E55 Net Weigher - User Manual

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com
User Manual – E55 Net Weigher
User Manual – E55 Net weigher
© 2012 by Premier Tech Chronos. Right of modification reserved. All rights reserved by Premier Tech Chronos.
Nothing may be reprinted or reproduced without the written consent of the company.
In this technical manual, we give the operator appropriate instructions for safe and proper operation as well as
instructions for installation and correct maintenance. Every person who is authorized for the transportation, assembly,
start up, operation, maintenance, upkeep and repair, as well as shutdown, of our machines and additional
components, is required to have read and understood the instructions in the individual chapters and sections.
In order to avoid operating error and to guarantee trouble-free operation of our products, this technical manual must
always be available to the operating and maintenance personnel.
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Version #1 – March 2012
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CONTENTS
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Contents
Page
Safety warnings.....5
General information.....8
User information ))))))))).)))))))...................))))).)).))9
Usage according to the intended purpose))))....)))).)))))))..))))10
Required training courses))))))))))))).)..)))).)..))))))))11
Technical description.........12
General overview and specifications................))))))))..))))))))))..13
Main component parts))))))))))...))))))))).))))).).))))13
General description)))..)))))))...))))))))).))))).).))))14
Weigher housing))))))))))...))))))))).))))).).))))14
Weigher hopper))))))))))...))))))))).))))).).))))14
Weight transducers (Load cells)))...))))))))).))))).).))))14
Weigh hopper check links)))))...))))))))).))))).).))))14
Pneumatics)))))).))))))...))))))))).))))).).))))14
Machine electrics)))))))))...))))))))).))))).).))))15
Feeder )))))))))))..))...))))))))).))))).).))))15
Control module))))))))))...))))))))).))))).).))))15
Auto calibration test weights (If fitted))...))))))).))))).).))))15
Functional description))))))))))...))))))))).))))).).))))15
Dimensions and product views))))))))))).)))))))))))))))))..) 16
Specifications)))))))))))))))))))))..)))))))))))))))))16
Installation and assembly......17

Installation prerequisites.............................))))))))..))))))))))..18
Pneumatics ...............................................))))))))..))))))))))..18
Installation information ............................))))))))..))))))))))..19
Installation sequence .............................))))))))..))))))))))..19
Electrical grounding ...................................))))))))..))))))))))..20
Electrical connections ............................))))))))..))))))))))..20
Initial commissioning checks .............................))))))))..))))).))20
Schematic diagram of test weight pneumatics)))))))..))))))))))..21
Schematic diagram of pneumatic services.....))))))))..))))))))))..22
Adjustment/calibration possibilities....23
Checking and alignment of check links...........))))))))..))))))))))..24

Load checking )))))))))))))))))))))).))))).).))))24
Alignment ))))))..)))))))))))))))))...))))).).))))24
Calibration of the weighing system..................))))))))..))))))))))..24
Initial commissioning ........25

Initial commissioning))))..))))))))))...........................................................26
General )))))))))))))))))))))).))))...)).))))))))))) 26
Mounting base/floor loading)))))))))))))...)))))))))))))))))26
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Maintenance.......27
Warnings)))))))))))))))))))))))..))))))))))))28
General preventative maintenance schedule)))).))).))))))..)))))29
General cleaning))))))))))))))).)).))).))))))..)))))29
Pneumatics systems adjustments))))))))).))).))))))..)))))29
Pressure regulator))))))))))))))))))))).))))).).))))29
Air line lubricator (If fitted)))))))))))))))))).))))).).))))29
Exhaust flow regulators))))))))))))))))).)))))).).))))29
Cylinder cushion adjusters)))))))))))))))).)))))..).))))30
Catchgate/Feedgate)))))))).)))))))))))).))))).).))))30
Weigh hopper discharge doors))))))))))))))).))))).).))))30
Mechanical systems adjustments ))))))))).))).))))))..)))30
Auto calibration test weights (If fitted))))))))))))).))))).).))))30
Replacing load cells)))))))))))))))))))).))))).).))))30
Replacing check links))))))))))))))))))).))))).).))))32
Setting hopper door proximity switch)))))))))))).))))).).))))32
Lubrication )))))))))))))).))).))))))..))))..))))33
Lubrication chart ))))))))))).))).))))))..))))..))))33
Bearings and guides ))).))).)))))))))))))).)))))))34
Pneumatic cylinders ))).))).))))))))))))))).)))))))34
Maintenance schedule ))))))))))))))))..))))))))))))34
Weigher - General ) ) ) ) )) ). . )) ) )) ) ) ) ). ) )) ) ). ). ) )) ) 34
W eigher – Load cells ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) . ) . ) ) ) ) 3 4
Weigher – Weigh hopper )))))))))))).))))))).).))))35
Weigher – Auto calibration test weights (If fitted)))))))))))).).))))35
Pneumatic equipment - General)))))))))))).))))).).)))..))35
Pneumatic equipment – Line filter)))))))))).))))).).))))...))35
Pneumatic equipment – Pressure regulator))))))).))))).).)))..))35
Pneumatic equipment – Directional control valve)))).))))).).)))..))36
Pneumatic equipment – Air cylinder).))))))))).))))).).)))..))36
Pneumatic equipment – Flow regulator)))))))))).))))).).)))..))36
Electrical equipment - General))))))).)))))).))))).).)))..))36
Fault diagnosis........37
Fault diagnosis)))))))))))))))))).))).))))))..)))))38
Common faults ) ) ) ) )) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) .) ) ) ) ) . ) .) ) ) ) 3 9
Spare parts list.....41

Spare parts ))))))))))..)))))))))).)))))))))))).))42
Weigh hopper – Mechanical parts).)))...))))))))).))))).).))))42
Weigh hopper – Electrical parts).)))...))))))))).))))).).))))45
Hopper sway links ) ) ) ) ) ) ) . . ) )) ) ) ) ) ) ) . ) ) ) ) ) .) . ) ) ) ) 45
Hopper suspension )))))))..))))))))).))))).).))))46
Load cell assembly )))))).))..))))))))).))))).).))))46
Auto calibration test weights (If fitted)))))..))))))).))))).).))))47
Control panel ) ) ) ) ) ) ) ) ) ) . ) ) ) ) ) ) ) ) ) . ) ) ) ) ) . ) . ) ) ) ) 4 9
Spare parts ordering instructions)))))))..) )))))))))))))49
Contact us50
By telephone or mail ))))))))))))))).)))))))))))))51
By email for spare parts and general queries))))))))))))))))))51
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SAFETY WARNINGS
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SAFETY WARNINGS
This sign is used to highlight important safety information and other

information regarding the correct operation of this equipment.
This safety information is grouped under two headings:
Attention!
Failure to observe Attention! information could result in damage to the
equipment and/or inefficient and/or incorrect operation.
Warning!
Failure to observe Warning! information could cause damage to the equipment
and/or injury to the operator or persons or equipment in the vicinity of the
equipment.
Warning!
Whenever you are in the vicinity of this (or any other) equipment, be alert and
careful. Although safety warnings appear throughout this manual, they
should be supplemented with the users’ own safety awareness. Additionally,
compliance with applicable local laws, rules and regulations must be
respected at all times. Remember that you are responsible for your own
safety and that of your colleagues.
Warning!
Do not operate the equipment until you have read and understood the
operating instructions and thoroughly familiarized yourself with the
equipment and its controls. Read this manual carefully and follow the
instructions given.
Warning!
This equipment must be connected to the building electrical safety ground.
Warning!
Do not operate this equipment with safety guards removed or where any
safety devices have been by-passed.
Warning!
Prior to operation, all fasteners and fittings must be checked for tightness and
retightened if necessary! This operation must be carried out daily.
Warning!
DO NOT start the equipment until all other personnel in the area have been
warned and have moved outside the operating zone.
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Warning!
Misuse of the equipment for purposes other than those defined as intended
purposes is NOT permitted. Usage according to the intended purposes also
includes compliance with the instructions contained in this operation manual.
Warning!
Modifications to the work and operating sequence, and to individual
assemblies, are NOT permitted except as allowed during normal operation.
Failure to comply with this requirement can cause unforeseeable risks to
personnel and to equipment, and may result in the loss of warranty cover.
Warning!
In the case of equipment with access doors for cleaning purposes, ALWAYS
take suitable measures to prevent unintentional and potentially dangerous
access whilst equipment is in use.
Warning!
In the case of equipment with pneumatic parts and motor-controlled parts take
extreme care when close to these parts since these parts can cause injury to
hands and other body parts. Ensure that maintenance is carried out ONLY
AFTER equipment has been disabled.
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GENERAL INFORMATION
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User Information
The equipment described in this manual has been built in accordance with the latest technological
findings and recognized safety rules. However, even the safest equipment may pose health and safety
risks to third parties and its users unless correct operation, control and training procedures are
stringently followed.
Following commissioning by the manufacturer’s specialists, read this manual before operating the
equipment. The user manual is designed to help the operator maintain a high level of performance and
safety throughout the equipment service life and ensure that accident prevention measures are taken.
Compliance with the operation and safety instructions within this manual for all work with and on the
equipment is therefore essential.
The user is obliged to eliminate all risks arising from the equipment use once it has been accepted
(upon issuance of relevant commissioning/acceptance certificates). This applies in particular to third-
party equipment.
This user manual must be permanently present and accessible at the site where the equipment is
installed for immediate access by operating personnel.
Appropriate measures must be taken to ensure that unauthorized persons are kept away from the
equipment. The equipment is intended exclusively for the purposes stated under “Usage According to
the Intended Purpose”.
Operate the equipment only under the conditions stated in the specifications “Usage According to the
Intended Purpose”.
For safety reasons, any other usage or usage exceeding the stated purpose is not permitted and is
associated with an increased risk to the user.
Usage in accordance with the intended purpose also includes compliance with the operating manual
with respect to maintenance and safety instructions.
The information contained in this manual is based on actual developments and the experience of
operation gained through the use of comparable systems. Following the instructions contained in this
manual allows the user to carry out all necessary work and operating tasks with maximum safety.
The recommended maintenance information contained in this manual must be regarded as the minimum
necessary. Bear in mind that the equipment manufacturer does not possess empirical data regarding
the long term operation under the specific operating conditions of each unique environment. For this
reason, you should incorporate personal experience in addition to information contained in this manual.
Therefore:
Attention!
Ensure compliance with all instructions and regulations contained in this manual.
Attention!
Pay special attention to all applicable safety regulations.
Warning!
Do not carry out any modifications, additions or conversions to the equipment without
the written consent of the supplier.
Warning!
DO NOT operate the equipment unless all safety equipment and devices are installed
and in proper working condition.
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Attention!
Assure the reliable operation of the equipment by ensuring cleanliness and careful
execution of maintenance work in compliance with all instructions and regulations
contained in this manual.
Attention!
IMPORTANT NOTE FOR THE OPERATOR/USER:
The safe operation of this equipment depends not only on the safe design and
manufacturing of the equipment itself, but also on the process parameters
necessary for users’ production which are solely under the control of the user.
It is therefore essential that the user carries out trial testing of all safety
equipment after installation has been completed and before equipment start
up. During initial test runs, extra safety measures must be taken, and all
process and equipment parameters should be adjusted in accordance with
contract specifications. The trial period should also be used to verify the
operating reliability of the selected equipment settings and the ability of
personnel to correctly and safely operate the equipment.
As the user (operator) you are obliged to instruct the operating personnel and
to provide information concerning current legal and accident prevention
regulations in addition to the operating instructions. You must ensure that
your personnel understand and comply with this manual and other local
regulations. This applies in particular to the safety, operating and maintenance
instructions.
Premier Tech Chronos reserves the right to change technical specifications

where and when necessary, and while every effort is made to ensure the
equipment manuals reflect the correct status of supplied equipment, there may
be differences between the equipment delivered and the contents of the
manuals. If in doubt, contact Premier Tech Chronos.
Usage According To The Intended Purpose

Warning!
Misuse of the equipment or modification of the equipment for purposes other
than those defined as the “intended purpose(s)” is not permitted! Usage
according to the intended purpose(s) also includes complying with the
instructions contained in this manual and other related manuals.
The E55 Net Weigher described within this manual is intended to be used solely for the consecutive
weighing and dumping of constant pre-selectable batches of bulk material. It is primarily intended to be
used as a bagging scale but can also be used for on-stream weighing in shipping and receiving
processes. For the intended filling material, it is understood that generally all granulated bulk material
can be handled that doesn’t require special care due to its consistency and/or shape (grain size, dust,
gas, corrosion etc.). The E55 Net weigher may only be used with permissible materials that will have
been agreed in advance with Premier Tech Chronos.
It is generally not permitted to operate this equipment in an explosive environment. If parts of the
equipment are required to have specific explosion precautions incorporated into the design of the
equipment, these parts and the precautions required must be defined in advance and agreed formally in
the official order confirmation.
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Required Training Courses

Please check regularly that your personnel demonstrate an awareness of safety and
risks in compliance with this manual.
With regards to training courses:
Regular training courses are required
The execution of such courses must be documented and filed
All course participants are requested to confirm that they have understood the
content of the training course
Ensure that personnel are able to resume duties without risk after periods of
absence
Clearly define the requested qualification duties and responsibilities of

personnel for operating, maintaining and repair of the equipment
Operating personnel should be provided with all necessary personal safety

equipment: protective clothing, etc
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TECHNICAL DESCRIPTION
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General Overview and Specifications

Main component parts
The E55 Net Weigher comprises the following main parts:
Item Description
1 Weigh hopper
2 Weigh hopper check links
3 Load cell terminal box
4 Load cells
5 Dust extraction vent
6 Air filter/lubricator unit
7 Weigher housing
8 Weigher terminal box
9 Air cylinder assembly
10 Weigh hopper gates
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General Description
Weigher Housing
The weigher housing is a fabricated steel box structure which supports and totally encloses the weigher
components.
Two large, lift-off doors provide easy access for set up and maintenance purposes. Two venting outlets
are provided on the side of the housing for use with a dust extraction system.
Weigh Hopper
The purpose of the weigh hopper is to accumulate material during the weighing cycle. It is suspended
from two vertical rods which are bolted to the weigh hopper and connected to the load cells by two rod
end bearings.
The weigh hopper incorporates two flap type discharge gates which are actuated by a pneumatic
cylinder. A proximity switch detects when the gates are fully closed and provides an interlock to prevent
the feeder operating when the hopper discharge gates are not closed.
Support racks are provided at the bottom of the weigh hopper – these are used to support test weights
when setting up and calibrating the weigher.
A removable door in the side of the weigh hopper provides access for cleaning.
Weight Transducers (Load Cells)

The two weight transducers are strain gauge load cells which convert a mechanical force (representing
weight) into an electrical signal.
The transducing element of the load cell is a shear beam type.
The application of the load to the cell distorts the transducer element; the variation in distortion is directly
proportional to the load applied.
Four strain gauges, which are electrical resistors, are bonded to (but electrically insulated from) the
transducing element in such a way that two are compressed and two are tensioned as the cell is loaded,
this has the effect of decreasing and increasing their resistance respectively.
The strain gauge resistors are connected in the form of a Wheatstone bridge. An excitation voltage is
connected to two points of the bridge and the output taken from the other two points.
When a load is applied to a cell, the transducing element distorts, changing the resistance values of the
strain gauges which causes an imbalance of the bridge thus producing an output voltage. The output is
directly proportional to the load applied to the cell.
Weigh Hopper Check Links

Two horizontal check links hold the weigh hopper in a vertical position as there is an "out of balance
condition” due to the weight of the door cylinder. The check links are stainless steel wire secured at one
end to the bottom of the hopper and at the other end to the weigher housing.
Pneumatics
The air cylinders which operate the weigh hopper discharge doors, feedgate and catchgate are of the
double acting type, used in conjunction with directional control valves having solenoid-pilot air actuators
and spring-pilot air return actuators.
The air cylinders incorporate adjusters for setting the internal cushions which control the end of stroke
impact.
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Adjustable exhaust flow regulators are included in each pneumatic circuit so that the operating rate of
each cylinder stroke can be set to suit its function.
Manual overrides are provided on the solenoid control valves to enable the valves to be operated
without an electrical control signal, for test purposes.
Machine Electrics
Two terminal boxes are mounted on the sides of the weigher housing, one is used for interconnecting
the load cells to the control module and the other interconnects control devices such as solenoid valves,
proximity switch etc., to the interlocking control panel. This second box normally incorporates an
emergency stop push button.
Feeder
The feeder provides the means of controlling the flow of material from the overhead supply hopper to
the weigh hopper.
Refer to the separate manual for details.
Control Module
The control module serves as a weight indicator, provides the means of presetting the weighing
parameters and it also controls and monitors the entire weighing cycle. For further details refer to the
control module operators manual.
Auto Calibration Test Weights (If fitted)

Two calibration test weights are provided, one on each side of the weigher, and each weight is located
in a steel box attached to the housing.
The weights are calibrated by the Weights and Measures Authorities, each one being equivalent to half
the weigher capacity (or calibration value), e.g. 2 weights of 25 kg are used for a weigher capacity of 50
kg.
The weights are normally held up by the vertical air cylinders supported by the steel boxes, and are
lowered onto the support bar of the weigh hopper for the SPAN calibration sequence and during the
TEST sequence to verify the system calibration accuracy.
The operation of the two test weights is controlled by the remote control module.
Functional description
Upon initiation of the weighing cycle, material is released at the full flow rate until a preset weight is
reached. The feed of material then continues at a dribble flow rate and stops when the preset total
weight is reached.
Discharge occurs as soon as the signal to do so is received (for instance, when the presence of a
correctly positioned bag is detected).
On completion of discharge the weigh hopper doors are closed and a new weighing cycle begins.
The entire weighing cycle is controlled and monitored by the control module on the basis of the preset
data and the actual weight signal supplied by the load cells. In addition to manual zero and full weight
adjustments, the module – depending upon the options selected – can automatically keep track of zero
cut-off and final cut-off settings.
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Dimensions and product views

Equipment as supplied in a production line assembly will already have been assembled to customer
specifications which will ensure consistency along production lines.
However, some parts can be mounted on either side of the equipment and it is possible that diagrams
and photographs may be represented by mirror images in some cases. This does not affect the
technical explanations nor the operation of the equipment.
Specifications
The E55 Net Weigher is designed to operate within the following parameters:
Parameter Parameter range Notes

Protection category IP55; not protected against Internal use only
explosion
Air temperature 0°C to +50°C
Relative humidity 80% non-condensing
Normal atmosphere No gas, oil or other corrosive
components
Installation Internal; fixed to firm foundation
Dimensions See engineering drawings
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INSTALLATION AND ASSEMBLY
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Installation Prerequisites
The weigher location should be relatively free from excessive plant vibrations, particularly those of low
frequency and high amplitude which can affect weighing operation and accuracy.
The natural frequency of the scale supporting structure under full load shall not be less than 12 Hz in
each direction. In order to achieve this, the maximum deflection of the structure in vertical and horizontal
direction must not exceed 1.65 mm. A shock proof and vibration-free installation guarantees best
results.
The scale should be freely accessible from all sides.
The environmental temperature must not exceed the following ranges:
o o
E55 standard +5 C - +40 C
o o
E55 with anti-freeze protection -10 C - +40 C
The maximum admissible relative humidity for all components is 80%. High humidity influences the
characteristics of the material and consequently on equipment function. The performance and the
accuracy of the weigher should be examined in cases of higher humidity.
Pneumatics
It is important that particular attention is paid to the design, installation and maintenance of the
compressed air supply to ensure that the weigher performance is satisfactory and reliable
Required air pressure 6 bar
Air consumption rate 8 litres (relieved air) per weighment
The figure given is an average value assuming continuous operation at maximum plant throughput.
Actual instantaneous flow demands can be high, requiring careful consideration of supply pipe sizing.
For various distances between the air mains and machine connection, the following table gives
recommended pipe sizes.
Distance (m) Nominal pipe bore (mm)

Up to 33 12
33 to 66 19
66 to 99 25
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Good pipe fitting practice should be followed, i.e. bends minimized, long horizontal runs sloping down in
the direction of flow, connection branches to the machine run vertically and taken from the top side of
horizontal runs.
It is STRONGLY RECOMMENDED that clients install automatic moisture drain traps close to the
machine connection points and at the base of vertical runs. This will greatly reduce the likelihood of
condensate run-over into the lubricator unit oil reservoir bowl during start-up surge.
Where there is any doubt over the cleanliness of the air supply, install large capacity ¾” or 1" BSP auto
drain in-line filters immediately upstream of Premier Tech Chronos equipment, in addition to the
machine FRL Unit.
This will give significant benefits in reliability, particularly where pneumatic logic elements are used in
machine control.
Protection of pneumatic equipment against damage or malfunction due to frosting should be considered
where installations are required to operate for prolonged periods at an ambient temperature of below
5°C. Chronos Richardson can supply a frost protection unit as additional equipment to be located in
parallel with the line lubricator unit.
Installation Information
Warning!
Do not attach the weigh hopper to the load cells until the weigher and
associated equipment are in place and in working order.
Warning!
Remove load cells from the weigher when carrying out electric welding on the
weigher and adjacent equipment or structures.
Installation Sequence
The weigher is normally shipped fully assembled but with the load on the load cells relieved by
supporting the weigh hopper suspension linkage on two slotted discs. The screws securing the rod end
bearings to the load cell angle pieces are also removed.
The equipment should be examined for damaged or missing parts before installation.
Once installed, follow these instructions in order to make the weigher operational:
1. Refer to the image below and proceed to attach the weigh hopper to the load cells, one side at a
time.
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2. Raise one side of the weigh hopper slightly and remove slotted disc [A] from the suspension
linkage [B].
Take care to hold the weigh hopper securely not allowing the suspension linkage to slip through
the hole in the load cell mounting block.
3. Align suspension linkage [B] with angle piece [F] on the load cell and fit screw [D] with one spacer
washer [E] on each side of the rod end bearing.
4. Tighten screw, taking care not to twist or bend the load cell. It is recommended that the angle
piece [F] be held by a spanner to prevent the load cell from twisting as the screw is tightened.
5. Repeat actions 2, 3 and 4 for the other load cell.
6. Tighten the two securing screws [H] on each load cell.
7. Check that the electrical bonding braids [G] are connected as indicated above.
8. With the weigh hopper empty, adjust the overload stop screws [C] to give a 0.25mm clearance.
9. Remove string ties from the discharge gates (these hold gates together during shipping).
10. Connect an air supply to the weigher FRL unit.
11. Install the electrical interface panel and the weigher controller as indicated on the plant layout
drawing.
Refer to the controller instruction manual for further installation information.
Electrical Grounding
Ensure that the electrical grounding cables/braided strips are securely connected between the machine
sub-assemblies and earth. These are necessary to prevent the buildup of electrical potentials between
sub-assemblies which may occur as a result of static electricity being generated by the flow of material
through the machine. It is particularly important that the braided grounding strips are connected across
the load cells to prevent the strain gauges being damaged.
Electric Connections
Check that the site power supply is the same as that indicated on the machine control panel label.
Complete the electrical connections in accordance with the installation diagrams supplied separately.
Initial Commissioning Checks

1. Adjust air pressure switch (air pressure switch available as an option):
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2. Turn on the air supply and use the pressure regulator to check that the control power can be switched
on at 5 bar by a rising pressure and is switched off at 3 bar by a falling pressure.
3. Adjust the pressure regulator to give an air pressure of between 5.5 and 6 bar.
4. Functionally test the pneumatic system by operating the manual overrides on the solenoid control
values.
NOTE: With the solenoid valve override OFF (de-energized condition) the gates should be closed.
5. Adjust the exhaust flow regulators and air cylinder cushion effect to suit their function.
6. Adjust the air line lubricator flow rate as per maintenance instructions.
7. Check the operation of the proximity switch by opening and closing the hopper doors. The switch
activating flag should be approximately 5mm from the switch face when the gates are fully closed.
8. Proceed with weigher calibration (see Adjustment/Calibration Possibilities section).
Schematic diagram of optional auto-calibration test weight

pneumatics
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Schematic Diagram of Pneumatic Services
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ADJUSTMENTS/CALIBRATION
POSSIBILITIES
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Checking and alignment of check links

Weighing results must not be disturbed by the check links. It is most important that the check links are
perfectly horizontal and do not apply any vertical force on the weigh hopper.
Check and correct their function and alignment prior to start-up, if necessary.
Load Checking
1. Switch the power on. Wait for one hour to let the control module reach its normal operating
temperature.
2. Set scale display to zero.
3. Load weigh hopper frame in centered position with test weights in the amount of maximum scale
capacity in splitting them equally between the right and left hand side of the weigh hopper.
4. Note the weight indicated on the display.
5. Shift the weights on the weigh hopper frame in order to increase tension of the check links.
6. Compare the weight indicated with the one previously noted.
7. In case the weight indications differ by more than 0.5 digits, realign the check links.
Alignment
1. Switch the power on and wait for one hour to let the control module reach its normal operating
temperature.
2. Detach one of the check links from the enclosure and deposit the cable on the weigh hopper frame.
3. Set the scale to display zero.
4. Load the weigh hopper frame on the side with check links attached on centered position with test
weights to the amount of half the maximum scale capacity.
5. Note the weight indicated on the display.
6. Shift the weights on the weigh hopper frame in order to increase the tension of the check links.
7. Compare the weight indicated with the one previously noted.
8. In the case that the weight indications differ by more than 0.5 digits, change the position of the
check links fixation on the enclosure in the vertical direction until the weight readings are identical.
9. Reattach the other check link to the enclosure and align as previously described. The other check
link remains in place.
10. Repeat full load checking.
Calibration of the Weighing System

Refer to the separate controller manual for details.
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INITIAL COMMISSIONING
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Initial commissioning
The E55 Net Weigher as provided has already been fully built and tested prior to shipment and will
generally only require reassembly and acceptance testing.
However, it is recommended that the following items be checked:
General
The equipment should be clean and free from damage. Any packing material should be removed. If in
doubt, refer to the installation engineer.
Mounting base/floor loading

Warning!
The user of the equipment MUST ensure that the mounting base(s) and floor loading
requirements are fully respected. Failure to do so may result in equipment failure and/or
incorrect operation and/or serious injury to personnel.
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MAINTENANCE
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Warnings
WARNING!
The internal parts of this machine can cause serious injury if the machine is
operated while adjustments and/or maintenance are being carried out. Power
from all sources (electrical, hydraulic, pneumatic, etc) must be switched OFF
and LOCKED OUT and TAGGED following safety procedures before
performing equipment maintenance, cleaning, adjustment or the clearing of
jammed bags or other blockages.
WARNING!
Never operate any controls while other persons are performing maintenance on the
equipment.
WARNING!
It is not permitted to conduct any welding work at the production line unless the
equipment is completely diconnected from the area which has to be welded. Take care
that an efficient gounding is prepared for any welding work.
WARNING!
As a general rule DO NOT remove any protection device or safety equipment. If it
necessary to remove such devices for, for example, maintenance work, the safety
devices MUST be reinstalled and checked IMMEDIATELY after the completion of
maintenance work.
WARNING!
DO NOT allow anyone to switch on or start up the equipment except those people who
have been explicitly tasked and authorised to do so.
ATTENTION!
All fasteners and fittings must be retightened after every two weeks of operation after
maintenance procedures.
ATTENTION!
Whenever a switch or any part is replaced, mark the original position of the part
before replacement. Premeir Tech Chronos Ltd is only responsible for any guarantee
if original Premier Tech Chronos Ltd spare parts are used.
ATTENTION!
Ensure compliance with the stated service and maintenance intervals. These intervals
depend on your specific operating requirements and must be defined based on the
manufacturer’s recommendations, and, if necessary, adjusted according to the user’s
experience.
ATTENTION!
Document the completion of service, and maintenance and repair work by entering
details of the work carried out in the service records which MUST be readily available
to maintenance staff.
___________________________________________________________________________________
29
General preventative maintenance schedule

The E55 Net Weigher is specifically designed with low maintenance requirements in mind. However, as
with all equipment, some basic maintenance will ensure trouble-free operation for extended periods.
For the most-part, it is not necessary to disassemble parts during maintenance inspections and work.
General cleaning
Careful and preventative maintenance and repairs are essential to protect the health and safety of
persons present in the vicinity of the equipment. Maintenance and repairs are also necessary to keep
the equipment in proper and safe working condition.
Therefore, the machine should be cleaned on a regular basis with the appropriate materials – brush, dry
cloth, compressed air, etc.
During general cleaning critical parts of the machine should be checked for indications of potential
problems – for example signs of air leakage from the air cylinder, etc.
Remember to also clean the floor areas around the machine to prevent people and equipment from
slipping causing injury or damage.
To ensure continued trouble free operation of the weighing system, it is recommended that the
maintenance tasks listed in the Maintenance Schedule section are carried out at the specified intervals.
Additional maintenance may be necessary on some installations. Points to consider when planning the
routine maintenance requirements of a particular installation:
1. More frequent cleaning may be necessary if any of the following factors apply:
• the material used is very corrosive and/or is likely to solidify if not cleared regularly
• the material is very dusty and likely to cause excessive build-up within the machine
• cross contamination of materials is likely to occur when changing products
2. When site environment and/or material being handled is very corrosive it may be necessary to
regularly clean and renew protective coatings (e.g. paint, grease, bond coat compounds etc.) on all
non stainless steel operating parts.
Pneumatic System Adjustments

Pressure Regulator
Set the pressure to 6 bar maximum.
Exhaust Flow Regulators

Exhaust flow regulators are normally located at the air cylinder ports. These regulators should be
adjusted in conjunction with the air cylinder cushions to suit the function of the air cylinder.
Turning the screw anti-clockwise increases the speed of the stroke being exhausted.
Cylinder Cushion Adjusters

Cushion adjusters are usually located adjacent to the cylinder port. Turning the screw clockwise
increases the cushioning effect.
Adjust the cushioning to the minimum setting and slowly increase until the piston "slap", or "bottoming"
ceases, cushioning will cause piston "bounce". Under cushioning reduces the life span of the cylinder.
___________________________________________________________________________________
30
Catchgate/Feedgate
Regulate the operation of the air cylinder(s) to give a smooth, steady opening and a rapid closing gate
action. Erratic closing of a feedgate will result in inaccurate weighments.
Weigh Hopper Discharge Doors

The operation of the discharge doors should be set for the fastest possible speed, bearing in mind that a
violent closing operation will necessitate a long zero stabilization time.
If a rapid discharge causes downstream problems, the flow regulator can be used to create a
"streaming" effect by slowing down the opening stroke. This should be adjusted in conjunction with the
discharge time (see control module manual).
Mechanical System Adjustments

Auto Calibration Test Weights (If fitted)
The flow regulators of the auto calibration test weight system must be set such that the test weights are
gently lowered and raised onto/from the weigh hopper cross bar, thereby minimizing the shock loading
effect. Lowering the weights rapidly may damage the load cells.
Replacing Load Cells

ATTENTION!
The shear beam load cells utilized on the E55 full load cell weigher are high precision
strain gauge devices which require careful and proper handling, both during
installation and removal. When carrying out either of these functions the load cell
body must not be subjected to forces which deflect it beyond its normal operating
range (at any time). Failure to take necessary precautions could result in irreparable
damage to the load cell.
IF IN DOUBT please contact Premier Tech Chronos Service Department (see Spare Parts Ordering
section for contact details).
Refer to the following image and proceed as detailed below.
___________________________________________________________________________________
31
1. With the weigh hopper empty, adjust the overload stop screws [C] to give a 0.25mm clearance.
2. Slacken securing screws [H] on both load cells at least 2.5 to 3 full turns.
3. Raise the weigh hopper slightly on the side where the load cell is to be changed and insert a
slotted disc [A] under the suspension linkage rod end [B].
4. Remove screw [D] and spacer washers [E] from the angle piece [F] taking care not to twist or bend
the load cell. It is recommended that the angle piece [F] be held by a spanner to prevent the load
cell from twisting as the screw is tightened.
5. Repeat steps 3 and 4 for the other load cell if it is to be changed.
6. Fully remove the securing screws [H] and load cell.
7. Disconnect load cell cables.
8. Transfer angle piece to new load cell ensuring that electrical bonding braids are connected.
IMPORTANT NOTE:
When fitting load cells ensure that they are orientated such that the name label [X] is in the correct
reading position (not upside down).
9. Place the new load cell in position and loosely fit securing screws [H].
10. Raise the side of the weigh hopper on which the new load cell has been installed and remove the
slotted disc [A]. Take care to hold the hopper securely not allowing the suspension linkage [B] to
slip through the hole in the load cell mounting block.
11. Align the suspension linkage rod end [B] with angle piece [F] on the load cell and fit screw [D] with
one spacer washer [E] on each side of the rod end bearing.
12. Tighten the screw, taking care not to twist or bend the load cell. Hold angle piece in a spanner as
per step 4.
13. Repeat Steps 6 to 12 inclusive for the other load cell if required.
14. Tighten the two securing screws [H] on each load cell.
15. Connect all load cell cables.
16. Check that the earth straps [G] are correctly connected.
NOTE: Ensure that the earth straps do not exert any force on the load cell otherwise accuracy
may be affected.
17. With the weigh hopper empty, adjust the overload stop screws [C] to give a 0.25mm clearance on
each load cell.
18. Carry out a complete weigher and system calibration.
___________________________________________________________________________________
32
Replacing Check Links

Fit the wire check links between the weigher housing and the weigh hopper as follows:
1. Attach one end of each check wire into the slotted brackets mounted on the weigher housing.
2. Pass one check wire through the clamp mounted on the side of the weigh hopper.
3. Place a spirit level on the weight bar at the side of the weigh hopper.
4. Pull the check wire through the clamp until the hopper is level, and then tighten the clamp.
5. Pass the second check wire through the other clamp on the hopper side, pull until it is in
tension and tighten the clamp ensuring that the two check wires are tensioned equally and
that the weigh hopper is still level.
6. Check the alignment of the check links (refer to the Checking and alignment of check links
section).
Setting Hopper Door Proximity Switch

To prevent the undetected discharge of material from the weigh hopper it is important that the hopper
door proximity switch be correctly set up.
The following procedure is used when operating the E55 Net Weigher.
NOTE: A second person will be required if the controller and control panel are remote from the weigher.
Proceed as follows:
1. Temporarily adjust the air cylinder exhaust flow regulators to give a very slow operation of
the hopper discharge doors.
2. Open the doors, checking that the system detects a door open condition just before (or at the
same time as) the doors start to open.
NOTE: Holding a piece of thin card between the bottom lips of the doors is a convenient
way of determining the actual point at which the door opens.
3. Close the doors, checking that the system detects a door closed condition as the doors reach
the fully closed position.
4. If necessary, adjust position of the proximity switch.
5. Repeat steps 2 and 3 several times to verify consistency of operation.
6. With the hopper doors closed, initiate a transaction (without material) and manually open the
hopper discharge doors during the feeding part of the cycle. Check that automatic operation
is stopped and a warning message is given as soon as the doors start to open.
7. When the above checks are satisfactory, re-adjust the air cylinder exhaust flow regulators to
allow normal operation of the discharge doors, and re-check.
___________________________________________________________________________________
33
Lubrication
Proper lubrication of the machine is required for some parts of the equipment although all rolling
bearings are of permanent lubrication type and do not require attention.
Where required, oil grades and lubricating intervals are to be noted from the respective manufacturer’s
instructions where applicable.
Joints with no defined lubrication point (grease nipple) should be greased by using adequate grease
applied by brush.
All lubricating points with grease nipples should use conical head grease nipples type A/M6 – DIN
71412.
Attention!
Use only adequate lubricants when lubricating – do not over-lubricate
For grease lubrication the use of according to DIN 51502 is recommended.
Attention!
In principle grease should be pressed into grease nipples slowly until the impure grease
exits through the expansion holes. Do not use excessive pressure with grease nipples.
Lubrication chart
___________________________________________________________________________________
34
Bearings and guides

Most of the bearings are lubricated for service life except for bearings with grease nipples which should
be greased monthly with a Li-saphonified bearing grease to remove impurities.
The remaining bearings, straight guides and pistons of the pneumatic cylinders must not be lubricated at
all. Guides are made of highly wear-resistent dry-running materials and require only cleaning on a
regular basis.
Pneumatic Cylinders
In principle, all pneumatic cylinders are maintenance free.
However, a visual check, especially of the rod gasket for leakage should be carried out regularly
(leakage whistles). If leakage is found, it will be necessary to replace the cylinder gaskets or the whole
air cylinder.
All rod ends must be greased with a Li-saponified grease whenever necessary.
Maintenance schedule
It is important that a maintenance scheduled be programmed, and the following schedule is
recommended as a mini mum maintenance schedule:
Weigher - General
Action Daily Weekly Monthly 3-monthly 6-monthly Yearly
Inspect and clean equipment
Clean the area around the

equipment
Clean off accumulations of

material and dirt
Inspect vent and/or dust extraction

connections
Bearings: Tighten set screws
Check that guards and covers are

serviceable and fitted correctly
Inspect and tighten nuts/bolts/etc
Visually inspect for signs of abnormal

operation with covers briefly removed
Inspect for damage and corrosion

Carry out a check of the weigher

calibration
Weigher - Load cells

Check that the weigh hopper suspension

is securely attached and aligned
Check clearance between load cells and

overload stops (0.25mm - empty hopper)
Inspect load cells for damage and check that

they are securely attached to frame
___________________________________________________________________________________
35
Weigher – Weigh hopper
Weigher – Auto calibration test weights (if fitted)

Ensure weights are lowered smoothly to

avoid shock load on weigh hopper
Ensure weights are clear of weigh hopper

when raised
Ensure weights are clear of support

mechanism/weigher housing when lowered
Pneumatic equipment - General

Check for air leaks
Inspect air lines for damage and correct

routing
Pneumatic equipment – line filter

Drain - More frequent draining may be required

for air with a high moisture content
Clean: Use paraffin or white spirit
Change filter element

Pneumatic equipment – Pressure regulator

Check main air pressure setting
Strip, clean, examine and reassemble
___________________________________________________________________________________
36
Pneumatic equipment – Directional control valve
Pneumatic equipment – Air cylinder

Check cushion adjustment
Strip, clean, examine and lightly smear spool

with silicon grease; reassemble
Replace piston rings and seals
Pneumatic equipment – Flow regulator

Check flow settings
Strip, clean, examine and reassemble
Electrical equipment – General

Inspect cables for damage and correct

routing
Check electrical connections and tighten if

necessary
Examine plugs and sockets for damage, and
ensure that they are secure and correctly

installed. NOTE: Look particularly for broken
wire strands at connection points
___________________________________________________________________________________
37
FAULT DIAGNOSIS
___________________________________________________________________________________
38
Fault diagnosis
Although the E55 Net Weigher is a relatively simple machine, faults may arise from time to time and
some guidance on fault diagnosis is useful. The most common areas to check are as follows:
Symptom Likely problem Recommended action

Hopper door proximity switch not correctly set Re-adjust
Proximity switch or wiring faulty Test; repair or replace
Weigh cycle will not start
Weigh hopper door not closing See below
Feed gates not opening See below
Check regulator output and for
Low air pressure
trapped or partially blocked pipelines
Exhaust silencers blocked Replace silencers in solenoid valves
Flow controllers incorrectly set Re-adjust flow controllers
Operation of feedgate and/or Air cylinder cushioning excessive Re-adjust cushioning
discharge doors sluggish Check lubricant level and flow rate
Air cylinder dry
in air conditioning unit
A "blow by" is indicated by continuous
Faulty air cylinder exhaust. Replace piston rings and
seals or replace cylinder
Air cylinder clevis pins seized Dismantle and clean, or replace
Operate solenoid valve manual
override:
If doors open:
Check weigher control circuit and
solenoid coil
Check by unplugging solenoid

Weigher control signal absent valve electrical connector
Feed gate and/or discharge Weigher control continually present
doors fail to open and/or Loss of air pressure If doors close:
close Door mechanism binding or seized Check weigher control circuit
Sticking spool in air cylinder solenoid valve
Air cylinder seized Check regulator output for air, and
check pipelines
Dismantle, clean or replace rings

and seals or replace valve
Dismantle, clean or replace rings

and seals or replace cylinder
Check the proximity switch is working

Proximity switch faulty correctly by confirming that the LED
indicator switches on and off
Control module net weight
indication is inaccurate or Check that:
inconsistent
Weigh hopper is not touching

(Note: Where symptoms housing or access covers
indicate that a fault exists in
the weigher, check the weigher Weigh hopper not suspended freely Air pipelines and cables to
faults before suspecting the hopper are not exerting a
load cell unless it is known that vertical force on the hopper
the load cell has been subjected
to extreme mechanical and/or Sway limits are adjusted correctly and
electrical stress) not broken
___________________________________________________________________________________
39
Symptom Likely problem Recommended action

WEIGHER FAULTS: CHECK THAT:
Load cell/hopper suspension assemblies Load cells and rod end bearings
misaligned or subject to extra forces, or are correctly aligned and secure
faulty wiring
Bonding braids do not exert any
LOAD CELL FAULTS: force on the load cells
High zero offset: Load cell stop screws are correctly

Control module net weight This is almost always the result of adjusted
indication is inaccurate or extreme physical stress either in the
inconsistent form of shock load or due to Wiring and connections between the
overloading of the load cell load cells and the controller are correct
Continuous high output:

This is usually caused by extreme IMPORTANT NOTE:
physical stress causing the Load cells are sensitive to stress and
Wheatstone bridge circuit to can be damaged if not handled
become open - circuited as a result correctly.
of severe mechanical stress
rupturing a strain gauge or through However, once set up and calibrated,
the injection of large electrical load cells should deliver accurate
currents into the bridge. readings for long periods.
If, therefore, load cells appear to be

operating incorrectly, even after
re-calibration, users should contact
Premier Tech Chronos for technical
advice in order to avoid further
problems. The contact details of
Premier Tech Chronos are listed in
the "Contact Us" section of this
manual.
Common faults
Air cylinder
If the air cylinder continues to exhaust air while the piston is at either end of its stroke (that is, with the
gate open or closed) it will be necessary to replace the piston cup or seal at the end from which the leak
occurs.
Generally, this type of air leak can be heard and the position of the leak can be confirmed by holding a
finger over the exhaust port on the foot valve and feeling the stream of air.
Since replacement will require the dismantling of the cylinder, it is recommended that all seals on the air
cylinder be replaced at the same time.
___________________________________________________________________________________
40
Blocked air lines and other air problems
If the pressure reading shown on the pressure regulator drops but there is no lack of air in the
pneumatic system, check the air compressor. If it is not faulty, examine the air lines up to the equipment.
Parts can be dismantled and checked for correct operation as required.
If the pressure reading at the regulator drops and there is no leakage in the system, the regulator should
be replaced.
If the regulator is operating correctly but there is still a lack of air in the system, the filter should be
removed, examined and either cleaned or replaced as appropriate.
Dirty air near the input of the compressor will result in dirt entering the filter system which could become
blocked quickly. The compressor inlet should have access to clean air at all times.
General
Hoses, clamps, pipe fittings etc should all be checked at regular intervals for damage and loosening and
should be replaced or retightened as appropriate.
___________________________________________________________________________________
41
SPARE PARTS LIST
___________________________________________________________________________________
42
Spare parts
Spare parts may be ordered per the details which appear on the relevant engineering drawings, and are
reproduced below for reference.
Weigh Hopper – Mechanical Parts
___________________________________________________________________________________
43
___________________________________________________________________________________
44
*Note: Item subject to wear and tear and spares should be kept in stock on site.
___________________________________________________________________________________
45
Weigh Hopper –Electrical Parts
Hopper sway links
___________________________________________________________________________________
46
Hopper suspension
Load cell assembly
___________________________________________________________________________________
47
Auto Calibration test weights (If fitted)
___________________________________________________________________________________
48
___________________________________________________________________________________
49
Control Panel
Refer to the panel general arrangement drawing and the system circuit diagram.
The contents of a particular control panel are dependent on the system requirements.
Orders for replacement parts should quote the following details:
• Drawing No. (as per the electrical drawing)

• Component ID tag
• Part Description
• Quantity Required
Spare parts ordering instructions
When ordering a new part, the following details must be indicated (where available):
Model (see label): E.g. E55 Net Weigher
Serial No. (see label): E.g. Read on machine label
Quantity required: E.g. 1
Name of part: E.g. Silencer
Item number of part: E.g. 12
Page number in user manual: E.g. #49
User manual title and version: E.g. User Manual – E55 Net Weigher
___________________________________________________________________________________
50
CONTACT US
___________________________________________________________________________________
51
Our Address
Premier Tech Chronos Limited
93 Moo 9, Bangna-Trad Km. 19 Road,
Tambol Bang Chalong, Amphor Bangplee,
Samutprakarn 10540, Thailand
Tel: +66 (0) 2740 5001
Fax : +66 (0) 2312 6836
For Spares and General Queries

Please contact us via:
info@chronosasia.com
___________________________________________________________________________________

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User Manual – E55 Net Weigher

User Manual – E55 Net weigher

User Manual – E55 Net weigher

Installation and assembly......17

Checking and alignment of check links...........))))))))..))))))))))..24

Initial commissioning ........25

Spare parts list.....41

Spare parts ordering instructions)))))))..) )))))))))))))49

User Manual – E55 Net weigher

This sign is used to highlight important safety information and other

This safety information is grouped under two headings:

User Manual – E55 Net weigher

User Manual – E55 Net weigher

Premier Tech Chronos reserves the right to change technical specifications

Usage According To The Intended Purpose

Required Training Courses

With regards to training courses:

Regular training courses are required

The execution of such courses must be documented and filed

Clearly define the requested qualification duties and responsibilities of

Operating personnel should be provided with all necessary personal safety

User Manual – E55 Net weigher

User Manual – E55 Net weigher

General Overview and Specifications

Weight Transducers (Load Cells)

The transducing element of the load cell is a shear beam type.

Weigh Hopper Check Links

Refer to the separate manual for details.

Auto Calibration Test Weights (If fitted)

Refer to the separate manual for details.

Refer to the separate manual for details.

Dimensions and product views

Parameter Parameter range Notes

User Manual – E55 Net weigher

INSTALLATION AND ASSEMBLY

User Manual – E55 Net weigher

The scale should be freely accessible from all sides.

The environmental temperature must not exceed the following ranges:

Required air pressure 6 bar

Air consumption rate 8 litres (relieved air) per weighment

Distance (m) Nominal pipe bore (mm)

5. Repeat actions 2, 3 and 4 for the other load cell.

6. Tighten the two securing screws [H] on each load cell.

10. Connect an air supply to the weigher FRL unit.

Refer to the controller instruction manual for further installation information.

Initial Commissioning Checks

1. Adjust air pressure switch (air pressure switch available as an option):

8. Proceed with weigher calibration (see Adjustment/Calibration Possibilities section).

Schematic diagram of optional auto-calibration test weight

User Manual – E55 Net weigher

Schematic Diagram of Pneumatic Services

User Manual – E55 Net weigher

User Manual – E55 Net weigher

Checking and alignment of check links

2. Set scale display to zero.

4. Note the weight indicated on the display.

6. Compare the weight indicated with the one previously noted.

3. Set the scale to display zero.

5. Note the weight indicated on the display.

7. Compare the weight indicated with the one previously noted.

10. Repeat full load checking.

Installation and assembly......17

Initial commissioning ........25

Spare parts list.....41