................... 49
8.2.6 Enter key ......................................................................................................................... 50
8.2.7 Decimal Point Enter Key ................................................................................................. 50
8.2.8 Clear key ......................................................................................................................... 50
8.3 MANUAL MODE ..................................................................................................................... 50
8.3.1 Manual Tare .................................................................................................................... 51
8.4 FIX MODE .............................................................................................................................. 51
8.4.1 Quick encoding ................................................................................................................ 51
8.5 ENCODING LOCAL-REMOTE ............................................................................................... 52
8.5.1 Remote Encoding ............................................................................................................ 52
8.5.2 Local Encoding ................................................................................................................ 54
8.6 TYPE CHANGE BY NETWORK ............................................................................................. 54
9. MENU FUNCTIONS .................................................................................................................... 55

9.1.1 Default and Limits ............................................................................................................ 55
9.2 GENERAL SERVICE .............................................................................................................. 57
9.2.1 Version ............................................................................................................................ 57
9.2.2 Input Output Test ............................................................................................................. 58
9.2.3 Counter ............................................................................................................................ 59
10. MACHINE SERVICE KEY ........................................................................................................... 60

10.1 SK65015 PROCESSED CYLINDERS ................................................................................ 60
10.2 SK65016 DISTRIBUTED CYLINDERS .............................................................................. 60
10.3 SK65010 BALANCING THE SCALE .................................................................................. 60
10.4 SK65011 INCREASED RESOLUTION ............................................................................... 62
10.5 SK65040 FILL HOSE .......................................................................................................... 63
10.6 SK65042 MEASURE INTERFACE, STATUS PROCESS .................................................. 63

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1. USER GUIDE
This document only contains actual documentation for the given functionality read on the
front-page (see Journal (e.g. ug_eu01_uk - Emptying Unit 01)
This means that one or more

• Chapters (e.g. Cylinder - or Lock Parameter Set-up)
• Set-ups (e.g. Set-up of Net Address)
• or Service Keys / Functions
may be left out deliberately as they have no meaning for the actual functionality.
To manage a quick start up of a new machine go directly to chapter:

HOW TO GET STARTED
1.1 GENERAL DESCRIPTION
1 Display
2 Keypad
3 Start/Stop push-button
1
The CUC is an intrinsically safe controller with:

• 16 digital inputs and outputs (plus 1 extra input for push-button)
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• 1 serial interface to load cell module

• or serial interface to extended IO module (+ 16 inputs)
• 1 serial interface for communication
• LCD display (4 lines with 20 alpha-numeric characters on each line)
• 16-key sealed membrane keypad (12 keys for encoding and 4 function keys)
• 1 push-button for start/stop of the process
• 1 serial interface for programming
The CUC is intended for installation in hazardous areas (butane/propane) and placed at
the actual process (machine).
The CUC controls the process.

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1.2 FUNCTIONALITIES
The CUC gives (per set-up) many functionalities, e.g.:
Carousel equipment:
• IT01-nn (Inlet Tangential w/ e g. Integrated Pre Scale, Valve orientation, etc.)
• IR01-nn (Ref. IT01-nn, but Radial)
• OT01-nn (Outlet Tangential w/ e.g. Integrated Check Scale)
• OR01-nn (Ref. OT01-nn, but Radial)
Fill equipment:
• FS01-nn (Fill Scale on carousel or floor w/ load cell)
• AS01 (Adjustment Scale. Fill-/Evacuation- and Check Scale combined)
• FF01-nn (Fill Flow on carousel or floor w/ mass flow meter)
• IF01 (Inline (conveyor) Fill Flow )
•
Control equipment:
• LP01-nn (Leak Pressure detector)
• LG01-nn (Leak Gas detector)
• CS01-nn (Check Scale w/load cell)
• CV01-nn (Cylinder Vision w/camera)
• IC01-nn (Inlet Check scale – pre weighing function)
Utility equipment:
• CC01 (Cylinder (sum) Counter)
• FC01 (Flow (sum) counter)
• VH01 ((Screw) Valve Handler)
• SM01 (Sealing Machine)
• SM02 (Sealing Machine w/ line for Sort Out)
• SM03 (Sealing Machine, 2 pos wo/ line for Sort Out)
• CU01 (Cleaning Unit)
• EU01 (Emptying Unit)
• CA01 (Cap Applicator 01)
• CA02 (Cap Applicator 02 combined with valve orientation)
• CA03 (Cap Applicator 03 with cap feeder system)

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• VO01 (Valve Orientation)

• CH01 (Cap Handler(Screw/Unscrew))
1.3 OTHER FEATURES AVAILABLE:
Other features are available e.g. for maintenance line, pallet line or options to existing
functions
Maintenance Line (MAL)
• SH01 (Screw Handler f/ valves and suspension)
• TH01 (Thread Handler f/ thread - and /or mill tools)
• CU02 (Combined Cleaning/Emptying Unit, 2 position)
• CU03 (Two Cleaning Units, 2 position)
• CF01 (Cylinder Fill, (co2/spirit)
• CF02 (Cylinder Fill, 3 position (co2/spirit)
• CI01 (Cylinder Inspection w/ camera)
• EU02 (Two Emptying Units, 2 position)
• IP02 (Ink jet Printer w/ Check Scale, 3 prints on body of cylinder)
• CL01 (Cylinder Loader. Load/Unload of cylinders between chain conveyor and over
head conveyor)
• ER01-nn (Evacuation Rack, nn machine positions in line)
• PM01 (Pressure test Machine)
• VC01 (Valve Changing Unit)
Pallet Line (PAL):
• PC01-nn (Pallet Compact, compact system, 1 or 2 storey w/wo bar lifts)
• PC01-nn w/ carrier2 (as above but with vertical carrier and 1 or 2 pallet(s) pr. storey, in
3 heights)
• PL01-nn (Pallet Linear, modular system, stacker, de stacker and w/wo bar lifts)
CUC Options:
Options are available on request. Ask us, it may already exist or it is possible to make
according to your specification. Following is available (pt):
• Cylinder queue for 25 cylinders (std 17) in inlet to carousel
• TareAdd which adds 1000 g to the cylinders with shroud ring in inlet (NOTE: ONLY
FOR IT01 and IT04 and 100 g. division)
• Dedication of Filling Machines to Cylinder types in inlet (enable/disable FM’s pr Type)
• Other languages (pt French)
Data Collection:
As an option, a PC and a printer can be installed in a non-hazardous area (e.g. in an office)
for:
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• Automatic transfer of data between the units

• Data collection from units
• Statistics
• Remote support from Kosan Crisplant
1.4 HOW TO GET STARTED

To start up a new machine do as follows:
1. Get familiar with Password (See chapter PASSWORDS)
2. Carry out set-up of functionality (See Chapter SET-UP OF FUNCTIONALITY
TO…)
3. Adjust and test Inputs and Outputs
(See Chapter INPUT/OUTPUT LISTS)
(See Chapter MENU FUNCTIONS, Input Output Test)
When a CUC is set up to its actual functionality (step 2), parameters are set to default
values, which (in most cases) enables it to run at once. Few parameters (if any) should be
adjusted when the above steps are made.
If included, also:
4. Carry out Machine Set-up (See chapter MACHINE SET-UP)
5. Carry out Cylinder Set-up (See chapter CYLINDER SET-UP)
6. Test the Manchester Code (See chapter MENU FUNCTIONS, Manchester Test, –
Count)
7. Balance the Scale. (See chapter MACHINE SERVICE KEYS, SK65010 Balancing
the Scale)
8. Carry out Lock Parameter Set-up (See chapter LOCK PARAMETER SET-UP (for
Approval))
9. Initiate and test the Bar Code Wand (See chapter BAR CODE WAND)
Be careful and carry out the above steps correctly
Hereafter get familiar with the remaining chapters such as:

• MACHINE FUNCTIONS
• MENU FUNCTIONS

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In case of troubles during start-up (or later), this manual contains various chapters to help
and guide you to trouble shoot, if necessary
You are also welcome to contact Kosan Crisplant for assistance

In this case, please report the software version.
! See chapter MENU FUNCTIONS, Version

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2. PASSWORDS
2.1 PASSWORDS FOR SET-UP AND FORCE OF OUTPUTS

To avoid incorrect set-up and use of the CUC’s by non-authorized personnel, password
protection has been incorporated for:
• Cylinder Set-Up
• Machine Set-Up
• Basic Set-Up
• Lock Parameter Set-Up
• Force of outputs
• IO Set-Up
To enter the above set-up facilities, a password must be entered first.
The password is equal to the numbers entered to reach the actual menu point, preset with 7
E.g. to enter cylinder set-up, the operator must encode:
Encoding: Password:
- Decimal point and enter (=> main menu) 7
- 2 and enter (=> set-up menu) 2
- 1 and enter (=> cylinder set-up) 1
Result: 721
Passwords:
Cylinder set-up……..…………..721
Machine set-up…….…………..722
Lock Parameter set-up………..7221
FM to (Cyl type) set-up……..7222
Basic set-up………..…………..723
Force of outputs……………….7312
IO set-up…….………………….7222

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3. BASIC SET-UP
This function applies when the CUC is powered on for the first time, a printed circuit board
is taken from stock or after a possible operational error, power failure, etc.
The Chapter SET-UP OF FUNCTIONALITY TO… (next page) is a step by step instruction
1
in how to set up the CUC to a given functionality
If the CUC has entered a state where the menu cannot be activated, use the SK65535 service
key.
Press 65535 and Enter. The CUC will reset to Basic Set-up
CUC-UI01 V. 00243
MAIN MENU: .↵
↵
3.1 SET-UP OF FUNCTIONALITY ADJUSTMENT SCALE (AS05)
Function Key Display Range/Comments

MENU
. MAIN MENU
1-STATUS 3-SERVICE
2-SET UP 4-
Select SET UP
2 SET UP 1/2
1-CYLINDER 3-BASIC
2-MACHINE 4-
Select BASIC ENTER PASSWORD:

3
Enter PASSWORD FUNC.SELECT:

X
Key in 260 FUNC.SELECT:260=AS05

X
1
The set-up is password protected. Please see: PASSWORD
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Confirm selection PLEASE WAIT.. The CUC will reset
3.2 DESCRIPTION OF FUNCTIONALITY FOR ADJUSTMENT SCALE (AS05)

The Adjustment Scale 05 is a full automatic filling/evacuation machine based on the load
cell principle. It is used to adjust the filling of incorrectly filled LPG-cylinders.
The Adjustment Scale 05 includes the following features:
• Accumulation Stop
• Lifting table
• Adjustment Scale w/ Centring,/Center Head
• Sort Out of cylinders
• Accumulation for main conveyor
• Accumulation for side conveyor (sort out)
• Pneumatic guard (stops process if pneumatic low)
• Bypass functionality
Options:
• Possible data (tare) by network
• Data transmission for statistics
• Battery for hazardous are
Process Description:
When started, the accumulation stop opens and the cylinder enters the process.
When the cylinder reach the lifting table it is lifted on to the scale where it is Check
weighed.
If = (~Normal, within limits), cylinder is released onto the chain conveyor
If < (~Under filled, below limit), filling head is connected and the cylinder is filled
If > (~Over filled, above limit), filling head is connected, and the cylinder is evacuated a
given time (pr. Set-up). When evacuated the cylinder is filled again.
When filled/evacuated-filled, the cylinder is check weighed and lifting table is lowered to
release the cylinder onto the chain conveyor.

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4. I/O-LIST FOR ADJUSTMENT SCALE (AS05)
4.1 MACHINE LAYOUT
Fig. 4-1 Machine layout for AS05

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4.2 INPUT LIST

Module Position Item Function Type Contact Remarks
CM01 pos0 B02 Pneumatic OK P NO

GS01 pos1 B03 Cylinder at Stop FD
AS05 pos2
SO01 pos3 B06 Cylinder at FD
Pusher
B07 Pusher in Plus MI
Pos
B08 Pusher in Minus MI
Pos
B10 Accumulation FD
AC01 pos4 B09 Accumulation FD
Note: *) Optional

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4.3 OUTPUT LIST

Module Position Item Function Type Contact Remarks
CM01 pos0
GS01 pos1 Y01 Stop Y
AS05 pos2 Y03 Lifting Table Y
Y05 Filling head Y
connection/Centring
Y06 Gasstop Y
Y07 Evacuate Y
SO01 pos3 Y04 Pusher Y
AC01 pos4
Note: *) Optional

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4.4 ABBREVIATIONS FOR MODULES:

Abbreviation Type Remarks
CM Common Module
GS General Stop
BF Buffer
SO Sort Out
AC Accumulation
VO Valve Orientation
LG Leak Gas Detector
LP Leak Pressure Detector
SM Sealing Machine
CA Cap Applicator
CV Cylinder Vision
VH Valve Handler
CF Cylinder Filling
CU Cleaning Unit
SH Screw Handler
TH Tread Handler
IT Inlet Tangential
IR Inlet Radial
OT Outlet Tangential
CS Check Scale
FS Filling Scale
FF Filling Flow
PM Pressure Machine
ER Evacuation Rack
BS Buffer Section
ST Stacker
DS DeStacker
IP In Pusher
OP Out Pusher
TI Take In
TO Take Out

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4.5 ABBREVIATIONS:
Abbreviations for Input / Output Lists:
Abbreviation Type Remarks
FD Photoelectric sensor, diffuse
FF Photoelectric sensor, fiber optic
FR Photoelectric sensor, with reflector
H Indicating lamp
I Inductive
K Relay
MI Magnetic inductive
NC Normally closed
NO Normally open
P Pressure switch
S Switch
SP Push button
SS Selector switch
Y Solenoid valve
A Output for horn, flash, signal etc.

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5. MACHINE SET-UP
5.1 ENTER MACHINE SET-UP

To enter machine set-up, press sequence as follows:
Enter:
MENU
. MAIN MENU
1-STATUS 3-SERVICE
2-SET UP 4-
Select SET UP
2 SET UP 1/2
1-CYLINDER 3-BASIC
2-MACHINE 4-MODE
Select MACHINE ENTER PASSWORD:
2
Enter PASSWORD ENTER NETADR:0;1-125 Example of a Set-up

X 0

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5.1.1 NET ADDR

Function key Display Range/Comments
NET ADDR: 0;1-125 NET ADDR: 0;1-125 Default value = 0
0 Max Value = 125
X
Min Value = 0
NET ADDR
If the unit is connected in a network, it must have a unique address between 1 and 125.
The value is default 0, and hereby disconnected from the network. The address is typically
1 to nn for the filling machines, 2 for inlet, 3 for outlet. See table below.
ONLY PCB’s (Print Circuit Boards) of rev.: JDP6459-K5 * (or higher), must be used in Inlet
(IT/IR01-nn) or Outlet (OT/OR01-nn) when running as a “system” with P-NET addr. (e. g.
addr. 2, 3 or 4)
* The rev. is seen in the upper right corner of the PCB
Carousel equipment (*)

CUC CUC Addr. P-NET Addr. Description
1st IT/IR 2 2 Inlet Tangential/ -Radial
1st OT/OR 3 3 Outlet Tangential/ -Radial
2nd OT/OR 4 4 Outlet Tangential/ -Radial
1st -50th FS/FF 1-50 32-82 Filling Scale/Fill Flow
1st -4th AS 51-54 82-85 Adjustment Scales
1st -3rd LG 55-57 86-88 Leak Detection Gas
1st -3rd LP 58-60 89-91 Leak Detection Pressure
1st -12th FS/FF 61-72 92-103 Stand-Alone (FS/FF)
1st -4th PC/PL 73-76 104-107 Pallet Compact-/Pallet Linear-system
1st -3rd CV 77-79 108-110 Cylinder Vision
1st -3rd CS 81-83 112-114 Check Scales
1st -3rd Utility 84-87 115-118 Stand-Alone (E.g. SM etc.)NOTE: Data collection
is not included by default.
- To be ordered separately!
Stand-Alone Equipment (*)
CUC CUC Addr. P-NET Addr. Description
1st -94th FS/FF 1-94 32-125 Filling Scale/Fill Flow

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(*) Please ref. CUC Monitor, System Set-up, System type for corresponding Set-up
5.1.2 LIGHT
LIGHT:0;1,2=AUT LIGHT:0;1,2=AUT 3=ON Default value = 0
3=ON 0
X Max Value = 3
Min Value = 0
LIGHT
Set the background light mode for LCD
0 = OFF.
1 = the display light will flash in case of an alarm.
2 = ON at key press, the light will turn off again after 10 sec of inactivity.
3 = the display light is always ON
This setup is only present in CUC MKIII. The CUC MKIII has an 8-line LCD display.
!
The display light must be used with care. Use of the display light function leads to increased
power consumption in the CUC. In some basic functionality it is advisable to use mode 0.
5.1.3 EXT DATA IN

EXT DATA IN: 0-1 EXT DATA IN: 0-1 Default value = 0
0 Max Value = 2
X
Min Value = 0
For Encoding position

If enabled the encoding position is able to receive cylinder data from external sources. The
value can be set in different modes. By default the function is disabled (EXTERNAL DATA IN
= 0). Refer to section ENCODING LOCAL –REMOTE in user guide.

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! After changing the value, the CUC must be reinitiated to open a network
channel to be able to receive data.
If EXTERNAL DATA IN is 2, the size of the tare queue of the central

2
encoding position is limited to one .
5.1.4 DQ SIZE [cyl]

DQ SIZE [cyl]: 4- ? DQ SIZE [cyl]: 4- ? Default value = 4
0 Max Value = 255
X
Min Value = 4
DQ SIZE [cyl]:4-?
Set the number of cylinders to hold data for (data/tare queue)
This sets the size of the data/tare queue (data buffer) in front of the encoding position (e.g.
Start Stop or Waiting Stop). The value will affect both externally received data as well as
locally encoded data (tare) on the CUC keypad.
Only the first 4 tare values are displayed on the display, even though the size here is set to 5
or above. The total number of values is constantly written on the display for reference.
When DQ SIZE is changed, CUC should be Reset !
!
If Data queue exceeds a size which is possible in CUC memory, an Error = 65238 will be
! shown in the display. In this case reduce size until the error message disappear
5.1.5 DQ DIR
DQ DIR: L-R=0 R-L=1 DQ DIR: L-R=0 R-L=1 Default value = 0
0 Max Value = 1
X
Min Value = 0
DQ DIR: L-R= 0 R-L=1

Data/tare queue direction.
Set the direction of the tare queue located on the upper most line of the display.
2
The tare queue size is normally four.
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0 = Left to right (cylinder going in next is to the left).

1 = Right to left (cylinder going in next is to the right).
5.1.6 REACTION TIME

REACTION TIME: REACTION TIME: Default value = 0
0 Max Value = 255
X
Min Value = 0
REACTION TIME
Due to reaction time in the solenoid valve and gas stop a cylinder is normally slightly
overfilled.
By subtracting the “reaction time” from the net value the set point is corrected until the
filling is correct.
The following is an Example of how to calculate reaction time

- Reaction time is set to 0 (default)
- Be sure that the hoses are filled up with LPG (See SK65040), and Zero Set the Scale (-
>0<-)
- Press SK65011 to increase display resolution
3
- Fill a 11 or 13 kg cylinder with e g. 5 kg
4
- Read the values A, T and D (e.g. 17320, 12.0, 5.0, 430)
- Calculate reaction time as follows:
Reaction time = (A - T - N) * 100/D

= (17320 – 12000 – 5000) * 100/430
= (5320 - 5000) *100 /430
= 32000/430 = 74.4 ~ 74
- Enter Reaction time = 74
- Press SK65011 to decrease display resolution to normal resolution
Remember to set NET to correct value when finished!
!
3
Set temporary NET in Cylinder Set Up to 5 kg, (See Cylinder Set Up, Net)
4
Press 65042 to see the actual value A, T and D (See SK65042)

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5.1.7 ENABLE EVACUATION

ENABLE ENABLE EVACUATION Default value = 1
EVACUATION 0
X Max Value = 1
Min Value = 0
ENABLE EVACUATION
Enable or disable the evacuation procedure from the adjustment process.
0 = Disabled - All overfilled cylinders will be sorted out.
1 = Enabled - All overfilled cylinders will be evacuated until under limit.
5.1.8 LIFT TMR1

LIFT TMR1: 0;1-255 LIFT TMR1: 0;1-255 Default value = 60
0 Max Value = 255
X
Min Value = 0
LIFT TMR1
Lift table timer delay. The timer delay is used to delay activation of the solenoid valve for
the lifting table on a check scale. The delay can be set in steps of 1/100 sec. (~10 ms). The
value can be adjusted between 1 and 255 (~10 to 2550 ms.). If the value is 0, the timer is
disabled.
This timer is chosen by mean of "pointer" in cylinder setup. (See Lifting Table Timer)
5.1.9 LIFT TMR2

LIFT TMR2: 0;1-255 LIFT TMR2: 0;1-255 Default value = 120
0 Max Value = 255
X
Min Value = 0
LIFT TMR2
Lift table timer delay. The timer delay is used to delay activation of the solenoid valve for
the lifting table on a check scale. The delay can be set in steps of 1/100 sec. (~10 ms). The
value can be adjusted between 1 and 255 (~10 to 2550 ms.). If the value is 0, the timer is
disabled.

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This timer is chosen by means of "pointer" in cylinder setup. (See Lifting Table Timer
5.1.10 START LIMIT

START LIMIT: START LIMIT: Default value = 50
0 Max Value = MAX
X
Min Value = 0
START LIMIT
Gives the value where (fill- or check-) scales start their process sequence (e.g. a fill scale
starts the filling sequence by requesting tare etc.)
5.1.11 NEGATIVE TARE

NEGATIVE TARE: NEGATIVE TARE: Default value = 2
0 Max Value = MAX
X
Min Value = 0
NEGATIVE TARE
Gives the value for accepted negative tare for the cylinders. E.g. if the printed tare on the
cylinder is 14.2 kg and the actual (weighed) tare is 13.9, it gives a negative tare - 0.3 kg. If
the negative tare limit is exceeded, a filling machine rejects to fill and a negative tare
message is shown in the display.
In a system with pre scale (e.g. IT04) the cylinder is sorted out before the carousel
5.1.12 DISCONN.TMR
DISCONN.TMR: 0;1- DISCONN.TMR: 0;1-255 Default value = 0
255 0
X Max Value = 255
Min Value = 0
Disconnect timer

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It is possible to delay automatic disconnect of the filling head if the filling machine is
5
operated in OPERATION MODE 3 .
The timer value is in step of 1/10 sec. (~100 ms). The value is adjustable between 1 and
255 (~100 to 25500 ms.). If the value is 0, the time delay is disabled.
5.1.13 MAX DOSING TIME

MAX DOSING TIME: MAX DOSING TIME: Default value = 0
0 Max Value = 255
X
Min Value = 0
MAX DOSING TIME

Gives the maximum allowable dosing (filling) time for a cylinder. On time-out the dosing
stops and the fill head is disconnected.
5.1.14 MIN FLOW

MIN FLOW: MIN FLOW: Default value = 0
0 Max Value = MAX
X
Min Value = 0
MIN FLOW
Gives the minimum filling flow required for filling. If the minimum value fails, the dosing
stops and the fill head is disconnected
5.1.15 MIN DOSING

MIN DOSING: MIN DOSING: Default value = 2
0 Max Value = MAX
X
Min Value = 0
MIN DOSING
Gives the minimum value required for filling. If the minimum value fails, the filling will not
start.
5
Refer to Cylinder setup in User guide
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E.g. Minimum dosing is set to 0.5 kg and the cylinder needs to be filled with 0.4 kg. In this
case the filling will not start.
In a system with pre scale (e.g.IT04) the cylinder is sorted out before the carousel.
5.1.16 EVA DMDT [g/s]

EVA DMDT [g/s]: EVA DMDT [g/s]: Default value = 250
0 Max Value = 255
X
Min Value = 0
EVA DMDT
The value gives the amount of evacuated gram of LPG per second. E.g. 250 are 250
gram/second.
Based on this value a time for evacuation is calculated. When the time elapses, the
Evacuation valve will close, and finish the evacuation.
To increase the time of evacuation, the value (250 g/s) should be lowered.
5.1.17 POSITIVE TARE

POSITIVE TARE: POSITIVE TARE: Default value = 0
0 Max Value = MAX
X
Min Value = 0
POSITIVE TARE
Gives the value for the accepted positive tare for cylinders. E.g. if the printed tare on the
cylinder is 14.2 kg and the actual (weighed) tare is 14.8, it gives a positive tare or a
registered quantity of residual gas of 0.6 kg. If the positive tare limit value is set and the
limit is exceeded, the filling machine rejects to fill and an error message is shown in the
display.
5.1.18 PUSHER DLY 1

PUSHER DLY 1:0;1- PUSHER DLY 1:0;1-255 Default value = 0
255 0 Max Value = 255
X
Min Value = 0

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PUSHER DELAY:
Give a delay timer between cylinder at pusher and the sort-out: in 1/100 sec (~10 msec.).
The time starts when the sensor input for cylinder present at pusher is triggered and finish
by pushing.
The value is default 0 (disable). The value can be adjusted if necessary from 1 to 255 (10
to 2550 msec.).
5.1.19 ACC TIMER

ACC TIMER: 1-255 ACC TIMER: 1-255 Default value = 30
0 Max Value = 255
X
Min Value = 1
ACC TIMER
Give the time for accumulation in 1/10 sec (~100 ms).
The time starts when the sensor input for accumulation on the main conveyor is activated.
The value is default 30 ~ 3000 ms (3 sec.). The value can be adjusted between 1 and 255
(~100 to 25500 ms).

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6. CYLINDER SET-UP
6.1 ENTER CYLINDER SET-UP
To enter cylinder set-up, press sequence as follows:

Enter:
MENU
. MAIN MENU
1-STATUS 3-SERVICE
2-SET UP 4-
Select SET UP
2 SET UP 1/2
1-CYLINDER 3-BASIC
2-MACHINE 4-MODE
Select CYLINDER ENTER PASSWORD:
1
Enter PASSWORD ENTER TYPE NO:

X
6.1.1 ENTER NET

ENTER NET: ENTER NET: Default value =100
0 Max Value = MAX
X
Min Value = 0
NET
Enter the net value that indicates how many kilos of gas can be filled into this cylinder type,
e.g. 11 kg.

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6.1.2 ENTER FIX TARE

ENTER FIX TARE: ENTER FIX TARE: Default value =0
0 Max Value = MAX
X
Min Value = 0
FIX TARE
If the cylinder type operates with a fix tare, key in the required fix-tare value.
6.1.3 ENTER TARE OFFSET

ENTER TARE ENTER TARE OFFSET: Default value =100
OFFSET: 0
X Max Value = MAX
Min Value = 0
TARE OFFSET
This is an option to enter an interval of tare values, which during normal operation will
simplify the keying in of tare values for the operator. The tare value interval can be up to
9.9 kg (if the minimum tare value for all cylinders of the same cylinder type is n, then the
maximum tare value within the same interval must be n+9.9 kg). This means that if all
cylinders of the same cylinder type by way of example has a tare weight of min. 14 kg and
the heaviest cylinder weighs no more than 23.9 kg (14+9.9=23.9 kg), then key in as
follows:
1 4
in which 14 indicates the minimum tare value. This means that when the operator is to fill a
cylinder of e.g. 17.9 kg (which is within the 14 - 23.9 kg interval) he needs only to enter the
last two digits, in this example 79 followed by ENTER (a total of three entries) instead of
keying in the entire value 17.9 followed by ENTER (a total of five entries). In the same way
e.g. 14.0 transforms into 40 + ENTER and 20.5 transforms into 05 + ENTER, etc.
6.1.4 ENTER TARE MIN

ENTER TARE MIN: ENTER TARE MIN: Default value =100
0 Max Value = MAX
X
Min Value = 0

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MINIMUM TARE
Enter the minimum tare allowed for the cylinder. Default the value is 10.0 Kg. The CUC
only accepts tare values above the minimum value. If tare is below, the process will not
start.
6.1.5 ENTER TARE MAX

ENTER TARE MAX: ENTER TARE MAX: Default value =200
0 Max Value = MAX
X
Min Value = 0
MAXIMUM TARE
Enter the maximum tare allowed for the cylinder. Default the value is 20.0 Kg. The CUC
only accepts tare values below the maximum value. If maximum is exceeded, the process
will not start
6.1.6 ENTER ENC MODE

ENTER ENC MODE: ENTER ENC MODE: 0-? Default value =0
0-? 0 Max Value = 3
X
Min Value = 0
ENCODING MODE
Encoding mode is a set up available in the cylinder set-up when basic machine
functionality is a machine where tare or gross weight of the cylinder is used to start the
process.
E.g. before a filling process or inlet process the operator keys in a specific value unique for
the cylinder.
When ENCODING MODE = 0, the keyed in value is interpreted as the cylinder tare weight.
When ENCODING MODE = 1, the keyed in value is interpreted as a cylinder gross weight
when the cylinder is filled with LPG. In this case the tare value is found by subtracting the
amount of LPG that is to be filled in the cylinder (the NET value).
E.g. the operator keys in 23.9 kg and the cylinder is to be filled with 9 kg of LPG. The tare
is therefore 23.9 – 9.0 = 14.9 kg.
6.1.7 ENTER Q-ENC


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ENTER Q-ENC: 0;1- ENTER Q-ENC: 0;1-3 Default value =0
3 0
X Max Value = 5
Min Value = 0
QUICK ENCODE
The following message is displayed: ENTER Q-ENC: 0;1-3. The display also shows the
value 0, 1 - 3. The operator now has the option to program function for quick encoding or
not.
0 = function disabled
1-3 = number of digit(s) to be encoded with function enabled
6.1.8 ENC DECI PNT POS

ENC DECI PNT ENC DECI PNT POS:1-2 Default value =1
POS:1-2 0
X Max Value = 2
Min Value = 1
ENC DECI PNT POS

Used to set the decimal point position for encoded data
The position is default 1.
6.1.9 REMOTE TARE OFFSET

REMOTE TARE REMOTE TARE OFFSET: Default value =100
OFFSET: 0
X Max Value = MAX
Min Value = 0
REMOTE TARE OFFSET

This is an option to enter an interval of tare values, for remote data received through the
EXTERNAL DATA IN. The tare value interval can be up to 9.9 kg (if the minimum tare
value for all cylinders of the same cylinder type is n, then the maximum tare value within
the same interval must be n+9.9 kg). This means that if all cylinders of the same cylinder
type by way of example has a tare weight of min. 14 kg and the heaviest cylinder weighs
no more than 23.9 kg (14+9.9=23.9 kg), then key in as follows:
1 4
14 indicate the minimum tare value for the received data.
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If the externally received tare value is 79 the value is converted to 17.9 kg. In the same
way 40 transform to 14.0 kg and 05 transforms to 20.5 kg.
6.1.10 REM DECI PNT POS

REM DECI PNT REM DECI PNT POS:1-2 Default value =1
POS:1-2 0
X Max Value = 2
Min Value = 1
ENC DECI PNT POS

Used to set the decimal point position for encoded data
The position is default 1.
6.1.11 ENTER OPER MODE

ENTER OPER MODE: ENTER OPER MODE: Default value =3
0 Max Value = 3
X
Min Value = 3
OPERATION MODE
Enter a value between 0 and 6 to indicate which operational mode to apply for the cylinder
type. The values 0-6 represent the following operational modes:
0 = No operation
1 = Filling with manual filling head
2 = Filling with semi-automatic filling head for centre valves
3 = Filling with automatic filling head for centre valves
4 = Filling with semi-automatic filling head for screw valves and with automatic valve
handler for open and close of valve.
5/6 = Filling with semi-automatic filling head for screw valves and with operator
acknowledge for manual close of valve.
As an example, cylinder type No. 1 is to be filled by means of an automatic filling head for
centre valves, key in as follows:

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6.1.12 ENTER CS HIGH LIMIT

ENTER CS HIGH ENTER CS HIGH LIMIT: Default value =3
LIMIT: 0
X Max Value = MAX
Min Value = 0
CHECK SCALE HIGH LIMIT

This is an option to program a high limit value for the Check Scale (CS). Weight values >
(more than) 0.3 kg above net nominal + tare actual, is sorted out.
To change the limit to 0.2 kg, key in:
. 2
The limit is ignored in functionalities with compare mode (CS MODE = 1).
6.1.13 ENTER CS LOW LIMIT

ENTER CS LOW ENTER CS LOW LIMIT: Default value =3
LIMIT: 0
X Max Value = MAX
Min Value = 0
CHECK SCALE LOW LIMIT

This is an option to program a low limit value for the Check Scale (CS). Weight values <
(less than) 0.3 kg below net nominal + tare actual, are sorted out.
To change the limit to 0.2 kg, key in:
. 2
The limit is ignored in functionalities with compare mode (CS MODE = 1).

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6.1.14 ENTER LIFT TIMER

ENTER LIFT ENTER LIFT TIMER:1-2 Default value =1
TIMER:1-2 0
X Max Value = 2
Min Value = 1
LIFTING TABLE TIMER

Enter the Lifting Table Timer used for the cylinder. Default the value is 1.
The Lifting Table Timer is a “pointer” to LIFT TMR1 and LIFT TMR2 in machine set-up. By
choosing LIFT TMR1 or LIFT TMR2, the time (delay) for lifting the cylinder on lifting table
can be selected.
The time itself is set in Machine Set-up (See Lift Timer)

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7. MACHINE FUNCTIONS
This chapter describes the actual machine functions included
7.1 POWER ON AND INITIATION

During Power On and Initiation the CUC:
• Displays the Kosan Crisplant a/s for approx. 3 seconds.
• Displays the Power On picture for approx. 3 seconds
• Initiates itself and possible external units
• Displays the Ready picture
• Displays the actual Encode Mode picture
• Finally displays the actual Process picture
Errors detected during initiation (Power On picture) are displayed. In case of any error,
correct the error and press the push-button.
1. If the error is corrected, the Ready picture appears
2. If the error is not corrected, the Init and Error pictures appear until the error has been
corrected

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KOSAN CRISPLANT A/S
Kosan Crisplant picture
CUC-XXYY V. 243 Actual Init error

Init Error
Power on picture Error picture
Start/stop
push-button
CUC READY! INIT PLEASE WAIT!

Error corrected
Ready picture Init picture
CUC IN PROCESS MODE

No encoding required
Encoding required
1
MAN_MODE NOP_MODE
FIX_MODE
CMP_MODE
No operation mode picture
Encode mode pictures

Ø Ø Ø Ø Actual Process picture Actual Bypass picture
FIX T= Ø.Ø
1 1
1 Process picture Bypass picture
1
Process pictures
Fig. Power on and initiation pictures
7.2 START/STOP
The operator starts and stops the process by pressing the push-button. The status
message (STARTED or STOPPED) appears briefly in the display.
When the functionality of the CUC is with inlet buffer (cylinder queue), the start/stop push-
button:
Starts and stops the inlet of cylinders into e.g. the carousel or check scale.
When stopped, it is still possible to encode and introduce cylinders to the inlet buffer.
7.3 PROCESS AND BYPASS MODE
Bypass mode is used in case of problems with the machine or if you just want to bypass
cylinders through the machine.
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It is possible to change the operation mode between process and bypass.

To change mode, enter Mode Set-up
Enter:
MENU
. MAIN MENU
1-STATUS 3-SERVICE
2-SET UP 4-
Select SET UP
2 SET UP 1/2
1-CYLINDER 3-BASIC
2-MACHINE 4-MODE
Select MODE
4 MODE SET UP
1-PROCESS 3-
2-BYPASS 4-
Do NOT change to Bypass mode during Process!.

Empty the machine first
7.3.1 Process Mode

Select PROCESS PLEASE WAIT..
1
• The CUC will reset and start up in Process Mode.
7.3.2 Bypass Mode

Select BYPASS PLEASE WAIT..
2
• The CUC will reset and start up in Bypass Mode

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7.4 PROCESS ERRORS
7.4.1 Errors
Errors detected during process may stop the process, request an action from the operator
or sort out the cylinder if a pusher is included.
The Error will always be shown in the display.
Example
03: CONNECT TO 03 CONNECT TO
c@ ERR
PLEASE RESTART..
1 1
Without sort out conveyor with sort out conveyor
03:
Specify the module position for the error
Positions is always given in the flow direction for the cylinders, starting with position 1
E. g.
01 ~accumulation stop
02 ~waiting stop
st
03: ~1 process
nd
04 ~2 process
Etc.
c@/ERR
Status for the process (See description for Status)
CONNECT TO
The Error show for the actual position
A Sensor error E. g. SENSOR B16 ERROR has no module position as the sensor number
gives the psychical position
Sort Out
• If there is a pusher included, the cylinder will be sorted out

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• If there is no pusher, the display shows PLEASE RESTART.. . Pressing the

Start/Stop push button will release the cylinder from centring
7.4.1.1 Sensor Errors

During process, the CUC supervises the process continuously, typically by mean of timers,
where a given change in an input must be executed within a given time. If time out occurs,
an error is given for the sensor that was expected to give the input.
If errors occur, the process stops
Sensor errors are shown in clear text in the display. The error shown in the display must
naturally be corrected before process can take place.
SENSOR B08 ERROR
Example of sensor error
Pressing the Clear key will repeat the error shown in the display
Sensor error correction

Check that the sensor is working properly. It could be the sensor itself, the cable, a loos
connection or incorrect adjustment of the sensor, which coursed the error
7.4.1.2 Pneumatic Low
PNEUMATIC LOW!
If pneumatic low is detected during process for more than 1.2 sec. the text “PNEUMATIC
LOW!! is shown in the display, and the process stops.
Check that the pneumatic to the machine is stable (also during process)
Check/adjust the pressure switch B02
It is only possible to run process with pneumatic OK

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7.5 SERVICE & MAINTENANCE

No service and maintenance is required except normal cleaning and checking for
mechanical damage of the terminal, the bar code wand, the cables and the plugs.
See to it that the reading field in the wand is clean (if included)
In case of questions or problems you may be unable to resolve by yourself, you are
welcome to contact Kosan Crisplant Service Department.
For further information, concerning the actual machine, please refer to the Service Manual
of the machine in question.
7.6 PROCESS MODE
7.6.1 Start/Stop of Filling Equipment

When the process has started, i.e. the filling machine is in engagement, it is possible to
stop the filling process. The filling machine will disconnect and revert to initial position. After
stop of process it is possible to restart the filling process.
ABORTED FILLING C= SO.. <┘=RESTART

< <
15.6 kg
15.6 kg
The filling sequence is restarted with the -button or terminated with the - button, to
C
sort out the cylinder
If clear key is pressed it is no longer possible to resume the filling. A new sequence must be
initiated. The info line will show : CYL SORT OUT
7.6.2 Auto zero for filling scale

If AUTO ZERO is enabled the scale makes an auto zero after process has ended and the
LPG cylinder is removed from the weighing table.
7.6.3 Process status for filling / evacuation

During the filling of the cylinder the display shows the remaining gas to be filled along with
the encoded tare.
FILLING T= 11.3
<
-9.4 K KG
1

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During the evacuation of the cylinder the display shows the amount of gas to be evacuated
along with the encoded tare
EVACUATING T= 11.3
>
1.4 K KG
1
Example of > (More than) status.
TILT CYL,PRESS START

> *
20.7 K KG
1
The cylinder is “overfilled” and the display shows the gross weight, along with the symbol
“>”(more than). The info line of the display shows the text “TILT CYL, PRESS START”. Tilt
the cylinder if the machine has a device for tilting. Otherwise place the cylinder in horizontal
position to ease the evacuation process.
The cylinder is evacuated to the variable preset minimum dosing value (see Min Dosing in
the CYLINDER setup) and then refilled to required weight.
Ex: If cylinder gross weight must be 20 kg and the Min Dosing is 0.5 kg, the cylinder will
be evacuated to 19.5 kg before it is refilled to 20 kg.
After Evacuation/filling is finished the display shows:
FINISHED 260 230

= *
0.0 K KG
1
The two numbers in the info line of the display show the maximum and minimum flow [gr./s]
registered during filling. The numbers are only shown if machine setup MIN FLOW is
enabled.
The equal sign indicate the status of the check weighing after the filling is finished.
Field 02 symbols
Symbol Comment
* No motion (stable, within no motion)
@ Process active (busy)
< Less than (given low limit exceed)
> More than (given high limit exceed)
= Equal (within given limits)

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7.6.3.1 Motion/No motion

The symbol “*” indicate no motion in the weight.
13.2 Kg
1
7.6.3.2 Zero indicating

The instrument has a digital indication if the deviation from zero is not more than ¼*e (e ~
scale verification interval).
The symbol for zero is placed next after the unit.

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7.6.4 Process error
7.6.4.1 Dosing low
DOSING LOW C= SO.. <┘=RESTART
15.6 15.6
Dosing stopped due to no increment of the filling value. This is a safety feature in the event
of e.g. gas leak. By default this feature is disabled. When enabled, one of the following
actions can be necessary:
1. The valve has an unacceptably long filling time. Check the valve.
2. The valve is blocked. Clean the valve
3. Gas leak in the filling head. Adjust the filling head.
4. The gas stop valve has stopped working. Check the solenoid and if necessary the
air pressure.
The filling sequence is restarted with the -button or terminated with the C - button, to
sort out the cylinder
If clear key is pressed it is no longer possible to resume the filling. A new sequence must be
initiated. The info line will show : CYL SORT OUT
7.6.4.2 Dosing timeout
DOSING TIMEOUT C= SO.. <┘=RESTART
15.6 kg
1
15.6 kg
1
Maximum dosing time-out. The maximum allowed filling time was exceeded. Possible
actions are:
1. Change the dosing time limit and restart the filling process. New input of tare is
required.
2. Check the valve -> clean if necessary. Press the button to resume the
process.
3. Press the clear key to set the SORT OUT flag (only for standalone filling machine
based on load cell principle)

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7.6.4.3 Negative tare
NEGATIVE TARE
12.6 1
The negative tare limit was exceeded. Possible actions are:

1. Check if the encoded tare corresponds with the tare value on the cylinder. If not,
begin a new filling sequence with the corrected tare.
2. In a system with a check scale the cylinder is sorted out.
7.6.4.4 Positive tare
POSITIVE TARE
12.6 1
The gross weight of the cylinder minus the encoded tare exceeds the allowed positive
(residual gas) value. Possible actions are:
1. Check if tare and cylinder type are correct.
2. In a system with a check scale the cylinder is sorted out.
7.6.4.5 Load cell failure
XX: LOADCELL FAIL
The CUC has lost connection to the load cell module.

3. Check the cable between CUC and load cell module.
4. Check load cell module
7.6.4.6 Lost cylinder
XX: LOST CYLINDER
During filling process the load on the scale was lost. The cylinder was removed before LPG
filling has ended. The process sequence is terminated.

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7.6.4.7 Awaits cylinder
XX: AWAITS CYLINDER
During the check weighing after LPG filling the load on the scale was removed before a
valid result. To detect a cylinder the load on the scale must exceed the start limit.
7.6.4.8 Zero range error

XX: ZERO RANGE ERR
Zero set of scale could not be completed. The allowed zero range is exceeded.
Possible reactions are:
• Check the scale for unintended loads. Press zero-button to retry.
7.6.4.9 AD-STARTUP ERR

XX: AD-STARTUP ERR
The CUC has lost connection to the load cell module during power up of the CUC.
1. Check the cable between CUC and load cell module.
2. Check load cell module.
7.7 BYPASS / STARTUP MODE

Machine cannot run in bypass or startup mode.

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8. ENCODING FUNCTIONS
8.1 ENCODING IN GENERAL

Encoding is done by means of the membrane keypad with
• 12 white keys
• And 4 grey keys
7 8 9
4 5 6
1 2 3
0 . C
The keypad
The white keys (0-9) are used for manual encoding whereas the white/grey keys in
combination are used as so-called function keys.
The encoding of data often has limits. If these limits are exceeded, or if errors of any kind
are detected, the request for encoding is repeated while INV is displayed.
0 128 122 MSO
INV
1
As an alternative (or parallel) to manual encoding, a bar code wand and a

tableau can be used
The function keys are keys which have special functions. When activating the key (key
combination), a given function e. g. selection of cylinder type is started
Encoding is cleared with the Clear key C

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and entered with the Enter key
8.2 FUNCTION KEYS
8.2.1 Reset key
The CUC is reset by pressing the reset key, and the system initiates (see chapter Power
On and Initiation)
CUC-XXYY V. 00243
The reset key should be pressed and held down for at least ~ 0.5 sec.
8.2.2 Zero key
8.2.2.1 Zero set the serial counter

The serial counters can be zero set by the zero key (see chapter Counter).
8.2.3 Cylinder key
The system holds 12 cylinder types, each containing a set-up to handle a specific cylinder.
New cylinders can be selected during process (started/stopped).

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8.2.3.1 Select a cylinder type

To select a new type, press the following sequence:
Select cylinder type ENTER TYPE NO: X = 1-12
X
Z

ENTER TYPE NO:
X
Z

0.0 KG
X
When the cylinder type (a number) is encoded, the process picture appears.
8.2.4 Decimal Point Cylinder Key
8.2.4.1 Select an owner number

The system holds 20 owner numbers.The purpose is to link an owner (of the cylinder) to
the actual cylinder type. To select a new owner, press the following sequence:
Select owner ENTER OWNER NO: Y = 1-20
. Y
• Z
ENTER OWNER NO:

Y • Z

0.0 KG
• Y
When the owner (a number) is encoded, the process picture appears.
8.2.5 Type and owner during process

Type and/or owner can be changed during process
• Type is by default shown in the display
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• If owner is encoded, owner is shown in the display

• if type is encoded, type is shown in the display, (and owner is reset to zero)
• To see type when owner is shown in display, press type, followed by C (clear)
Type and/or owner is only to be changed, when the actual cylinder is in

(encoding) position, since there is no encoding queue for type/owner. Then
tare is encoded.
Owner is optional, and demands special statistic/report program
8.2.6 Enter key
Used to enter numeric data, menu choices, etc., and Start Fix Tare (if Fix Tare Mode)
8.2.7 Decimal Point Enter Key
Used to enter the menu.
8.2.8 Clear key
Used to clear numeric data, menu choices, etc., and Stop Fix Tare (if Fix Tare Mode).
8.3 MANUAL MODE

When the cylinders have different tare values, the tare value is entered when the cylinder is
in position for encoding
Here the fix tare register (see Fix Tare) for a given cylinder type is zero, and the system
runs in MAN_MODE

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8.3.1 Manual Tare

During the process, the operator encodes the actual tare by keypad.
To simplify the tare encoding, a tare offset can be added (see Tare Offset)
8.4 FIX MODE

When all cylinders have equal tare values, the tare value is entered in the Fix Tare register.
(see Fix Tare).
Here the fix tare register for a given cylinder type holds a value, the system runs in
FIX_MODE
In fix tare, the equipment runs/stops automatically when started/stopped
8.4.1 Quick encoding
See Cylinder Set-up, quick encoding, for activation of quick encoding, and set-up of digit(s)
to key in (1-3)
When quick encoding is enabled, a Q is shown in the display.

0 128 122 123
Q
1
Fig. Process picture (MAN_MODE and tare in tare queue, and quick encoding enabled)
The operator keys in the tare or gross value WITHOUT use of the enter key. The value is
shown in the display. When the last digit is entered, the value is calculated/validated. If ok,
it is put into the tare queue, - if not, it is cancelled and INV is shown. (if cancelled, check for
incorrect set-up of max. or min tare, tare offset etc.)
8.4.1.1 Disable quick encoding

It is possible to disable the quick encoding by means of the decimal point key. When
disabled, a q is shown in the display.
0 128 122 MSO
q
1
Fig. Process picture (MAN_MODE and tare in tare queue, and quick encoding disabled)
Here the operator can key in as usual followed by enter.

Disabling of quick encoding is used e.g. to:
• enter the menu (decimal point, decimal point and enter)

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• enter service keys (SK65xxx)

• or enter manual sort out (9999 is entered and MSO is shown in the display)
q is cleared by the clear key or by selecting a cylinder type
8.5 ENCODING LOCAL-REMOTE

When EXT DATA IN is enabled (See Machine Set Up, EXT DATA IN) it is possible to Enter
data either
LOCAL via Keyboard or
REMOTE via network connection
During initial Start up, LOCAL encoding is selected. This mode is the ordinary way of
keying in data (tare)
8.5.1 Remote Encoding

To switch to REMOTE ENCODING, press .
REMOTE ENCODING
Key in data+↵
↵ to put
one cyl in front, C
to clear,↵
↵ to start
REMOTE ENCODING is shown for few seconds, and then the CUC will start collecting
data from external source into the data queue
144 132 151 160
Now CHECK if these values match the cylinder’s in front of the Stop
• If not (See Fix of Data, below)
• if ok, press to Start
REM ENC STARTED
1
REM ENC STARTED will appear on display and cylinders will start entering the system
(provided that CUC is started)
The data queue will constantly show the cylinders passing through

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if external source is too slow, ---- will appear in front of the queue
One or two ---- is no problem
if 3 or more (or stop closes) check external data source.
If no data in queue this will be shown as follows

QUEUE NOT FULL
In this case, please verify the DQ SIZE is set to the correct no. of cylinders and that the
external data source has “captured” all cylinders
- It is IMPORTANT, that the Data Queue is able to contain the physical amount of cylinders
! - When accumulation of cylinders, count these and be sure DATA QUEUE SIZE are >= this
amount
8.5.1.1 Fix of Data

If cylinders did NOT match at start of remote encoding it’s possible to fix this:
1. There is a cylinder (or more) in FRONT of where the queue seems to match:
Key in the tare for the extra cylinder(s) ONE by ONE (stop will open for each keyed in
cylinder if CUC is started)
When the cylinder where the correct tare is at the Stop, press ENTER and remote
encoding will start as above.
2. There are tare values in the queue for cylinders NOT PRESENT in front of the Stop:
Press "C" key to remove the FRONT cylinder (please note that this is OPPOSITE of what
happens in LOCAL ENCODING MODE) keep removing cylinders from front of queue ONE
by ONE by pressing the "C" key, when queue matches the cylinders in front of stopper,
press ENTER to start remote encoding as above
REM ENC STARTED
At any time, pressing the "C" key will temporarily suspend the remote encoding function
REM ENC PAUSED
1
REM ENC PAUSED is shown in display - here any of the above scenarios can be repeated
until the queue matches the cylinders.
It is also possible to return to LOCAL ENCODING again by pressing the .
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Items in the tare queue will remain there when switching between REMOTE and LOCAL,
but remember:
"C" key operates on FRONT of tare queue in REMOTE, but in REAR of queue in LOCAL
8.5.2 Local Encoding

.
To switch to LOCAL ENCODING, press
LOCAL ENCODING
1
LOCAL ENCODING is shown for few seconds, and then the CUC will show the data queue
144 132 151 160
8.6 TYPE CHANGE BY NETWORK

When a CUC receives data via the network, and the cylinder type differs from the current
type, the type is automatically updated to the new type, and cylinders are treated according
to this.

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9. MENU FUNCTIONS
The operation of the CUC is carried out from a menu dialogue where the operator is guided
through the different menus in clear English. The operator has to encode correctly to
continue.
Menu choices are executed by entering the required key sequence, according to the text
shown in the display.
Menu functions are divided into:
• Set-up (e.g. Cylinder-, Machine or Lock Parameter Set-up, see this)
• Service (e.g. General-, or Machine Service, see this)
Enter the Menu

Menu mode is entered by pressing the decimal point key followed by the enter key!
It is ONLY possible to enter the Menu when the process is stopped!
! If not, the text STARTED! is shown for ~ 2 sec. (see fig. below)
STARTED!
It is ONLY possible to enter Menus which are available for the actual functionality
! If not, the text NO SERVICE AVAILABLE is shown (see fig. below)
NO SERVICE AVALIABLE
9.1.1 Default and Limits

In Set up, the Set up value is always shown, (often) with Limits or enabling/disabling of
function
Example with Limits:

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ACT SET UP TXT: ACT SET UP TEXT: Y-Z
X X
ACT SET UP TEXT: Y-Z

Display shows the values X, Y – Z where:
X = Actual value
Y = Low limit value
Z = High limit value
Example with Enable/Disable:
ACT SET UP TXT: ACT SET UP TEXT: 0;?
X X
ACT SET UP TEXT: 0;?

Display shows the values X, 0;? where:
X = Actual value
0 = Disable the function
; = Separator
? = Enable the function (value = 1 to high limit)
If the limits are exceeded display shows INV and the value must be re entered
ACT SET UP TEXT: Y-Z
X
INV
If within limits, next Set up will be shown

Running Basic Set up, Values (X) are changed to default value
See chapter: Set-up of functionality to …

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9.2 GENERAL SERVICE
9.2.1 Version
To see the CUC (HMI) software version, press sequence as follows:

Enter:
MENU
. MAIN MENU
1-STATUS 3-SERVICE
2-SET UP 4-
SERVICE
3 SERVICE
1-GENERAL 3-
2-MACHINE 4-
GENERAL
1 GENERAL SERVICE
1-VERSION 3-COUNTER
2-IO TEST 4-
VERSION (MKIII KC) KOSAN CRISPLANT A/S
1 CS01 FIL30101#30
HCTx0128 BTL10003
Version of connected
LCM 10105
modules:
Extended IO, Load EXT EXT10016
cell module
Version
Gives the actual program version/functionality:
• Line0 shows the Logo (KOSAN CRISPLANT A/S or KOSAN CRISPLANT PAM)
• Line1 shows the functionality and version for the CUC (FIL ~Filling Line, MAL
~Maintenance Line PAL ~Pallet Line)
• Line 2 shows the MCU version (Micro Controller Unit) and the version of the software
bootloader (BTLxxxxx).
If any extended module is connected to the CUC use the ENTER button to scroll for
showing the version of the modules.

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9.2.2 Input Output Test

To enter Input Output Test press sequence as follows:
Enter:
MENU
. MAIN MENU
1-STATUS 3-SERVICE
2-SET UP 4-
SERVICE
3 SERVICE
1-GENERAL 3-
2-MACHINE 4-
GENERAL
1 GENERAL SERVICE
1-VERSION 3-COUNTER
2-IO TEST 4-
IO TEST
2 IO TEST
DI:XXXXXXXX XXXXXXXX
DO:XXXXXXXX XXXXXXXX
Enter PASSWORD
To force outputs X IO TEST
(see below) DI:XXXXXXXX XXXXXXXX
DO:XXXXXXXX XXXXXXXX
IO Test
DI = Digital Input
DO = Digital Output
X = Respective I/O active (=high)
. = Respective I/O inactive (=low)
Force of Outputs
It is possible to force all the outputs (1 through 16) high or low.
• Force active output (=high) - To force e.g. output 14 to high press “14” and “Enter”.
• Force inactive output (=low) - To force e.g. output 14 to low press “14” and “Enter”.
• Reset all outputs - To reset all outputs to low press “0” and “Enter”.
When leaving this menu (“Clear”), the high and low status for the outputs are set to their
original state!
WARNING! Make sure that no persons are placed near any moving parts of the machine(s) in
! question when setting the outputs (moving parts such as pushers, centring device, fill head
suspensions, etc.)!

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9.2.3 Counter
To see the Counter press sequence as follows:

Enter:
MENU
. MAIN MENU
1-STATUS 3-SERVICE
2-SET UP 4-
SERVICE
3 SERVICE
1-GENERAL 3-
2-MACHINE 4-
GENERAL
1 GENERAL SERVICE
1-VERSION 3-COUNTER
2-IO TEST 4-
COUNTER
3 SERVICE COUNTER
TOTAL = 0007630164
SERIAL= 0000006382
TOTAL and SERIAL are counters that count

• The number of cycles in process mode (e.g. number of cylinders that have passed
through a leak detector or completed a filling process in a filling machine).
• The amount of LPG in [KG]
• Or pallets in a pallet system
The counters are not active in bypass mode.
• The TOTAL counter cannot be zero set (lifetime counter).

• It is possible to zero set the SERIAL counter at any time (service counter).
Zero Set of Serial Counter
Enter the Menu to see the Counter and press the Zero Key
Enter:
ZERO KEY Counter is Zero set
SERVICE COUNTER
TOTAL = 0007630164
SERIAL= 0000000000

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10. MACHINE SERVICE KEY
10.1 SK65015 PROCESSED CYLINDERS

Activate the service I01743 O01731 =00012
key 65015 6 5 0 1 5
This service key gives the status for the number of cylinders processed. “I” gives the
number of cylinders let in. “O” gives the number of cylinders let out (e.g. into carousel) and
“=“ gives the difference between “I” and “O” (e.g. no. of cylinders in inlet or outlet conveyor
to a carousel).
At 65535, reset or power off, the counters are reset!
!
10.2 SK65016 DISTRIBUTED CYLINDERS
Activate the service I01743 -00031 +01704
key 65016 6 5 0 1 6
This service key gives the status for the number of cylinders processed and how they are
distributed. “I” gives the number of cylinders let in. “-” gives the number of cylinders let out
into sort out conveyor and “+“gives the number of cylinders let out e.g. into a carousel
Example: “I” = 1743. Sum of “-“ and “+” = 1735. the difference (8 cylinders) is the No. of
cylinders in process (e.g. cylinders between Inlet and the two outlets “–“ and “+” in a carousel
inlet)
At 65535, reset or power off, the counters are reset!
!
10.3 SK65010 BALANCING THE SCALE
If a scale function is included (e.g. fill scale, adjustment scale, pre scale in inlet or check
scale in outlet etc.) service key SK65010 gives the possibility to balance the scale.
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The weighing platform on the scale must be unloaded and empty before the weighing-in
procedure starts. The following step by step instruction shows how to weigh in the scale:

Activate the service ENTER PASSWORD:
key 65010 6 5 0 1 0
1
Enter PASSWORD CUC calibrates the zero

X
Enter load value ENTER LOAD VALUE: Put a test weight on the
(e.g.40 Kg) 4 0 weighing platform (in this
example 40 kg)
1
PLEASE WAIT: CUC calibrates the load

* KG
40 1
CUC-FS01 V. 1.06.XX CUC reset

*
KG
1
CUC READY! CUC is ready
KG *
1
Error detection is built into the calibration procedure. If e.g. the entered load value will result in
AD-overflow a message “AD-OVERFLOW” is shown in the display, and the calibration is
cancelled.
If the functionality is a Check Scale, you can:

- Raise the lifting table. Press 65011 (before entering the load value)
- Lower the lifting table. Press 65010 (before entering the load value)
- Alternatively activate/deactivate the solenoid to the lifting table if available

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*When balancing the scale, make sure that the scale measures the same value all over the
weighing platform. Comparing the value measured in the centre of the weight, with the values
measured in all four corners, easily checks this.
If this is not the case
• check that nothing touches the scale mechanically

• that cables/hoses are loosened (gives no force to the scale)
Fig. 10-1 Calibrating and corner check
10.4 SK65011 INCREASED RESOLUTION

If a scale function is included (e.g. fill scale, adjustment scale, pre scale in inlet or check
scale in outlet etc.) service key SK65011 gives the possibility to increase the scale
resolution.

Activate the service CUC READY! Shows increased resolution
key 65011 6 5 0 1 1 *
(shows an extra decimal)
40.00 KG
1
To obtain normal resolution again, press again.

6 5 0 1 1

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10.5 SK65040 FILL HOSE

Activate the service
key 65040 6 5 0 4 0
0.0 KG
1
This service key is used to fill the gas hose (test gas stop valve) for 3 sec.
! • The function is only available with empty scale (below limit down)
10.6 SK65042 MEASURE INTERFACE, STATUS PROCESS

.
Activate the service T 12.8 N 10.0 A 22.8
key 65042 6 5 0 4 2 RE 0.3D 460 S 000A
This service key gives the actual (last)

T = Tare
N = Net
A = Actual Weight
RE = Residual gas
D = Dosing in [g/s]. Used to calibrate Reaction Time (see this)
SK 65011 gives increased resolution of weight values
S = actual status (see Table for Status)

Table for Status
Status Value Bit no. Description
MEA_U_LIM 0x0001 Bit 0
MEA_N_LIM 0x0002 Bit 1
MEA_O_LIM 0x0004 Bit 2
MEA_ALRDY_FILLED 0x0008 Bit 3
MEA_NEG_TARE 0x0010 Bit 4
MEA_POS_TARE 0x0020 Bit 5
MEA_DOS_LOW 0x0040 Bit 6
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Status Value Bit no. Description

MEA_DOS_HIGH 0x0080 Bit 7
MEA_DOS_TO 0x0100 Bit 8
MEA_CHK_TO 0x0200 Bit 9
MEA_DOS_ACT 0x0400 Bit 10
Not used 0x0800 Bit 11
MEA_DOS_DONE 0x1000 Bit 12
Not used 0x2000 Bit 13
MEA_CALIBRATION_DONE 0x4000 Bit 14
MEA_ZEROSET_DONE 0x8000 Bit 15
E.g. S = 000A (combined MEA_N_LIM + MEA_ALRDY_FILLED

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User Guide

CUC (Crisplant Universal Controller)

© Kosan Crisplant 2013

1. USER GUIDE ................................................................................................................................. 5

3. BASIC SET-UP ............................................................................................................................ 12

4. I/O-LIST FOR ADJUSTMENT SCALE (AS05) ............................................................................ 14

5. MACHINE SET-UP ...................................................................................................................... 19

5.1.14 MIN FLOW ................................................................................................................... 26

6. CYLINDER SET-UP ..................................................................................................................... 29

7. MACHINE FUNCTIONS .............................................................................................................. 36

7.7 BYPASS / STARTUP MODE .................................................................................................. 46

8. ENCODING FUNCTIONS ............................................................................................................ 47

9. MENU FUNCTIONS .................................................................................................................... 55

10. MACHINE SERVICE KEY ........................................................................................................... 60

© Kosan Crisplant 2013

This means that one or more

To manage a quick start up of a new machine go directly to chapter:

1.1 GENERAL DESCRIPTION

CUC (Crisplant Universal Controller)

The CUC is an intrinsically safe controller with:

• 1 serial interface to load cell module

© Kosan Crisplant 2013

The CUC gives (per set-up) many functionalities, e.g.:

© Kosan Crisplant 2013

• VO01 (Valve Orientation)

1.3 OTHER FEATURES AVAILABLE:

• Automatic transfer of data between the units

1.4 HOW TO GET STARTED

Be careful and carry out the above steps correctly

Hereafter get familiar with the remaining chapters such as:

© Kosan Crisplant 2013

You are also welcome to contact Kosan Crisplant for assistance

! See chapter MENU FUNCTIONS, Version

© Kosan Crisplant 2013

2.1 PASSWORDS FOR SET-UP AND FORCE OF OUTPUTS

© Kosan Crisplant 2013

3.1 SET-UP OF FUNCTIONALITY ADJUSTMENT SCALE (AS05)

Function Key Display Range/Comments

Select BASIC ENTER PASSWORD:

Enter PASSWORD FUNC.SELECT:

Key in 260 FUNC.SELECT:260=AS05

Function Key Display Range/Comments

3.2 DESCRIPTION OF FUNCTIONALITY FOR ADJUSTMENT SCALE (AS05)

© Kosan Crisplant 2013

4. I/O-LIST FOR ADJUSTMENT SCALE (AS05)

4.1 MACHINE LAYOUT

Fig. 4-1 Machine layout for AS05

© Kosan Crisplant 2013

4.2 INPUT LIST

CM01 pos0 B02 Pneumatic OK P NO

© Kosan Crisplant 2013

4.3 OUTPUT LIST

© Kosan Crisplant 2013

4.4 ABBREVIATIONS FOR MODULES:

© Kosan Crisplant 2013

© Kosan Crisplant 2013

5.1 ENTER MACHINE SET-UP

Enter PASSWORD ENTER NETADR:0;1-125 Example of a Set-up

© Kosan Crisplant 2013

5.1.1 NET ADDR

Carousel equipment (*)

2nd OT/OR 4 4 Outlet Tangential/ -Radial

1st -50th FS/FF 1-50 32-82 Filling Scale/Fill Flow