Advanced Poly Packaging Inc 2400 Ultra Count Parts Counter Instruction Manual
- June 1, 2024
- Advanced Poly-Packaging Inc
Table of Contents
- Advanced Poly Packaging Inc 2400 Ultra Count Parts Counter
- Specifications
- Product Information
- Product Usage Instructions:
- FAQs
- Introduction
- Getting Started
- Touch Screen Operation
- Adjustments, Maintenance, Troubleshooting
- Parts and Drawings
- Appendix
- References
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
Advanced Poly Packaging Inc 2400 Ultra Count Parts Counter
Specifications
- Product Name: Ultra-CountTM 2400 and 3000 Parts Counter
- Operation Guide: Version 4 Revision F
- Setup, Operation and Parts Manual
Product Information
The Ultra-CountTM parts counter is a trademark product of Advanced Poly- Packaging, Inc. It is designed to accurately count and package parts efficiently.
Features:
- Touch screen operation for easy use
- LED panel for clear visibility
- System settings for customization
Product Usage Instructions:
Chapter 1: Introduction
Welcome to the Ultra-CountTM parts counter. This manual provides detailed information on how to set up, operate, and maintain the product.
Specifications:
Ensure you review the specifications section for details on the product model and version.
Available Options:
Check the available options section to see if there are any additional features or accessories that can enhance your experience with the parts counter.
Chapter 2: Getting Started
Follow the unpacking and setup instructions carefully. Ensure you consider safety precautions and risks associated with operating the machine.
Machine Setup:
Properly set up the machine in the designated operating environment. Make necessary hookups and connections for smooth operation.
Air and Power Requirements:
Understand the air and power requirements of the parts counter to ensure it functions correctly.
Turning on the Power:
Follow the steps outlined in the manual to safely turn on the power of the parts counter.
Chapter 3: Touch Screen Operation
Learn how to operate the touch screen interface efficiently for accurate counting and packaging of parts.
Panel LEDs:
Utilize the LED panel for clear visibility and status indications during operation.
System Settings and Function Keys:
Explore the system settings and function keys to customize the operation according to your requirements.
Screen Contrast Settings:
Adjust the screen contrast settings for optimal visibility based on your working environment.
Auto Screen Off / Manual Screen Off:
Understand the options for screen off settings to conserve power when not in use.
FAQs
- Q: Can I use the Ultra-CountTM parts counter for counting small electronic components?
- A: Yes, the Ultra-CountTM parts counter is designed to count various small parts including electronic components with accuracy.
- Q: How often should I calibrate the parts counter?
- A: It is recommended to calibrate the parts counter periodically as per the usage frequency and manufacturer’s guidelines for accurate counting results.
“`
Ultra-CountTM 2400 and 3000 Parts Counter
Operation Guide, Version 4 Revision F
Setup, Operation and Parts Manual
Acknowledgments
Written By: Charles Tolbert, updated by David Kolinski-Schultz Reviewed By:
Stuart Baker
Copyright
© 2000 (Ver. 1), 2003 (Ver. 2), 2013 (Ver. 3), 2014 (Ver. 4), 2015 (Ver. 4A),
2015 (Ver. 4B), 2016 (Ver. 4C), 2017 (Ver. 4D), 2018 (Ver. 4E), 2018 (Ver. 4F)
Advanced Poly-Packaging, Inc. (APPI). All rights reserved.
This manual and the program operating the equipment described in it are
copyrighted. You may not copy this manual in whole or part without written
consent of Advanced Poly-Packaging, Inc.
All information pertaining to the promotion, sale, distribution, operation and
maintenance of the Ultra-Count 2400 and UltraCount 3000 Parts Counter
including this manual, drawings, schematic, wiring diagrams, VHS video tapes,
brochures, specification sheets, figures, charts or any other information, due
to its proprietary design and manufacture, remain the property of Advanced
Poly Packaging, Inc. Unauthorized duplication, distribution or disclosure to
third parties without the express permission of Advanced Poly Packaging, Inc.
is strictly prohibited.
Trademarks
Ultra-Count is a trademark of Advanced Poly-Packaging, Inc. Advanced Poly-
Packaging, Inc. also owns the following trademarks: T-1000, Advanced Poly-
Bags, Twin-Seal, Advanced Poly-Pack, Advanced Poly-Bag, Blist-a-Bag, Ultra-
Feed, FlipSeries, Seal-a-Print, Roll-a-Print.
Warranty
Warranty period is one year. The warranty commences on the date of delivery of
the equipment to the purchaser. APPI warrants to the Purchaser that the
equipment is free from defects in workmanship or material under normal use and
service. During the warranty period, APPI agrees to repair or replace, at its
sole option, without charge to Purchaser, any defective component part of the
equipment. To obtain service, Purchaser must return the equipment or component
to APPI or an authorized APPI distributor or service representative in an
adequate container for shipping. Any shipping charges, insurance, or other
fees must be paid by Purchaser and all risk for the equipment shall remain
with Purchaser until APPI takes receipt of the equipment. Upon receipt, APPI,
the authorized distributor or service representative will promptly repair or
replace the defective component and then return the equipment or component to
Purchaser, shipping charges, insurance, and additional fees prepaid. APPI may
use reconditioned or like new parts or units, at its sole option, when
repairing any component or equipment. Repaired products shall carry the same
amount of outstanding warranty as from original purchase. Any claim under the
warranty must include a dated proof of delivery. In any event, APPI’s
liability for defective components or equipment is limited to repairing or
replacing the components. This warranty is contingent upon proper use of the
equipment by Purchaser and does not cover: expendable component parts such as
print heads, rollers, bushings, and the like; or if damage is due to accident,
unusual physical, electrical or mechanical stress, neglect, misuse, failure of
electric power, improper environmental conditions, transportation, tampering
with or altering of the equipment, packaging of corrosive or contaminating
products or other products damaging to components, and equipment or components
not owned or in the possession of original Purchaser. APPI will not be liable
for loss of production, profits, lost savings, special, incidental,
consequential, indirect, or other similar damages arising from breach of
warranty, breach of contract, negligence, or their legal action even if APPI
or its agent has been advised of the possibility of such damages or for any
claim brought against the Purchaser by another party. This warranty allocates
risks of equipment failure between Purchaser and APPI. APPI’s pricing reflects
this allocation of risk and the limitations of liability contained in this
warranty. The warranty set forth above is in lieu of all other express
warranties, whether oral or written. The agents, employees, distributors, and
dealers of APPI are not authorized to make modifications to this warranty, or
additional warranties binding on APPI. Accordingly, additional statements such
as dealer advertising or presentations, whether oral or written, do not
constitute warranties by APPI and should not be relied upon. Warranty on
equipment is considered void when outstanding balances become delinquent (over
30 days late 60 days after ship date). Equipment Integration to other
Equipment: APPI assumes no responsibility for the integration of its products
to other products or within a system unless APPI performs the integration,
testing and provides the results of the tests to the purchaser in writing.
Furthermore, APPI assumes no responsibility for bag sizing whether suggested
or recommended.
Introduction
Welcome Using This Manual Specifications Available Options Warranty
Registration
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Welcome
Thank you for selecting the Ultra-CountTM 2400 or 3000 Parts Counter. Designed
to accurately sort and count various molded, medical, industrial and food
products, the Ultra-CountTM will lower your packaging costs with automatic
operation, increased speeds, versatility, reliability, and simplicity.
Using This Manual
The following manual conventions are frequently used to assist in
understanding important information, to alert the operator of potentially
dangerous or damaging practices and to describe the normal functions of the
Ultra-Count TM Parts Counter.
· Text Normal text. · Italics Used for emphasis. · Boldface Used to identify
heading names and touch screen buttons. · CAUTION: Warning messages. To avoid
physical harm, damage to equipment or damage to the
product, be sure to read these messages carefully. · Note: Identifies
important information.
Specifications
General · Machine Dimensions: 54″ high x 36″ wide x 42″ deep · Conveyor Motor:
Stepper drive · Optical Frame: 80mm x 120mm staggered emitter / receiver ·
Weight: Approximately 400 lbs. (varies based upon bowl and drive size) · Air:
60 PSI · Electric: 115V/60Hz
Touch Screen Specifications · Power: 24 VDC (+/- 10%) · Operating Environment:
0-50°C, 85% RH or less · Display: Color LCD · Resolution (W x H): 320 x 240
dots · Display Area: 174 x 131mm (5.7″) · Backlight: CCFL · Backlight Hours:
Approx. 75,000 · PLC Connection: RS232 · Number of Characters: 40 columns x 30
lines max.
Touch Screen (Back Panel) · MJ1: Connector used for serial communication with
an external device and screen data transfer · MJ2: Connector used for serial
communication with an external device · USB-A Port: Provides connection to a
USB printer · USB-B Port: Provides connection to a computer for screen data
transfer · LAN Connector (Optional): Provides Ethernet communication
Drive Specifications – Performance Data · Part movement approaching 100 feet
per minute is obtainable · Overall Dimensions: 8 ¾” high, 16 ½” square base,
18″ or 24″diameter bowl
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· Weight: 222 pounds (drive unit less bowl) · Power Required: 3.5 amps maximum
amperage draw at 120 Volt AC, also available at 240 Volt · Springing: 4 spring
banks 90° apart, 15° spring angle · Rotation: Counterclockwise or clockwise ·
Bowl Mounting: One hole (or four holes on some models), top or bottom mount,
bolt circles up to
16 ½” · Bowl Size: Up to 30″ stainless steel fabricated or cast aluminum ·
Operating Mode: 7200 cycles per minute at 60 Hz; 50 Hz tuning available
Available Options
Although the UC-2400 and UC-3000 are extensively equipped with many “built-in”
options, APPI offers some additional options that may better suit your Ultra-
Count Piece Counting machine and your specific needs.
· Bowl configurations: The UC-2400 and UC-3000 come equipped with a flat track
(or highnegative bowl) as a custom feature.
· Vibratory hopper with leveling arm: A supply hopper, triggered by a level
switch designed to keep the bowl filled to a consistent level, provides a
greater accuracy of parts flow. The leveling switch may be in the form of a
leveling arm, an ultrasonic sensor, or a photo optic sensor.
· Incline feed conveyor and hopper with leveling arm: A hopper with a floor
level stand provides for lower filling of the hopper. An incline conveyor
feeds the bowl and maintains a constant level in the bowl for greater feed
accuracy.
· FDA coating or rubber coating: PTFE coatings are available for food contact.
Rubber or polyurethane coatings are also available.
· Special tooling: Bowls can be custom-tooled to provide for the orientation
requirements of special parts.
· LAN connection: Provides for Ethernet communication.
· UF-2000 Takeaway Conveyor: This conveyor removes the packaged product to a
packing station or directly feeds a carton or table. Small, lightweight, and
equipped with castors, this conveyor can be used anywhere in the plant.
Designed for 24 hour / 7 days a week operation.
· Photo eyes: APPI can provide different types and configurations of sensors
to meet the specific needs of your product.
· Recipe management system: The Ultra-Count allows for a system with the
ability to create, manage and store “recipes” of past jobs settings from
multiple machines operating in a system. These recipes can be saved and
applied to future jobs to make operation faster and easier.
Contact Information
To better serve your bagging needs, call
330-785-4000 or toll free
1-800-754-4403 for convenient service
solutions, Monday through Thursday, 9:00 AM to 5:30 PM EST, or Friday 9:00 AM
to 5:00 PM EST. For technical assistance with current machinery, ask for
Service. To order spare parts for your system, ask for Parts. To order
auxiliary equipment for your current system, ask for Machine Sales. To place
an order for bags, ask for Bag Sales.
You may also contact any of these departments by email:
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Reach Service at Service@advancedpoly.com Reach Parts at
Parts@advancedpoly.com Reach Machine Sales at MachineSales@advancedpoly.com
Reach Bag Sales at Bagsales@advancedpoly.com For general inquires:
Sales@advancedpoly.com Or visit us online at www.advancedpoly.com In order to
provide the best service possible, please have model and serial number ready.
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Warranty Registration
This section must be completed and returned to Advanced Poly-Packaging, Inc.
to register the scale for Warranty Protection.
Serial Number:
(Serial Number located on the back panel)
Company Name and Address
Contact Name(s) / Title(s) / Phone Number
Please fax or mail this page to:
Service Manager Advanced Poly-Packaging, Inc. 1331 Emmitt Road Akron, OH 44306
USA
Fax # (USA) 330-785-4010 Or email the
information above to: service@advancedpoly.com
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Chapter 2:
Getting Started
Chapter Summary Unpacking and Setup Safety, Risks Machine Setup Hookups and
Connections Operating Environment Air and Power Requirements Turning on the
Power
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Chapter Summary
This chapter describes procedures to receive and set up the Ultra-Count,
including uncrating and assembly instructions, environmental, air and power
requirements, and safety precautions.
Unpacking and Setup
The Ultra-Count System is typically shipped completely assembled on a pallet.
However, photo eye or accumulating assemblies may be removed to various levels
of disassembly. Cartons securing the electronic module, cables and manual will
be also on the pallet. Remove all tape, banding or packing materials that
secure the machine.
Safety, Risks
Many safety features have been included in the mechanical, electronic, and
pneumatic systems of this machine. Despite these safety precautions, operators
may receive lacerations or crushed or broken bone injuries if they come in
contact with any moving components. Improper use, improper adjustments and
neglect of preventative maintenance may also result in serious personal
injury. No special personal protective equipment is required to operate the
equipment, but eye protection, gloves or other protection should be worn,
depending on the characteristics of product being packaged or the method of
loading the product.
Please carefully read the following precautions to operate the equipment
properly and avoid injury:
· CAUTION: Initial setup of the machine must be performed by specialized
personnel. Qualified service engineers should uncrate the equipment, assemble
the equipment (if required), test and connect power sources, test the
equipment for proper operation and set up the equipment for use.
· CAUTION: Do not attempt to adjust the height without assistance and without
supporting the weight of the machine. Attempting to make a height adjustment
without assistance could cause the machine to drop suddenly, causing severe
injury. APPI offers several optional accessories that can reduce the risk of
injury during height adjustments. These accessories include carts, motorized
height adjustment components and stabilizing bars.
· CAUTION: Ensure that height adjustments allow for sufficient movement of the
operator. Improper height adjustments could negatively affect operator
movement, causing strain, added stress, discomfort and fatigue.
· CAUTION: To avoid injury, do not operate the equipment if funnels, guards,
covers or other access panels have been removed. If any of these safety
measures have been removed or modified or if any openings have been increased,
the operator will have access to moving components that can cause crush, cut,
or burn injuries to hands or fingers.
· CAUTION: To avoid injury, do not reach under guards or elsewhere under the
machine.
· CAUTION: Do not remove or loosen fasteners on the frame. If loosened, the
equipment may drop suddenly, causing injury or damage to the machine.
· CAUTION: To avoid injury, avoid coming in contact with pinch points
including rollers, automatic funnel doors or other moving components.
· CAUTION: Exercise care when adjusting or relocating the touch screen.
Movement of the touch screen could cause unexpected movement of the machine
and injury to the operator.
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· CAUTION: Do not attempt to feed parts that are not suited to the machinery. Doing so could cause jams, damage to machinery and ejection of parts. For example, parts too large for the accumulating funnel may jam and eject when the door closes.
· CAUTION: If control or air pressure settings are set too high, higher noise levels may result from increased part on part contact or part on machinery contact. Limit these settings and add guards or covers to reduce airborne noise.
· CAUTION: Exercise extreme care when clearing jams, replacing materials, changing controls or mechanical settings, and cleaning internal parts. Be sure to de-energize energy sources prior to removing guarding. Failure to do so may result in unexpected movement or flying objects, which could cause crush, cut, or eye injuries.
· CAUTION: Maintenance must be performed by specialized personnel. Qualified service engineers must remove guards or covers to gain access to electrical or mechanical areas.
· CAUTION: Maintenance must be performed regularly to ensure that the machine
is operating properly and to protect against injury. Routine maintenance
includes: periodic inspections, the replacement of worn or damaged components,
the tightening of loose bolts or components, and regular cleaning and
adjustments. Contact APPI and/or service centers for service support if there
is not sufficient maintenance staff at the user facility to perform regular
maintenance.
Machine Setup
First, position the stand in its operating location. Then, with a lift truck
or other lift device, position the drive unit onto the stand, locating the
feet in their mounting pads or mounting holes. Check the unit to make sure the
four rubber feet are securely attached to the base of the unit. It is
essential that these feet are in good condition and are securely attached to
the base. The rubber mounting feet will isolate the slight vibrations of the
drive unit from the mounting structure. Mounting screws restrain the drive
unit from moving. Secure the feeder bowl to the top plate of the drive unit
with the screws provided. Mount or position the electronic module so that the
cables reach the connections.
Note: The base drive may not be bolted to the stand. Do not attempt to move the counter while the base drive is positioned on the stand. Remove the feeder bowl, then the base drive, prior to repositioning the stand.
Note: Erratic parts feeding will occur if the bowl mounting screws are not
drawn down tightly or if the screws become loose.
Hookups and Connections
The back of the Ultra-Count control module has eight clearly marked ports:
PORT Belt Drive Bowl Drive Level Input Optical Input IOP Serial Port Hopper Aux In Aux Out
CONNECTION Military Connector, 10 Pin Female, Belt Drive Military Connector, 3 Pin Female, Base Drive DB9F, 9 Pin Female, Leveling Switch DB9F, 9 Pin Female, Optical Frame 5 Pin Female, Touch Screen Operator Panel 110 Outlet, Line Out, Vibratory Hopper Military Connector, 7 Pin Male, Aux. In Signal (from bagger/conveyor) Military Connector, 6 Pin Female, Aux. Out Signal (to other counter, bagger, check weigh scale or terminator
14
Operating Environment
When you choose a location for installation, make sure the area is free of
excess dust, dirt, and moisture. To ensure the highest production possible,
consider product flow to the counter and ensure that the finished (packaged)
product can easily flow from the system. Note: For suggested system layouts,
please contact an APPI technical sales person for layout drawings.
Air and Power Requirements
The Ultra-Count is equipped with an external regulator, and the air supply
should be fed to the UC-2400 or UC-3000 with ¼” O.D. poly tubing. Make the
connection at the rear of the machine. Set the air pressure on the UC-2400 /
UC-3000 between 20 and 40 PSI. Note: Air should be dry and oil free. The
UC-2400 and UC-3000 require an 115V/50Hz dedicated power source and will draw
15 amps total per unit.
Turning on the Power
The main power switch is located on the control module at the base of the
machine. To turn the machine on, turn the switch clockwise from its horizontal
OFF position to its vertical ON position. The green Power light on the touch
screen will illuminate and the Introduction screen will be displayed. The
program version will also be identified. The Introduction screen will only
appear for a few seconds until automatically changing to the Operation screen
or Main Menu.
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Chapter 3:
Touch Screen Operation
Chapter Summary Panel LEDs System Settings and Function Keys Screen Contrast
Settings Auto Screen Off / Manual Screen Off System Settings: Parameter and
Communication Settings Touch Screen Program Password Functions / Default Pass
Codes Introduction Screen Counter Main Menu Counter Operation Screen Counter
Settings Screen Hopper Settings Eye Test / Eye Settings Counters Screen Job
Save and Recipe Management Memory Files and Data Structure Production Screen
Counter Auxiliary Options Screen Technical Assistance Screen Password Setup
Screen PLC I/O Status Screen Counter APPI Factory Screen Counter Factory
Settings Counter Operation Mode Machine Info Information Screens
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Chapter Summary
The touch screen is comprised of LEDs, system and function buttons and the
screen operation itself. This chapter describes the identification, operation,
and settings of the touch screen program.
Panel LEDs
Power: Green LED is lit when machine is turned on. Run: Green LED is lit when
touch screen is in run mode and the program is operating properly.
System Settings and Function Keys
There are three levels of access to the System Settings:
- Press Function keys (F1 to F5) directly. 2) Press the System key first, and
then press the Function keys. 3) Press the System key. Then hold down the F1
and F5 keys for parameter settings.
The System key and Function keys are located to the right of the touch screen. Function keys are programmed as “hot” keys and may be changed depending upon the program version. However, the F1 key displays a HELP screen. F5 displays a password screen.
Screen Contrast Settings
To access the Screen Contrast Settings, press the System key first, and then press the Function keys. Pressing the System Key followed by F2 through F5 allows for screen contract adjustments, as follows:
· F2 – Function key 2: Reduces the screen contrast. · F3 – Function key 3: Sets the screen contrast to mid-scale. · F4 – Function key 4: Increases the screen contrast. · F5 – Function key 5: Backlight ON/OFF (locked in ON position).
The contrast control for the Ultra-Count is accessed through the Function keys. To enable the Function keys, press the System key. Hold down the F2 key or depress it repeatedly to decrease the contrast and darken the touch screen display. Hold down the F4 key or depress it repeatedly to increase the contrast and brighten the touch screen display. Press the F3 key to set the contrast to the mid-scale position. Press the System key again to disable the function keys.
Note: The function keys will only remain active for 5 seconds after the last key is pressed.
Auto Screen Off / Manual Screen Off
The backlight will automatically turn off after 30 minutes of nonuse of the touch screen for longevity of the screen components. If the backlight is off, simply touch the screen or press the System or Function Key to illuminate the screen. To turn off the backlight manually, press the System key, followed by the F5 function key. Again, pressing any key or the touch screen will illuminate the screen.
System Settings: Parameter and Communication Settings
System settings can only be accessed by pressing the System key and then holding the F1 and F5 function keys simultaneously. System settings provide access to the COMM parameters, I/O Test, and memory card information.
Note: Parameter settings are set at the factory and should not be altered. Any changes may cause the touch screen to become inoperative.
17
COMM parameters are set at the factory as follows:
· SIG LEVEL: RS232C · CONNECT: 1:1 · PC Stat: No: 1 · Baud Rate: 19,200
Data: 8 · Stop Bit: 1 · Parity: ODD
The I/O test provides for Touch / Contact Switch tests. Each button can be
tested to ensure proper operation of the screen. Press the right corner of the
screen to return to the Main Menu.
From the Main Menu, press System / Mode to return to normal operation.
Touch Screen Program
The touch screen program is a user-friendly, menu-driven setup and operation
program. To move through the system, touch the area of the screen that
describes the desired operation. A particular color scheme is used to identify
functions:
· Blue is the background color used for text information. No “buttons” or
functions are blue. · Green is the color used for “buttons” that change
settings. For example, pop-up windows may be
displayed or a function turned on/off when a green button is pressed. · Red
indicates that a function is off or stopped. For example, pressing a red
button may turn a
function on. · Yellow is the color used for menu buttons. A menu button
displays another screen and allows for
movement throughout the entire program.
Password Functions / Default Pass Codes
APPI has included a pass code function in all touch screen equipment to
prevent operators from changing settings.
There are two pass code levels, described as follows:
1. Level 1: This is the highest-level pass code. It prevents operators from
accessing the technical assistance functions of the machine. Additionally, the
pass codes are maintained in this area.
2. Level 2: This level pass code, when the pass code function is enabled,
prevents the operator from accessing settings screens that affect the
operation of the equipment.
Pass codes prevent unauthorized individuals from tampering with settings. When
equipment is shipped, APPI uses the following codes that can be changed by the
customer at any time:
1. Level 1 pass code: 1001 2. Level 2 pass code: 1002
To enable the pass code function, press the Technical Assist button on the
Main Menu. Enter the Level 1 pass code (1001 by default from APPI). Then press
the ON/ OFF toggle button to toggle the pass code function ON. If you change
the pass codes, ensure that these codes are written down.
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Once the pass code function is enabled, the operator will have a programmed
amount of time (time-out time) to make changes. Once this time has elapsed,
the Counter Operation screen will automatically be displayed. This time can be
changed by accessing the Password Setup Screen. By default, the time is set to
five minutes.
If you misplace or forget the pass codes, contact the APPI Service Department
for assistance. APPI will provide a “factory code” so that the current pass
codes can be displayed. Once you receive the factory code, press the F5
function key, located to the right of the touch screen, to enter the factory
code and display your preset codes.
Note: Refer to the section 3.21 Password Setup Screen for further information
on this function.
Introduction Screen
When the Ultra-Count is turned on, an Introduction screen is “flashed” on the
screen momentarily. See Figure 3-1.
Counter Main Menu
The Counter Main Menu screen allows the operator to navigate quickly through
the entire program. See Figure 3-2.
The yellow buttons located in the center of the Main Menu screen are menu
command buttons. Pressing one of these buttons will change the screen
currently displayed on the IOP. To access another screen, simply press the
corresponding menu command button. Menu buttons appear throughout the touch
screen program to assist in navigation and are normally located on the right
side of the screen.
Figure 3-1 Figure 3-2
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Counter Operation Screen
The Counter Operation screen allows the operator to monitor operation, begin
operation, and stop the system from running. See Figure 3-3.
Top line toggle switches appear on most screens throughout the program. These toggle switches include the RUN/STOP button, MANL/AUTO button, AUX button and the HOPPER button.
· RUN/STOP: This toggle button
Figure 3-3
changes the current state of the
counter’s operation. To start the counter, toggle the button to RUN. To stop the counter, toggle
the button to STOP.
· MANL/AUTO: This toggle button switches operation to Manual or Automatic mode. In Automatic mode, the counter will cycle in a continuous mode (if AUX is OFF) or in a closed loop communication mode (if AUX is ON). To run with a bagger or conveyor, this switch must be in the AUTO position. In Manual mode, the operator must press the Manual Cycle button to cycle the machine.
· AUX: To set up communication with the bagger, conveyor, or other equipment (including the CW scale), the AUX toggle button must be in the green ON position. If you wish to operate the unit as a standalone machine, then the AUX toggle button must be in the grey OFF position. For setup, place the AUX button in the OFF position.
· HOPPER: If equipped with a hopper or hopper/conveyor system, the toggle button must be in the green ON position. However, even in the ON position, the hopper will turn on only if the bowl is in fast operation mode and the leveling switch is ON. To turn the hopper OFF, toggle this button to the grey OFF position.
Manual Cycle: Press this button to manually cycle the counter. If the final
count has been reached, the unit should cycle. Before running the counter in a
“system,” the counter should be cycled several times as a standalone unit to
test parts flow and count accuracy. The Manual Cycle button can be pressed any
time during the count sequence.
The Counter Operation Screen displays the preset number of batch counts before operation will stop, displayed in the right box under Count, the remaining number of batch counts, displayed in the left box under Count, and the total number of parts processed during the cycle, displayed under Total Parts. A message will be displayed when the preset count has been reached. Pressing the Reset button will zero the Totals Parts count. The status of the accumulator, bowl and hopper are also displayed on this screen.
Accumulator ON/OFF: This indicator displays the status (ON’ orOFF’) of the
Accumulator, which can be activated from the Counter Factory Settings Screen.
Bowl Speed serves as an indicator for the status of the bowl. When STOP is
displayed, the bowl is off. When RUN is displayed, the bowl is on.
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Hopper serves as an indicator for the status of the hopper. When HOPPER
displays STOP, the hopper is off. When HOPPER displays RUN, the hopper is on.
If the pass code function is enabled, the Operation Screen will automatically
be displayed after the password timeout period, which can be adjusted on the
Password Setup Screen, has expired.
Counter Settings Screen
The Counter Settings screen contains all the timer settings, count settings
and speed settings used to control the operation of the counter. Pressing a
button on this screen will display a numeric keypad that allows the operator
to change the setting value. Enter the value and press the ENT button to
accept the value. If entered incorrectly, press the CLR button, then reenter
the value. The LEDs on these buttons indicate whether or not the function is
turned on. See Figure 3-4.
Figure 3-4
Belt Speed: The Belt Speed button displays the current belt speed. To change
the Belt Speed, press the Belt Speed button and change the value using the
numeric keypad. The minimum and maximum values for each parameter are
indicated in white to the right of the numeric pad. Use the numeric pad to
enter a new value for the Belt Speed and press the ENT button. The Belt Speed
will change only after the next cycle operation begins.
Note: Values below the minimum value or above the maximum value will not be
accepted when the ENT button is pressed. Press the CLR button and enter a new
value that is acceptable.
Note: Overcounts may occur if parts continue to travel through the optical
frame after the belt stops. If parts on the belt continue to move after the
belt stops, the Belt Speed may need decreased.
Bowl Fast / Slow: The Bowl Fast and Bowl Slow buttons display the current fast
bowl speed. The bowl speed changes immediately after pressing ENT on the
numeric keypad, if the value has been changed. Two speeds are provided in
order to increase production and accuracy. The fast speed is used to reach the
final count quickly, and the slow speed is used for accuracy.
Note: Overcounts may occur if the bowl is feeding parts onto the belt too
closely, causing the optical frame to count two parts as only one. Slow the
fast and/or slow bowl speeds down to avoid overcounts.
Over Count Setting: The Over Count Setting is provided to stop the system if
an Over Count condition exists. To enable this feature, press the Over Count
button and use the numeric keypad to set the Over Count to one or higher. To
disable this feature, set the Over Count setting to zero. If set to one, the
cycle operation will stop and a message will appear on the screen, indicating
an Over Count condition (an Over Count of one or higher). To continue
operation, touch anywhere on the screen.
21
Final Count Setting: Press the Final Count button to set the Final Count value
to the desired count. Once the Final Count is reached, the cycle operation
will stop and await a signal to drop the parts.
Slow Count Setting: Press the Slow Count button to set the Slow Count to a
value that causes the bowl (and/or belt) to slow down when the counter
approaches the Final Count. The Slow Count setting helps prevent extra parts
from being counted. For small value counts (such as 1 through 5), the Slow
Count value may be set to the Final Count value since the bowl will be running
more slowly for smaller counts. To determine the Slow Count setting, first set
the value to 80% of the Final Count and adjust after testing.
Note: The difference between the Final Count and Slow Count settings must be
greater than the number of parts on the V-track belt at any one time.
Door Delay: Door Delay is the amount of the time the accumulator door remains
open before it closes. This allows the batch quantity of parts to fully escape
the accumulator before it closes.
Cont. Cycle Setting: The Continuous Cycle timer provides a delay time if the
counter is running in a standalone mode and automatic mode. The operator can
keep pace with the counter and, if needed, increase the Continuous Cycle
counter to slow down the operation.
Max Count: Press the Max Count button to adjust the maximum number of parts
that can be in the accumulator. Adjusting this number will help avoid
overfilling the accumulator. To disable this function, set the Max Count to
zero.
Accumulator ON/OFF: This indicator displays the status (ON’ orOFF’) of the
Accumulator, which can be activated from the Counter Factory Settings Screen.
Hopper Settings
The Hopper Settings screen allows for adjustment of the hopper settings,
including speed and on and off time. See Figure 3-5.
Hopper Speed: Press this button to enter a numeric value and adjust the speed
of the hopper that distributes parts to the vibratory bowl.
Note: The higher the number, the faster the hopper will vibrate to distribute
the parts to the bowl more quickly.
Figure 3-5
On Time: The amount of time the hopper will continue distributing parts to the
bowl after the proximity sensors tell the hopper it is full.
Off Time: The amount of time the hopper will remain resting until it is turned
on again.
22
Level Sensor: The Level Sensor toggle button controls the style of sensor that is used in operation. Typically, the Level Sensor should remain on DARK and should not be adjusted during operation.
There are indicators on this screen that illuminate to help troubleshoot the hopper:
· Bowl Run: Indicates whether the bowl is running. · Level Input: If this is
on, input is low. If this is off, input is high. · Hopper Run: Indicates
whether or not the hopper is feeding into the bowl.
Eye Test / Eye Settings
The Eye Test must be performed prior to full operation in order to obtain the
minimum length and maximum length of the part to be counted when passing
through the eye. The purpose of this is to a) ensure scrap pieces of parts or
materials are not counted as a part and b) ensure two parts passing through
the eye are not counted as one part. See Figure 3-6.
To perform an Eye Test, turn off the vibratory
bowl while leaving the belt running. Neither
the bowl nor the hopper can run while an Eye Test is performed. Press the Eye Test button
Figure 3-6
from the Eye Settings screen (See Figure 3-7) and follow the instructions. Randomly drop parts onto the
belt. Parts must be loaded manually. The counter will begin counting and measuring the parts. The test
will display the last nine counts only and will take the lowest and highest lengths of the tested parts.
These will be your minimum and maximum sizes, which are displayed at the bottom of the Counter Eye
Test screen after each test.
Minimum Size: The minimum size is used to filter scrap. For example, if, through testing, the minimum value detected was 0.2, setting the value to 0.1 would cause parts that are 0.1 or less to not be counted. If the minimum setting is too close to the actual minimum test value, however, some parts may not be counted, causing overcounts. Setting the minimum setting to zero will cause all parts to be counted.
Maximum Size: The maximum size is used to count parts connected or parts falling through the eye together (overlapped) as two parts. For example, if, when testing the parts length, the maximum value was determined to be 0.5, you could set the maximum setting to 0.8. Then, if two parts overlapped through the eye with a size of 0.9, they would be counted as two parts. However, if you set the maximum setting too close to the maximum value, one part may be counted as two, causing undercounts. To disable this function, set the maximum value to zero.
Figure 3-7
23
Note: Min and Max are NOT the same as Min Size and Max Size. Min and Max
display the results of each eye test. Min is the smallest size recorded during
the test and Max is the largest size recorded during the test. The values for
Min Size and Max Size are determined through a formula based on the results of
the eye test, and they function as part of the eye settings and affect
operation. Min Size is 80% of the Min measurement. Max Size is 160% of the Max
measurement.
If Min and Max do not change after performing multiple eye tests, press the
Accept button to accept those settings, which will then be displayed on the
Eye Settings screen. Pressing the Reset button will zero the Current Samples
values. To manually enter minimum and maximum settings, press the green Min
Size and Max Size buttons on the Eye Settings screen. Enter a value into the
numeric keypad and press ENT.
For more detailed information on eye testing and eye settings, refer to the
Detailed Setup Procedure in the Appendix.
Time Out: Time Out is located on the Eye Test screen, and it displays the
period of time the eye does not take a measurement while reading a part. Time
Out is automatically calculated. It is 80% of the Max measurement.
Count To: The Count To button allows the operator to adjust the Time Out
setting. Press the Count To button and enter a value on the numeric keypad to
change the Time Out setting.
Final and Current on the Eye Settings screen display the count. Final is the
preset number. Current is the count the machine is processing.
Pressing the large green button that displays either Small Parts Function or
Filter Count Function will display a Counting Change Mode message. Press the
message to return to the Factory Settings Screen. The button will have changed
to either Small Parts Function or Filter Count Function, depending on what the
button displayed initially. Press Filter Count Function to change the counting
mode from Filter Count Function to Small Parts Function. This will zero the
Eye Settings. Press Small Parts Function to change the counting mode from
Small Parts Function to Filter Count Function. This will start an Eye Test
that will set minimum and maximum size.
Setting the counting mode to Small Parts Function allows the PLC to detect
small inputs from the eye faster and more reliably. The Small Parts Function
causes the eye to read every part, regardless of the size, as one part. For
example, if a toothpick and a pencil pass through the eye, the toothpick would
be counted as one part and the pencil would be counted as one part, despite
their different lengths and widths.
Setting the counting mode to Filter Count Function allows the PLC to ignore
parts that are below and above the min and max size. These size settings are
measured in seconds and are created by running an eye test. These can also be
set manually or adjusted. When using this setting, parts within the min and
max are counted and parts that lie outside of the range are not counted.
The Slow LED displays when the counter reaches the Slow Count. The Final LED
displays when the counter reaches the Final Count. For example, if the
operator has set the Final Count to 50, meaning the counter will stop
operation once 50 parts are counted, and the Slow Count to 40, meaning the
bowl and/or belt will slow down for the last ten counts to ensure counting
accuracy, the Slow LED will display when the count reaches 40 and the Final
LED will display when the count reaches 50.
24
ON / OFF button: The ON / OFF button on the Eye Settings screen controls the
Double Count function, a function that automatically adds a count if the eye’s
measurement exceeds the maximum size. The Double Count can only be used when
in Filter Count Function.
For example, if the maximum size is set to 0.04 and the eye reads a part as
0.05, the 0.05 measurement would be counted as two parts. To disable the
Double Count function, toggle the ON / OFF button to OFF. This will set the
Double Count setting to zero. If the Double Count function is turned off, an
overcount condition may occur if parts are not properly separating when coming
off the belt. To enable the Double Count function, toggle the ON / OFF button
to ON. If the Double Count function is turned on, an undercount condition may
occur if the maximum setting is too low and one part is counted as two parts.
A message will be displayed after the ON / OFF button is pressed to inform the
operator of the change in function.
If the eye is blocked for an extended period of time (parts jam), the machine
will stop and a message will be displayed.
Counters Screen
The Ultra-Count is equipped with a start-up counter that allows for system
startup (numerous counters), a batch counter that counts the machine cycles, a
parts counter that counts the individual parts and a maintenance counter that
cannot be reset. The Counters screen allows for adjustment of the Start-up
Counter and the Preset Count. See Figure 3-8.
Start-up Counter: When in a system
comprised of numerous parts counters feeding
a compartment or bucket conveyor, the counter can be set up to begin operations when a
Figure 3-8
preset number of “empty” compartments or buckets go by each counter “station.” The counter will “wait”
a predetermined number of cycles before it starts running. A station number can be set so that the counter
will begin operation only after that preset number of input signals is received. Press the green button
below Start-up and use the numeric keypad to set the station number. When the Start-up function is ON,
the auxiliary communication is suspended until the Start-up count has been reached. When the count is
reached, normal auxiliary communications resume and the Start-up function will automatically switch
OFF. Additionally, when the Start-up function is first switched ON, the current start-up, counts, functions
and batch values are reset to their respective set values. Pressing the Reset button will reset the Start-up
value.
Preset Count: The number of parts desired in one “batch” or bag. Press the green button under Preset Count and use the numeric keypad to enter a preset value. Press Reset to zero this value. If the Preset Count is set to zero, the LED will turn off, indicating that there is no preset count. If the Preset Count is set to one or higher, the indicator light will turn on, indicating that a preset count has been set.
Total Count: The Cycles total shows how many cycles have occurred since the counter was reset. Press the Reset button to zero this value. The Parts total shows the number of parts that have run through the eye since the counter was reset. Press the Reset button to zero this value.
25
Aux Out: The Aux Out button will display either READY or HOLD (or OFF if there
is no auxiliary equipment). When Aux Out displays READY, the counter is ready
to drop parts. When Aux Out displays HOLD, the counter is still cycling.
Job Save and Recipe Management
From the Main Menu (Figure 3-9) touch
Figure 3-9
Figure 3-10
Figure 3-11
Figure 3-12
Note: There must be a USB Flash Drive / Memory Stick inserted into the machine for the External Memory function to operate. If there is no memory stick inserted, ensure the Job Save is in PLC mode in order to save job recipes. See Figure 3-12.
26
Note: All units with a 7″ Touch Screen should support Recipe Management; a
unit without a Touch Screen will have only PLC Storage.
There are benefits to using either memory option. The PLC Internal option,
referred to as “Job Save”, allows the user to save up to 24 jobs to the PLC
without any extra hardware required. The USB External option has the
additional functionality of Recipe Management, and allows the user to save an
unlimited number of jobs to the USB memory stick as well as performance data.
A file will be automatically created on the memory stick that contains
Recipes, Alarm data, and Production data from the machine. These files can be
viewed when the memory stick is inserted into a PC Please refer to 3.17
“Memory Files and Data Structures” for more information regarding the files
and directory structure
Note: Remove the back cover of the touch screen housing to locate the USB port and insert a memory stick (not included).
Note: These instructions are for saving settings only. Labels are saved using printer software (such as Labelview).
A. Internal Memory (PLC)
The Ultra-Count is equipped with memory storage to save the settings for 96
different parts. A part number can be assigned to each part for easy
reference. See Figure 3-13.
Job Save Function: When all settings have been created and tested, press the Job Save button, located on the Main Menu. A listing of jobs will be shown as follows:
· No.: Each column of the part save/recall screen is numbered and describes a
memory address/order.
· PN: Enter a part number (up to six numbers) for your reference.
Figure 3-13
To save a job to a memory address that has no settings saved, press the field
located to the right of the number (No.). Enter a part number that you will
reference at a later date.
Note: You can also save the settings over a previously saved job, but this
will cause the previous settings to be lost.
Figure 3-14
27
Job Recall Function: To recall a job that has already been saved, press the
field that has your part number displayed (Figure 3-15). Then press the View
button to display the settings. See Figure 3-14. From this screen, you can run
/ load the job by pressing the Load button.
If you attempt to load a job that does not exist, a message will be displayed.
Figure 3-15
B. External Memory (USB)
To save a job to the External Memory:
Select
(as described in the next section: Memory
Files and Data Structures) and exit to Main
Menu. Go to Settings and set the
specifications for your job. Once the job is set,
touch
Job Save screen, see Figure 3-16. Press the
box that reads “Part” which will access a
keypad. In the USB Mode, Jobs can be saved
by either numbers or letters. Enter the name or
Figure 3-16
number you wish to save the job as and press
enter. To enter a note, press the box that says Note, and enter the information using the keypad that is
displayed. Touch
numeric keypad where the operator can enter the number of products that will go into each bag. For
instance, if three items go into the bag before it is sealed, the number 3 can be entered into that field.
When all the information is setup touch
To recall a job from External Memory: Press Job Search from the Main Menu to
access the Job Search Screen. From there either scan (if you have a bar code
reader option) or enter the job name using the keypad, (accessed by pressing
the area under the heading “Current Scan”) and press
28
Figure 3-17
Figure 3-18
Memory Files and Data Structure
While the information related to Bagger/Counter settings may be stored
internally on the PLC or externally on a USB Memory Stick (Flash Drive) is
similar in content, the data structures and methodology are different.
PLC Storage Information regarding the settings for a particular job, such as
Fill Time, Seal Temperature, and Bag Length, are stored in the PLC as data
files of various types. These data types include:
· Integers data type used to store whole numbers · Floating Point data
type used to store decimal numbers · Strings an array used to store
characters These data files are stored in PLC memory, and are accessible to
the Ladder Logic of the PLC Program File. See Figure 3-19.
PLC Memory
The Program File contains the system files, user-created instructions (Ladder
Logic), and sub-routines.
Figure 3-19
29
Contains the information required for operation of the Program File, organized by data type.
External Storage The Memory Stick contains several types of data from the
machine. The Bagger/Counter Settings are stored, similar to the information in
PLC Storage. There are also files for the additional functionality of Recipe
Management, and information on Alarm and Production Data. To access this
information, plug in the memory stick from the bagger or counter to your PC
and open the DAT0000 folder. There will be a list of folders that have been
set up by the touch screen program, (see Figure 3-20). The two folders that
contain the Recipe Data and Production Data are called Recipe and Sample.
Inside DAT000 Folder:
Figure 3-20
BITMAP, CARD, DISP, FONT, HDCOPY, JPEG, LADDER, MEMO, MSG, OPELOG, SCRN, SNAP,
SRAM, WAV, and WEBSERV are folders used by the touch screen software and will
appear empty on the PC. This is because the files are hidden to prevent
damage, and therefore do not show up in Windows Explorer. Do not store any
information in these files as it will alter the program and will not function
when the memory stick is re-inserted in the touch screen. Note: These hidden
files include types used to store images, fonts, functions, database
information, and macros that are used to control the Touch Screen, so it is
important to not accidentally over-write these files. RECIPE–contains
REC0000.CSV which is a list of all the jobs / recipes saved to the USB memory
stick as a .CSV (Comma-Separated-Values) file. This file type is essentially
just a table of data in plain text where the values are separated by commas,
as in the following example:
Item 1, Item 2, Item 3
30
This type of file (CSV) can be opened as an Excel spreadsheet.
To access this information, open the
Note: If you wish to change the data listed in the spreadsheet, “Save As” a
different name, then make your changes, keeping the original intact.
Note: Some files may not be used depending on the options of the machine. For
instance, if your machine does not have a scale, you will not have any
information recorded in the SMP0003.CSV file. SMP0003.CSV Cycle Log records
every Scale production cycle. (See Figure 3-21). The data recorded in each
column is as follows:
A. Date & Time–Records when the occurrence happened B. Production#–the number
assigned to the production run. C. Part#–the number to identify each part. D.
Part weight–the weight of the part E. Target quantity–records the quantity
that is to go in the bag. F. Actual quantity–records the actual quantity that
is in the bag. G. FULL/PARTIAL mode–records if the kit is in Full or Partial
mode. Note: There is a Backup Period every day at midnight. A new backup file
with full day data is created; old data is then cleared from the buffer to
start the new day. Previous records are not erased. Cycle count and timing
start over from Zero every day.
Figure 3-21
SMP0004.CSV Production Time Log records the length of time the machine has
been in production and gives details on the length of time the machine has
been in the modes listed below. (See Figure 3-22) The data recorded in each
column is as follows:
32
A. Date & Time–records the date and time the mode was switched. B. Power On
time–the length of time the power has been turned on. C. Auxiliary mode
time–the length of time the machine has been in Aux Mode. D. Auto mode
time–the length of time the machine has been in Auto Mode. E. Manual mode
time–the length of time the machine has been in Manual Mode. F. Stop time–the
length of time the machine has been in Stop Mode. G. Setup time–the length of
time the machine has been in Setup Mode. H. Power On total cycles–the number
of cycles made since the machine has been powered
on. I. Auxiliary mode cycles–the number of cycles made since the machine has
been in
Auxiliary Mode. J. Auto cycles–the number of cycles made since the machine has
been in Auto Mode. K. Manual cycles–the number of cycles made since the
machine has been in Manual Mode. L. Setup cycles–the number of cycles made
since the machine has been in Setup Mode.
Figure 3-22
SMP0005.CSV, SMP0006.CSV and SPM0007.CSV Event Logs records every device
fault event during operation, (See Figure 3-23). The data recorded in each
column is as follows:
A. Fault description–the name of the error that has occurred. B. Occurrence
time–the initial time the occurrence happened. C. Clear time–the time the
error was acknowledged / reset. Note: Dashes (—) or asterisks
(***) in a field on the spreadsheet indicate no data was recorded for that
error.
Note: There is a Backup Period on 1st of the month at midnight a new backup
file with the event list is created. Then old data is cleared from the buffer
to start new month.
33
Figure 3-23
Manual Backup: Data is recorded and saved automatically as described above. It
can also be done manually using buttons on Log screens:
· ‘Write’ – overwrite (save) the same file · ‘Backup’ – create new file (save
as) · ‘Record’ – add a new record · ‘Reset’ – clear buffer.
Production Screen
Press the Production Graph button on the Main Menu screen to display the
Counter Production screen, which features a graph that shows the batches per
minute performed over an eight-hour period. See Figure 3-24.
Press the left arrow key to scroll back one hour at a time to review past production. Press the right arrow key to check more recent production information.
Press the Reset button once to reset the
production time and twice to reset the graph. Press the Prod Parts/m button to display the
Figure 3-24
Counter Production Chart. This chart displays the number of bags per minute produced. Pressing the
Prod Part/m button returns the operator to the Counter Production screen.
34
Counter Auxiliary
Options Screen
The Ultra-Count is equipped to operate within a system for fully automatic
parts counting. From the Counter Auxiliary Options screen, the type of
communications that match the equipment you are running the counter with can
be set up. See Figure 3-25.
Option 1 or 2: This option is set at the factory to match the bagger, conveyor or CW scale the counter is connected to.
Continuous Cycle Timer: This causes a delay between cycles if the counter is running in standalone mode or during setup.
Figure 3-25
Aux Time Delay: This timer delays the output of the counter to allow the parts to settle once they have been dropped from the accumulating funnel of the counter. Increase this delay timer if the bagger is cycling before the parts are in the bag, for instance.
Aux Out: When Aux Out displays READY, the counter is prepared to drop parts to the auxiliary equipment. When Aux Out displays HOLD, the counter is still cycling. When Aux Out displays OFF, no auxiliary equipment is present.
Aux In: When Aux In displays READY, the auxiliary equipment (i.e. bagger) is prepared to operate. When Aux In displays HOLD, the auxiliary equipment is still cycling. Aux In displays OFF when no auxiliary equipment is present.
Technical Assistance
Screen
The Technical Assistance screen provides for operator information, factory
settings adjustments, function testing and troubleshooting. The screen is
protected from access with a Level 1 password. The password is set by default
(from the factory) to 1001. This code can and should be changed when the
system is put into operation. See Figure 3-26.
The Technical Assistance screen displays the
Figure 3-26
current touch screen (TS) program version and
programmable logic controller (PLC) versions. This information should be shared with an APPI service
technician when requesting technical assistance. Contact information is also provided to receive technical
service via phone or mail.
35
Password Setup Screen
The pass code function, as described in the beginning of this chapter, is
provided to safeguard the settings from changes by unauthorized operators. See
Figure 3-27.
If this function is ON, the operator has a certain amount of time to make
settings changes. After this set amount of time elapses, the Operation screen
will be displayed and the operator will have to enter a pass code.
PW Timeout: To adjust the amount of time the operator has to make settings
adjustments, press the PW Timeout button, and enter a value using the numeric
keypad.
The Level 1 pass code is always on, which protects only the settings that can
be accessed from the Technical Assistance Screen. See Figure 3-28. However,
the Level 2 pass code, if enabled, safeguards the remainder of the equipment
settings.
PLC I/O Status Screen
The Ultra-Count inputs and outputs are illustrated on the I/O Status Screens.
These screens assist in the troubleshooting of the equipment and assist APPI
service technicians in helping operators or maintenance personnel. See Figure
3-29. During the cycle operation of the UltraCount, the input and output
conditions are illustrated with LEDs. To determine what each LED indicates,
press the row of LEDs. A short description is provided.
Figure 3-27 Figure 3-28 Figure 3-29
36
Counter APPI Factory Screen
The settings on this screen are additional settings that should only be set by
qualified technicians or by the factory. See Figure 3-30.
Figure 3-30
Counter Factory Settings
The Counter Factory Settings Screen displays additional counter settings that
should only be set by qualified technicians or by the factory. See Figure
3-31.
Belt Time Out: Toggle this button to the ON position to run the Belt Off setting. This will turn the belt off after a specified number of seconds that the eye does not detect any parts passing through it. This setting can be adjusted by pressing the Belt Off button and entering a value into the numeric keypad.
Figure 3-31
Alarm History: Toggle this button to the ON position to monitor the frequency of warning signals.
Small Parts Count: Displays the number of parts processed when the counter is set to Small Parts Function.
Filter Count: Displays the number of parts processed when the counter is set to Filter Count Function.
Job Save: If the toggle button reads “PLC” the machine will save all jobs internally on the PLC. If the button reads “USB” all jobs will be saved externally to a USB memory stick.
Accumulator Mode: Allows for the selection of “Closed” or “Open” modes. In
Closed Accumulator mode, the Final Count will be reached with the accumulator
doors closed. In Open Accumulator mode,
the Final Count will be reached with the doors open, and the doors will close
as soon as the Final Count
has been reached. If the accumulator button displays Closed Mode, pressing the
Closed Mode button will change the accumulator mode from “Closed” to “Open”,
and the button will then display Open Mode. If the Accumulator button displays
“Open Mode”, pressing the “Open Mode” button will change the accumulator mode
from “Open” to “Closed”, and the button will then display “Closed Mode”.
37
Accumulator ON/OFF: Turns Accumulator ON’ orOFF’. If the Accumulator is
turned off, the belt will run parts directly into the bag, and will stop when
the final count is reached. The belt will restart when the next bag is in
position.
Counter Operation Mode
Pressing the Alarms button on the Main Menu screen takes the operator to the
Counter Operation Mode screen, which displays the time and frequency of a
particular operation. Alarm Status and Alarm Data can also be viewed from this
screen. See Figure 3-32.
The Alarm Status window will give the status of a particular warning signal. The Alarm Data screens keep track of how long and how often a particular warning message has been signaled.
Figure 3-32
Machine Info
This screen provides information about the machine, such as the model number
and the serial number. See Figure 3-33.
Information Screens
The Ultra-Count program provides for many informational screens that display
descriptions of functions or screens. See Figure 3-34 through Figure 3-38 for
examples of messages that indicate the status of the counter. Some screens
provide functional messages that describe errors or the status of equipment,
and some provide instructions for operators to follow to bring the unit back
online.
To reset a message screen, clear the condition first (if required) and then
touch the screen.
Figure 3-33
Figure 3-34
38
Figure 3-35
Figure 3-36
Figure 3-37
Figure 3-38
39
Chapter 4:
Adjustments, Maintenance, Troubleshooting
Bowl Discharge Position Skivers Drop Gate Level Switch Bowl Drive Erratic
Feeding of the Bowl Dead Spots in the Bowl Adjustment of the Coil Gap Spring
“Tuning” Belt Tracking Accumulator Funnel Adjustment Optical Frame Pot
Settings Setting the Vibra-Drive Potentiometer Height Adjustment
Troubleshooting Checklist for Ultra-Count Systems Troubleshooting: Base / Bowl
Drive Unit Troubleshooting Checklist (Conveyor Feed Problems) PLC IO Listing
40
Bowl Discharge Position
Position the bowl so that it feeds onto the center of the belt drive and as
close to the belt as possible. Loosen the bowl by loosening the bolts that
hold the base drive to the bottom ring of the bowl and turn the bowl to the
desired position. A clamp collar holds the V-track belt in position. Loosen
the clamp collar to turn, raise or lower the V-track assembly.
Note: It may be necessary to adjust the feet on the bowl drive to accomplish
proper bowl position. On some models, the V-track conveyor assembly can be
positioned without moving the bowl for proper feeding of parts from the bowl
to the conveyor.
Skivers
Adjust skivers so that parts flow in a consistent, steady, inline pace.
Skivers are designed to orient the part to assist with parts separation. Use
the skivers to brush off components stacked on top of other components. Use
skivers to decrease the volume of parts on a track by pushing the product off
the track and back into the bowl.
Drop Gate
The drop gate should be opened just far enough to allow a single part to pass
over without dropping off. A second drop gate is provided to decrease the
volume of parts to the final drop gate. Loosen the drop gate slide screws and
push the gate in or out.
Level Switch/Sensor
Vibratory bowls should be consistently fed with parts for best operation.
Bowls that are full run slower than empty bowls, and inconsistent levels may
cause incorrect counts. To maintain a consistent level of parts in the bowl,
hoppers or a conveyor should be used to feed the bowl. A parts Level Switch or
Level Sensor is used to detect the level of parts in the bowl and to cause
hoppers, conveyor, alarms, and stack lights to turn on. Hoppers and conveyors
can feed more material into the bowls as they become low.
Note: Hoppers only feed when the bowl is in a fast feed mode.
Several types of Level Switches or Level Sensors may be supplied, depending
upon the bowl size and types of parts. If parts are not heavy enough to cause
a leveling arm to move, then other types of sensors must be used, which
include ultrasonic sensors or photo optic sensors.
Leveling Arm / Switch Adjustment: With a leveling arm, the switch should turn
ON when the “paddle” portion of the arm is approximately ½” from the floor of
the bowl and should remain ON from zero to ½”. Adjust the arm by either
resetting the position of the arm on the shaft or by turning an adjustment
screw located on the side of the switch.
Some switches also have an LED that, when ON, indicates that the switch is ON.
The LED should come ON when the paddle is approximately ½” above the surface
of the bowl. Turn the adjustment screw counterclockwise to raise the paddle
before the LED comes on. In other words, turn the screw counterclockwise to
allow more parts to feed in the bowl before the hopper turns off.
41
If by turning the screw, the LED does not turn ON at a different paddle
position, then the leveling arm must be repositioned. Loosen the screw that
holds the shaft of the leveling arm in position and turn the shaft coming out
of the sensor block until the LED remains ON when the paddle is touching the
bowl up to ½” above the bowl. Retighten the screw.
Ultrasonic or Photo Optic: The sensor will be setup and calibrated from the
factory according to customer specifications. This sensor is on when the
equipment is on and is always operating when the equipment is operating. The
sensor will need to be adjusted over time due to the vibrations from the
Vibra-Drive system and when the material being bagged changes.
When detecting a specular (mirror-like) object, such as aluminum or other
reflective surface, or an object having a glossy surface or coating, the
object may not be seen by the sensor due to a small change in angle or
wrinkles on the objects surface. When a specular object is present below the
sensor, tilting the sensor slightly upwards will increase its ability to see
the object. See Figure 4 – 1.
Figure 4 – 1
Adjusting Procedure: Use the diagrams for adjusting the sensor. (See Figure 4
– 2 and Figure 4 – 3). Turning adjustments screws with excessive force will
cause damage to the adjuster. The sensor operates in an industrial environment
and is likely to accumulate dust on the sensory lens. Be sure to clean the
lens when performing other maintaince to the system.
Note: Overfilling the bowl will prevent the parts from moving smoothly or may
cause the parts to stop flowing.
Figure 4 – 2
42
A green LED is located on a box to the rear of the hopper (or on the conveyor
if a hopper conveyor system is supplied). The LED indicates that the hopper
should be feeding. The hopper will only feed if the bowl is in fast feed mode.
If the leveling switch turns ON and the bowl is in fast mode, the hopper will
start to vibrate. The hopper will vibrate for at least five seconds even if
the switch turned on for only a moment. To increase the vibration level of the
hopper, turn the potentiometer clockwise. To decrease the vibration level of
the hopper, turn the potentiometer counterclockwise.
Figure 4 – 3
43
Bowl Drive
The drive has several adjustment points to allow for high production parts
flow. However, do not advance the drive setting (fast or slow speed) to a
higher feed rate than necessary as excessive vibration may decrease the useful
output of the feeder. Do not mount external tracks or extensions to the feeder
bowl without the manufacturer’s approval. Such additions may create dead spots
in the feeder bowl or may harm the power unit or decrease the feed rate.
Additionally, maintain a gap between the feeder bowl discharge and the V-track
so the bowl is not vibrating against components of the V-track or housing
components.
Erratic Feeding of the Bowl
When erratic feeding is observed, ensure that the feeder bowl is securely
mounted on the drive unit. All mounting screws must be tight. Check the bowl
track to be sure there are no physical obstructions causing interruptions in
the feed, such as parts stuck under wipers or parts wedged together and jammed
between tracks. Check also to see if coatings on the parts, such as mold
release compound, oil, dirt, or some other foreign matter, may have made the
track slippery or sticky, thus preventing the parts from properly driving up
the track. A broken spring in any of the spring banks will cause the feed rate
to diminish or stop. A broken spring screw will have the same effect. Removal
and assembly of each spring bank, one at a time, will permit examination of
springs. A cracked spring will make a dead sound when struck against a hard
surface. A broken screw will be self-evident. All drive units are tuned before
shipping. Tuning is accomplished by adding springs to the unit until a
resonance is established between the driving coils and the mass being driven.
A broken spring, or a broken or loose spring screw, destroys this resonance
and the feeding ability diminishes or stops.
Dead Spots in the Bowl
Dead spots may occur in either the fabricated or cast bowls and are usually
the result of an unequal distribution of mass in the bowl construction caused
by tooling. They may also occur when one section of the bowl is not securely
fastened to the drive unit, when a weld has broken or when part of the bowl
track has loosened. This may be determined by removing the bowl from the drive
unit and rotating it 90° from its original position. If the dead spot remains
at the same point in the bowl, it can be assumed that the problem is in the
bowl. Dead spots, caused by an unequal mass distribution in the bowl, are
generally corrected by adding weight to a selected spot or spots on the outer
periphery of the bowl, usually 180° from the dead spot.
Adjustment of the Coil Gap
The XL Series drive units are equipped with two adjustable coils mounted on
the base casting and two fixed armatures mounted on the top plate. The air gap
between each armature and coil is adjusted at the factory and under normal
operation should not require any further adjustment. Should a continuous
metallic rapping sound develop during feeder operation or when the power
control knob is turned to maximum, it will indicate that the armature is
striking the coil and damage to the feeder unit will occur if not corrected.
To adjust the coil for a larger air gap, first back off the two ½” socket head
cap screws whose centers form a vertical line in the four-screw pattern, an
approximately 1/8″ turn. Then tighten the two ½” socket head cap screws whose
centers form a horizontal line in the four-screw pattern, an approximately
1/8″ turn. This will draw the coil back away from the armature about an
additional 0.009″ and should eliminate the metallic rapping sound. Care should
be taken to loosen both vertical screws the same amount and tighten the two
horizontal screws the same amount so that the surface of the coil remains
parallel to the surface of the armature. Normal air gaps run from 0.025″ to
0.040″. Some units could have as little as a 0.015″ gap or as much as a 0.075″
gap. To adjust the coil for less air gap, back off the two horizontal screws
and tighten the two vertical screws, the same amount each. Make sure all four
screws are tight after making the adjustment.
44
Spring “Tuning”
The XL Series drive units employ four spring banks for tuning the drive unit.
These spring banks usually contain the same number and thickness of springs;
however, sometimes due to bowl construction or bowl tooling, it is necessary
to vary the number and thickness of the springs in each bank. When springs of
different thickness are used in a spring bank, the thickest spring should
always be placed so that it is next to the base and top plate castings and the
thinner springs toward the screw heads. A smaller diameter and lighter weight
bowl will require less or thinner springs than a larger diameter and heavier
bowl.
The XL Series drive units are powered by alternating 60-cycle current, which
energizes the coil at a rate of 120 pulses per second. These pulses cause the
coils to magnetize and draw the armature toward them, thereby flexing the
springs. The combined spring force must be sufficient to return the armatures
to their original or neutral position at the same rate of 120 reactions per
second. When this happens, the unit is properly tuned for 60-cycle current. If
the power source is 50-cycle, as used in some European countries, the drive
unit must be re-tuned by reducing the number or thickness of springs. If the
power source is other than 110/120 Volt, then different coils must be used
(240-volt AC coils are available from stock).
Belt Tracking
The V-track belt is constructed of two small conveyors at 90 degrees to each
other. Each belt has a drive roller and a tracking roller. The tracking roller
is located at the discharge end of the belt where all adjustment points are
located.
To adjust the belt tracking, first remove the accumulator/eye assembly. Bolts
holding the accumulator to the V-track assembly are located beneath the belt,
to the rear of the accumulating funnel.
With the accumulator removed, the adjustment screw and slot can be seen to
adjust the position / alignment of the rollers.
Adjust the roller up or down to correct the belt alignment. When properly
adjusted there should be a very small (1/16″) gap between the belts as they
are running.
Accumulator Funnel Adjustment
The accumulator funnel mounts to the V-track conveyor assembly. The optical
frame slides into the accumulator funnel. The optical frame must be positioned
at the end of the V-track so that parts discharging from the belt completely
pass through the photo array. If parts only partially pass through the eye
(beneath the eye), miscounts can occur. Larger / longer parts may require the
optical frame to be positioned further away from the end of the conveyor to
avoid parts blocking the photo array when hanging from a stopped belt. To
adjust the accumulator funnel, loosen the bolts positioned beneath and to the
rear of the accumulator.
Optical Frame Pot Settings
The optical frame (four-sided frame) has four potentiometers that control the
functionality of the outputs to the PLC. Factory settings provide for a static
output (output is ON while the detection area is blocked or parts are
present). Additionally, the sensitivity is set to the highest possible
setting.
Factory settings are described while holding the frame so that you are looking
at the pots with the cable extending out from the eye, to the LEFT of the
pots.
You will see that there are four pots with covers over the two center pots.
Remove these covers to change settings (Figure 4 – 4).
45
POT 1 (left most pot): OUTPUT DURATION: Set at the factory to the most CCW
(counter-clockwise) position. This pot is used only when the optical frame is
set to Dynamic functionality. Since the optical frame is set at the factory to
Static (not Dynamic), you only need to adjust this pot if you have changed POT
2 to the Dynamic position. Again, POT 2 is set at the factory to the most CCW
position. If you do reset POT 2 to Dynamic, use a small flat head screw driver
and turn the pot clockwise to increase the output duration. POT 2 (second from
the left): STATIC / DYNAMIC: Set at the factory to STATIC, the most CW
position. Static functionality means that when the eye is blocked, the output
is ON. To test the eye, you can place your finger in the eye field and you
will notice that the LED at the base of the cable is ON continually while the
eye is blocked. To change to the DYNAMIC functionality, turn the pot using a
small flathead screwdriver to the most CCW position. Dynamic functionality
means that the output to the PLC will be a fixed time, regardless of the
length of the part. If you change to the DYNAMIC functionality, you may need
to change the output duration (POT1) to achieve the correct counting function.
Be careful not to set the duration too long or two parts may be passing
through the optical frame while only one output is given to the PLC. POT3
(third from the left): DARK/LIGHT mode: Set at factory to DARK, the most CCW
position. Do not reset this POT or the output to the PLC will not be in the
proper sequence. POT4 (right most pot): SENSITIVITY adjustment: Set at the
factory to the most sensitive position, which is the most CW position. The eye
is set to the most sensitive setting so that even the smallest parts can be
detected in the field. To cause the detection to be less sensitive (to not see
scrap, for instance), turn the pot CCW until the scrap is not detected (may
not work properly for parts that are too large).
Figure 4 – 4
Note: Illustration of factory settings/pots.
46
Setting the Vibra-Drive Potentiometer
These instructions may be used to set the POTs on each of the Vibra-Drives
inside the Module, the Bowl and Hopper (if your machine includes a Hopper).
Each Vibra-Drive should be labeled accordingly. If your machine is not
labeled, please call Service at 1(800)754-4403 for assistance in identifying
your Drives.
The Vibra-Drive has three potentiometers (POTs) that control the speed at
which the bowl or hopper vibrates; Maximum Output, Minimum Output, and Soft-
Start. These potentiometers are set at the factory but may require adjustment
over time. A small flat-head screw-driver should be used for these setting
changes once the electrical panel has been removed. Power must be disconnected
by turning the yellow and red lockout switch located on the module to OFF. To
remove the cover of the module, unscrew the four socket head screws located on
the corners. The POTs will need to be adjusted with the power on. While the
cover is removed, use a lockout power key to turn on power to the module.
CAUTION: These settings should be performed by qualified maintenance personnel
since power may need to be applied when making setting adjustments. Screw-
driver must be long enough to extend outside of the electrical panel.
Additionally, the screwdriver handle should be produced from non-conductive
materials and no contact should be made with any metal portion of the screw-
driver.
Note: Adjusting the Pots will cause vibration changes, so touch screen
settings will also need to be changed. All recipes will need to be recalled
and for each “job”, settings will need to be changed and saved.
Note: POT adjustments are conditional to the type of product and the fullness in the bowl.
Initial Adjustment Empty Bowl Adjustment: First, to make all initial POT adjustments, ensure the bowl is empty and the machine is in <Stop / Manual / Setup>. Adjust the POTs in order of MAXIMUM OUTPUT (POT 3), then MINIMUM OUTPUT (POT 2), and finally, SOFT-START (POT 1). Each POT is labeled on the driver board (See Figure 4 – 5).
POT 3 (furthest right pot): MAXIMUM OUTPUT: Set Maximum Output first. This pot is set to control the maximum level of vibration when the main control dial is turned up all the way. The Pulse Setting is set at the factory 120 pulse setting (Pulses per Minute).
Figure 4 – 5
47
Steps: 1. While in
Final Adjustment: The power will now be ON and the machine will be ready to
adjust the touch screen settings. Adjust the touch screen settings with
product in the bowl. Place product in the bowl so it reaches 1″ to 1 ½” above
the bottom of the bowl and access the Settings Screen to set the Bowl Fast and
Bowl Slow speeds. Setting the Bowl Fast speed:
1. Put the machine in <Start / Manual / Setup>. 2. Adjust the Fast bowl speed
on the Settings Screen of the touch screen to the proper settings to
achieve proper counts or weights, a typical setting is between 50 and 70.
Note: Speed will vary depending on product weight and fullness of the bowl. 3.
Save the Settings to a Recipe / Job Save. 4. Put the machine in
Note: The Hopper Speed will be located in the Hopper Setting Screen if you are
working on a UCS-2400 (section 3.15 in the manual) or a UC-2400 / UC-3000
(section 3.13). For the US9000 the Hopper Speed can be found on the Bagger
Settings Screen, section 3.10 in the manual.
Height Adjustment
The UC-2400, when sold individually, mounts to a single column telescoping
stand. The height can be adjusted, but due to the weight of the unit, a lift
truck or other similar device must be used. Position the forks of the lift
truck beneath the mounting plate of the bowl. Slightly lift the forks and tilt
back the forks so that the weight is off the stand and so that if the unit
slides, it will slide toward the lift truck. Loosen the screws from the side
with two others holding the unit in position. Raise or lower the unit with the
lift truck and tighten the screws. The UC-3000 mounts to a double column
telescoping stand but still requires the same adjustment procedure as the
UC-2400.
CAUTION: Extreme safety must be used due to the weight of the unit to avoid
severe injury. Only trained and licensed lift truck operators should perform
these tasks.
49
Troubleshooting Checklist for Ultra-Count Systems
PROBLEM POSSIBLE CAUSE
CORRECTIVE ACTION
1. Power off
1. Check main/individual power switch;
Plug in power cord
Touch screen does 2. Main fuse blown
not display
3. Breaker tripped
4. IOP cables loose/damaged
2. Replace fuse #1 on the module 3. Check breaker in main power box. 4. Check cables behind IOP cover
5. Contrast out of adjustment
5. Adjust screen contrast
1. Power off
1. Check main/individual power switch;
Plug in power cord
No main power LED
2. Main fuse blown 3. Breaker tripped 4. IOP cables loose/damaged
2. Replace fuse #1 on the module 3. Check breaker in main power box 4. Check cables behind IOP cover
5. LED burned out
5. Replacement not possible
No run LED
1. IOP in program mode
1. Press “System” key then “F1” key
2. LED burned out
2. Replacement not possible
Accumulating
1. No/low air pressure
1. Check main and individual regulators;
funnel not
Check for kinked air hoses
functioning
2. Leaking hoses or air cylinders
correctly or not at 3. Accumulator in “open” mode
2. Check all air hoses and cylinders 3. Check mode on “Operation Screen”
all
4. “Batch toggle switch” is “off”
4. Check switch on “Operation Screen”
5. Belt drive cable loose/damaged
5. Check belt drive cable
Part sensor (eye) 1. Part dust in eye
1. Wipe inside of eye
not functioning
2. Eye cables loose/damaged
2. Check eye cables
1. Bowl overfilled
1. Empty bowl
Bowl not driving well or not at all
2. “Bowl Fast” and/or “Bowl Slow” values set too low
3. Bowl drive cable loose/damaged
2. Check values on “Settings Screen” 3. Check bowl drive cable
1. “Hopper toggle switch” is “off” 2. Counter running in “Bowl Slow” mode
1. Check switch on “Operation Screen” 2. Check the “Slow indicator” on
“Operation Screen”- adjust “Slow
Hopper does not
Count” on “Counter Settings Screen”
run
3. Part level in bowl too high
3. Move parts so level arm can touch
the bottom of the bowl
4. Hopper cable loose/damaged
4. Check hopper cable
5. Level sensor cable loose/damaged
5. Check level sensor cable
6. Hopper fuse blown
6. Replace fuse #2 on the module
1. Gate on hopper raised too high
1. Lower gate
2. Ramp on front of hopper sloped
2. Raise ramp
Bowl overfills
down too far
3. Hopper running after bowl is full
3. Adjust part level sensor
4. Level sensor cable damaged
4. Check level sensor cable
1. Part(s) jamming belt
1. Check belt housing for loose parts
Belt does not
2. “Belt Speed” set too low
2. Check “Belt Speed” value on
move
“Counter Settings Screen”
3. Belt drive cable loose/damaged
3. Check belt drive cable
50
Troubleshooting: Base / Bowl Drive Unit
Should your bowl stop completely (i.e., no vibration or humming sound at all),
the reason will be an electrical failure. Carefully check the following to be
certain that:
1. The power cord is plugged into a live outlet. For troubleshooting
purposes, unplug the power during remaining electrical checks.
2. The fuse on the controller is good. 3. The auxiliary contacts inside the
controller are properly shorted or jumpered together. 4. The input and output
power connections inside the controller are good and sound. 5. The coil wires
are properly connected to the controller output wires. 6. The coils themselves
show continuity with the controller disconnected. If there is still no output,
then the controller should be returned to the factory. If the failure is not
our responsibility, APPI will advise you of repair costs.
If your bowl feeder does not stop feeding completely, or starts feeding slowly
or erratically (i.e., fast then slow), and you can hear the unit humming, then
the problem is mechanical. Carefully check the following to be certain that:
1. Parts are not jammed under track wipers or wedged between tracks. 2. The
feeder bowl mounting screws are tight. 3. The rubber mounting feet are not cut
and are securely tightened to the feeder base. 4. The rubber mounting feet are
not tight in the foot locators (if used). 5. The armatures and coils have an
air gap between them. 6. There is no loose tooling in the feeder bowl. 7.
Parts are not slipping or sticking on the track due to oily air contamination,
mold release
compound from parts, etc. 8. There are no broken welds, especially track
welds, on the fabricated bowls. A broken track weld
could cause a dead spot, erratic feeding, or a metallic rattle. 9. Other
equipment is not restricting the bowl from vibrating freely. 10. There are no
cracked or broken springs in any of the spring banks. 11. There are no broken
spring mounting screws.
If, after checking all of the above, the feeder still does not feed properly,
then get a 13/16″ box wrench and check both the upper and the lower spring
mounting screws for tightness. If the screws seem excessively tight, try
loosening each set of four screws about 1/8″of a turn each. (The amplitude
control knob should be set at the maximum feed position while doing this.)
If the screws are loose, the feed rate will slow down to a point where feeding
will stop entirely. Progressively tighten the four upper spring screws, and
then tighten the four lower screws.
As you tighten the screws, the feed rate should immediately pick up. You will
know by the sound of the feeder when you have attained the proper torque on
the screws. Attempt to tighten all screws to the same torque.
51
Troubleshooting Checklist (Conveyor Feed Problems)
PROBLEM
Conveyor feeds more than once
POSSIBLE CAUSE
1. Conveyor is in “continuous” mode instead of “auto”
2. Conveyor’s part sensors are dirty or out of alignment
3. Cleat sensor under the conveyor is dirty, has been moved or needs adjusted
4. Cable connecting the counters, conveyor, bagger loose/damaged
5. Cleat sensor cable damaged 6. Part sensor cables loose/damaged
1. Conveyor is unplugged 2. Conveyor switch on back of panel is off 3. Main
power switch is off 4. Cable connecting the counters, conveyor,
bagger loose/damaged 5. Conveyor motor breaker tripped
Conveyor does not feed
6. Damaged conveyor motor relay 7. Conveyor not in “run” mode
8. Bagger not ready
9. A counter has auxiliary “on” and is not in “run” mode
10. Parts jam at an individual counter
11. Counter eye problem
CORRECTIVE ACTION
1. Change mode on the conveyor control panel
2. Wipe the part sensors/check that the eyes are in line
3. Wipe sensor, tilt sensor bracket, turn sensitivity adjustment
4. Check the cables connecting the counters, conveyor, and bagger
5. Check cleat sensor cable 6. Check conveyor’s part sensor cables 1. Plug in
conveyor 2. Switch conveyor on 3. Throw main power switch 4. Check the cables
connecting the
counters, conveyor, and bagger 5. Check main power box for tripped
breaker 6. Check main power box for bad relay 7. Change mode on the conveyor
control
panel 8. Confirm bagger is in auto mode, is not
paused, has a properly threaded supply of bags, has a supply of heat transfer
film, etc. 9. Check all counters. Auxiliary should be “on” if counter is being
run. 10. Check all counters for “Part Flow
Interruption Screen” 11. Check for a counter that cannot “see”
parts – wipe the inside of the eye
52
PLC IO Listing
The Main PLC IO (Inputs and Outputs) Listing is provided to assist in
troubleshooting the UC-2400.
Card:
Address
Description
Normal State
Inputs
Main PLC
X 0 Part counting eye
off
Main PLC
X 1 Not Used – Reserved
Main PLC
X 2 Not Used – Reserved
Main PLC
X 3 Auxiliary In
off
Main PLC
X 4 Level sensor
select
Main PLC
X 5 Not Used – Available
Main PLC
X 6 BeltDrive 1 Alarm
on
Main PLC
X 7 BeltDrive 2 Alarm
on
Main PLC
X 8 Not Used – Available
Main PLC
X 9 Not Used – Available
Main PLC
X A Not Used – Available
Main PLC
X B Not Used – Available
Main PLC
X C Not Used – Available
Main PLC
X D Not Used – Available
Main PLC
X E E-STOP
off
Main PLC
X F Not Used – Available
Main PLC
X 10 Not Used – Not Available
Main PLC
X 11 Not Used – Not Available
Main PLC
X 12 Not Used – Not Available
Main PLC
X 13 Not Used – Not Available
Main PLC
X 14 Not Used – Not Available
Main PLC
X 15 Not Used – Not Available
Main PLC
X 16 Not Used – Not Available
Main PLC
X 17 Not Used – Not Available
Main PLC
X 18 Not Used – Not Available
Main PLC
X 19 Not Used – Not Available
Main PLC
X 1A Not Used – Not Available
Main PLC
X 1B Not Used – Not Available
Main PLC
X 1C Not Used – Not Available
Main PLC
X 1D Not Used – Not Available
Main PLC
X 1E Not Used – Not Available
Main PLC
X 1F Not Used – Not Available
Main PLC Main PLC
53
Outputs
Y
0 Not Used – Available
Y
1 Not Used – Available
Main PLC Main PLC Main PLC Main PLC Main PLC Main PLC Main PLC Main PLC Main
PLC Main PLC Main PLC Main PLC Main PLC Main PLC Main PLC Main PLC Main PLC
Main PLC Main PLC Main PLC Main PLC Main PLC Main PLC Main PLC Main PLC Main
PLC Main PLC Main PLC Main PLC Main PLC
PLC Exp1 PLC Exp1 PLC Exp1 PLC Exp1
Y
2 Auxiliary Out
Y
3 Hopper drive
Y
4 Bowl drive
Y
5 Accumulator door
Y
6 Not Used – Available
Y
7 Belt drive
Y
8 Stack Light Green
Y
9 Stack Light Red
Y
A Belt drive Alarm reset
Y
B Stack Light Yellow
Y
C Not Used – Available
Y
D Not Used – Available
Y
E Not Used – Available
Y
F Not Used – Available
Y
10 Not Used – Not Available
Y
11 Not Used – Not Available
Y
12 Not Used – Not Available
Y
13 Not Used – Not Available
Y
14 Not Used – Not Available
Y
15 Not Used – Not Available
Y
16 Not Used – Not Available
Y
17 Not Used – Not Available
Y
18 Not Used – Not Available
Y
19 Not Used – Not Available
Y
1A Not Used – Not Available
Y
1B Not Used – Not Available
Y
1C Not Used – Not Available
Y
1D Not Used – Not Available
Y
1E Not Used – Not Available
Y
1F Not Used – Not Available
WY
2_1 Bowl Speed Analog Output (V0)
WY
3_1 Belt Speed Analog Output (V1)
WY
2_2 Hopper Speed Analog Output (V2)
WY
3_2 Not Used – Available (V3)
54
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55
Chapter 5:
Parts and Drawings
Ultra-Count 2400 Electronics Assembly Cable Assemblies V-Track Assembly, Long
Touch Screen Assembly Accumulator Funnel Assembly Optical Eye Assembly Supply
Hopper Assembly CCW Vibratory Bowl Assembly Prox Sensor Assembly Ultra-Count
Stand Ultra-Count 3000 System Layout UC-3000 Stand Assembly UC-3000 Supply
Hopper Assembly Thirty-Inch Counter Clockwise Bowl Assembly Upper V-Track
Assembly 110 VAC Electrical Drawing FPG I/O Electrical Drawing Analog Control
Electrical Drawing DB9 Electrical Drawing DB25 Electrical Drawing Aux
Interface Electrical Drawing
56
Ultra-Count 2400
PN: T-UC2400
ITEM NO.
1 2 3 4 5 6 7 8 9 10
QTY
1 1 1 1 1 1 1 1 1 1
PART NO
TA-UC1000-DC TA-UC2000-DC TA-UC2400-LDC TA-UC3000 TA-UC5000 TA-UC5560 TA-
UC6500 TA-UC7000 TA-UC8000 TA-UCSTAND
DESCRIPTION
ELECTRONICS ASSEMBLY CABLE ASSEMBLIES V-TRACK ASSEMBLY, LONG TOUCH SCREEN
ASSEMBLY ACCUMULATOR FUNNEL ASSEMBLY OPTICAL EYE ASSEMBLY SUPPLY HOPPER
ASSEMBLY CCW VIBRATORY BOWL ASSEMBLY PROX SENSOR ASSEMBLY ULTRA-COUNT STAND
SECTION NO. 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11
PAGE NO. 59 61 63 71 75 77 79 81 83 84
Note 1: If you purchased the UC-2400 with the Short V-Track configuration, your part numbers are the same as those listed above, with the following exception: Item 3 is replaced with TA-UC2400-SDC.
Note 2: If you purchased the UC-2400 with the Clockwise Bowl configuration, your part numbers are the same as those listed above, with the following exception: Item 8 is replaced with TA-UC7000-1.
57
See Note 1
See Note 2
Standard UC-2400 Model
ULTRA COUNT 2400 SYSTEM LAYOUT PN: T-UC2400
Optional Clockwise Bowl Model
58
ITEM NO.
1 2 3 4 5 6 7 8 9 10
11
12 13
14
15 16 17 18 19
20
21 22 23 24
25
26 27 28 29 30 31 32 33
Electronics Assembly
PN: TA-UC1000-DC
QTY.
PART NO
DESCRIPTION
1 TP-MM1-0001
ELECTRONICS BACK PANEL
1 TP-MM1-0002
ELECTRONICS PANEL
1 TP-MM1-0003
BACK COVER
1 TP-MM1-0004
FRONT COVER
2 TP-MM1-0005
STAND-OFF
1 TP-205108
EMI FILTER, CORCOM
1 TP-219455-1
AUXILIARY RELAY
2 TP-224001
PCB, SUPPLY HOPPER CONTROLLER
2 TP-112240
POWER CORD STRAIN RELIEF
1 TP-212410
AC OUTLET
1 TP-212248
CONNECTOR, MULTIPOLE RECTANGULAR
1 TP-207216, TP-207344
FUSE HOLDER & FUSE
1 TP-212160
5 POS MINI DIM
3 TP-212247 1 TP-212167
CONNECTOR, MULTIPOLE RECTANGULAR
6 PIN FEMALE
1 TP-TP-212229
7 PIN AMPHENOL MALE
2 TP-212333
3 PIN FEMALE AMPHENOL
1 TP-215005
SWITCH
1 TP-215004 4 TP-110766 1 TP-T10MM1006
SWITCH KNOB 1 INCH DIA. RUBBER FOOT – 1/4-20 x .375 STUD OVERLAY FOR UC-2400
1 TP-220515
PLC ANALOG
1 TP-213426(US), 213427(NON- US) 24 VOLT POWER SUPPLY
1 TP-218020
1
TP- 220511 (TP-2141411 & TP220513)
2 TP-501173-3
DIN RAIL PLC, FPG-C32T2H GREY DC MOTOR DRIVE
4 TP-214275
3/4″ LONG 6-32 STANDOFF
2 TP-218021
DIN RAIL
4 TP-214285
STAND-OFF 1-1/2″ LONG 6-32
6 TP-208141
SMALL TERMINAL BLOCK
13 TP-208142
LARGE TERMINAL BLOCK
1 TP-215116
RELAY SOCKET
1 TP-215115
AUX RELAY
59
ELECTRONICS ASSEMBLY
60
PN: TA-UC1000-DC
ITEM NO.
1 2 3 4 5 6
Cable Assemblies
PN: TA-UC2000-DC
QTY
1 1 1 1 1 1
PART NO
TA-UC2020 TA-UC2011 TA-UC2030 TA-UC2040 TA-UC2061 TA-UC2070
DESCRIPTION
POWER CABLE EYE CABLE AUX IN / OUT CABLE HOPPER CABLE DC DRIVE V-TRACK CABLE
BOWL DRIVE CABLE
61
CABLE ASSEMBLIES
62
PN : TA-UC2000-DC
V-Track Assembly, Long
PN: TA-UC2400-LDC
ITEM NO.
1 2 3 4 5
QTY
1 1 1 1 1
PART NO
TA-UC2400-LDC1 TA-UC2400-DC2 TP-T10MA8022 TP-503103 TP-503104
DESCRIPTION
LONG BELT GUIDE ASSEMBLY BELT DRIVE HOUSING ASSEMBLY CCW CASE CONVEYOR BELT
CONVEYOR BELT
Note: If you purchased the UC-2400 or UC-30000 with the Short V-Track
configuration, your part numbers for the V-track assembly are the same as
those listed above, with the following exceptions: Item 1 is replaced with TA-
UC2400-SDC1, Item 4 is replaced with TP-503105, and Item 5 is replaced with
TP-503106.
Note: If you purchased the UC-2400 with the Clockwise Bowl configuration, your
part numbers for the V-track assembly are the same as those listed above, with
the following exception: Item 3 is replaced with TP-T10MA8033.
63
V-TRACK ASSEMBLY, LONG
64
PN: TA-UC2400-LDC
ITEM NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A. Long Belt Guide Assembly
PN: TA-UC2400-LDC1
QTY.
1 1 1 1 2 1 1 1 1 1 1 2 2 2 4
PART NO
TP-T10MA8011 TP-T10MA8014 TP-T10MA8012RH TP-T10MA8012LH TP-T10MA8013 TP-
T10MA8018LH TP-T10MA8017LH TP-T10MA8018RH TP-T10MA8017RH TP-T10MA8023 TP-
T10MA8024 TP-T10MA8025 TP-T10MA8015 TP-T10MA8016 TP-504104
DESCRIPTION
CONVEYOR PLATE ANGLE MOUNT ROLLER BLOCK ROLLER BLOCK IDLER ROLLER UPPER GUARD
LOWER GUARD UPPER GUARD LOWER GUARD BELT SUPPORT ANGLE BELT SUPPORT FLAT BELT
SUPPORT BLOCK ADJUSTER ROLLER SHAFT BEARING
Note: If you purchased the UC-2400 or UC-3000 with the Short V-Track configuration, your part numbers for the Belt Guide Assembly are the same as those listed above, with the following exceptions: Item 1 is replaced with TP- T10MA8011-S, Item 6 is replaced with TP-T10MA8018LHS, Item 7 is replaced with TP-T10MA8017LHS, Item 8 is replaced with TP-T10MA8018RHS, Item 9 is replaced with TP-T10MA8017RHS, Item 10 is replaced with TP-T10MA8023-S, and Item 11 is replaced with TP-T10MA8024-S.
65
LONG BELT GUIDE ASSEMBLY
66
PN: TA-UC2400-LDC1
ITEM NO.
1 2 3 4 5 6 7 8 9 10 11 12
B. Belt Drive Housing Assembly
PN: TA-UC2400-DC2
QTY
1 1 2 1 1 1 1 1 1 2 2 2
PART NO
TP-T10MA8007 TP-T10MA8008 TP-T10MA8009 TP-T10MA8010 TP-T10MA8019 TP-T10MA8020
TP-402175 TP-402255 TP-401277 TP-404263 TP-108124 TA-UC2400-DC3
DESCRIPTION
FRAME BLOCK TIE PLATE TIE ROD SPRING CUP VERTICAL SUPPORT ROD SUPPORT COLUMN
BRACKET VALVE ELBOW, 1/4″ TUBE x #10-32 MUFFLER COMPRESSION SPRING BELT DRIVE
ASSEMBLY
67
BELT DRIVE HOUSING ASSEMBLY
68
PN: TA-UC2400-DC2
ITEM NO.
1 2 3 4 5 6 7 8 9 10 11 12 13
C. Belt Drive Assembly
PN: TA-UC2400-DC3
QTY
1 1 1 1 1 2 1 2 1 1 1 1 3
PART NO
TP-T10MA8002 TP-T10MA8003 TP-T10MA8004 TP-T10MA8005-1 TP-T10MA8006 TP-504115
TP-107343 TP-504133 TP-T10MA8026 TP-501173 TP-T10MA8031DC TP-503102 TP-308398
DESCRIPTION
SLIDE BLOCK STAND-OFF MOTOR BRACKET DRIVEN ROLLER SHAFT DRIVEN ROLLER BALL
BEARING THRUST BEARING CAM FOLLOWER BELT DRIVE PULLEY DC MOTOR MOTOR PULLEY
DRIVE BELT 1/8 SQ. INCH KEYSTOCK
69
BELT DRIVE ASSEMBLY
70
PN: TA-UC2400-DC3
Touch Screen Assembly
PN: TA-UC3000
ITEM NO.
1 2 3 4 5 6
QTY.
1 2 2 2 2 2
PART NO
TP-T10MA0214 TA-T10240-IOP TP-103070 TP-102144 TP-102157 TP-101114
DESCRIPTION
IOP FRAME SEVEN INCH TOUCH SCREEN SCREW, SHCS 3/8-16 x 2-1/4 WASHER, 3/8 FLAT
WASHER, 3/8 LOCK NUT, 3/8-16 HEX
Note: The UC-2400 / UC-3000 can be equipped with either one touch screen or with two touch screens. The quantities listed above apply to the two Touch Screen model. If your UC-2400 / UC-3000 only has one touch screen, halve the above quantities, except for Item 1, the IOP frame.
Note: For multiple Ultra-Count Systems, each module may have its own mounting bracket.
71
TOUCH SCREEN ASSEMBLY
72
PN: TA-UC3000
A. Touch Screen Subassembly PN: TA-T10240
ITEM NO.
1 2 3 4 5 6 7 8 9 10
QTY.
1 1 1 1 4 4 1 1 1 1
PART NO
TP-T1MD00040 TP-T1MD00040-1 TP-111131 TP-111125-2 PART OF TP-220363 PART OF
TP-220363 TP-220364 TP-IOPBOLT-L TP-102147 TP-101125
DESCRIPTION
TOUCH SCREEN HOUSING BACK COVER BALL GRIP POSITIONING ARM SOCKET ARM SCREEN
STUD SCREEN CLIP TOUCH SCREEN MODIFIED BOLT WASHER, 5/8 FLAT NUT, 1/2-13 HEX
JAM
73
TOUCH SCREEN SUBASSEMBLY
74
PN: TA-T10240
ITEM NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Accumulator Funnel Assembly
PN: TA-UC5000
QTY
1 1 1 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1
PART NO
TP-T10MA9001 TP-T10MA9002 TP-T10MA9004 TP-T10MA9005 TP-T10MA9010 TP-T10MA9013
TP-T10MA9012 TP-T10MA9014 TP-T10MA9015 TP-T10MA9006 TP-T10MA9017
TP-T10MA9003
TP-T10MA9011 TP-T10MA9016 TP-109164 TP-111102 TP-109162 TP-403269 TP-403267
TP-403268 SEE ASSEMBLY
DESCRIPTION
FRONT PANEL LEFT SIDE PANEL REAR PANEL TOP BRACE DEFLECTOR BLOCK CYLINDER BASE
CYLINDER MOUNT MOUNTING ANGLE TOP BRACE SPACER TOP COVER COVER HINGE RIGHT
SIDE PANEL DEFLECTOR BLOCK BOTTOM PALM GRIP 3-ARM PHENOLIC KNOB CLAMP COLLAR
CLAMPING KNOB 1/4-20 TRUNNION BRACKETS CYLINDER 3/4″ X 2 PISTON ROD CLEVIS
GATE ASSEMBLY
75
ACCUMULATING FUNNEL ASSEMBLY
76
PN: TA-UC5000
ITEM NO 1
2
3
Optical Eye Assembly
PN: TA-UC5560
QTY
1 1 2
PART NO
TP-UC5560 TP-UC5561 TP-T10MA5562
DESCRIPTION
EYE EYE CABLE EYE MOUNTING BRACKET
77
OPTICAL EYE ASSEMBLY
78
PN: TA-UC5560
Supply Hopper Assembly
PN: TA-UC6500
ITEM NO 1 2 3 4 5 6 7 8 9 10 11 12
QTY
1 1 1 1 2 1 2 8 1 2 2 1
PART NO
TP-T10MA6504 TP-T10MA6503 TP-T10MA6508 TP-T10MA6501 TP-T10MA6506 TP-T10MA6505
TP-T10MA6502 TP-120150 TP-224005 + (4) TP-110761 TP-109105 TP-109104 TA-UC8000
DESCRIPTION
VIBRATOR SHELF VERTICAL SUPPORT TUBE VERTICAL SUPPORT TUBE HOPPER HOPPER GATE
PAN VIBRATORY TRAY ANGLE MOUNT U-BOLT 1/4-20 VIBRATORY DRIVE & MOUNTS NYLON
PAD THUMB SCREW KNOB PROXY SENSOR ASSEMBLY
79
SUPPLY HOPPER ASSEMBLY
80
PN: TA-UC6500
CCW Vibratory Bowl Assembly
PN: TA-UC7000
ITEM NO 1 2 3
QTY
1 1 1
PART NO
TP-720122 TP-T10MA0043 TP-109161
DESCRIPTION
24″ BOWL AND DRIVE CCW SKIVER CLAMPING KNOB
Note: If you purchased the UC-2400 with the Clockwise Bowl Configuration, Item 1 is replaced with TP-720122-1 and Item 2 is replaced with TP-T10MA0043-1. Item 3 is the same for both configurations.
81
CCW VIBRATORY BOWL ASSEMBLY
82
PN: TA-UC7000
ITEM NO
1
2
Prox Sensor Assembly
PN: TA-UC8000
QTY
1 1
PART NO
TP-216144 TP-T10MA8035
DESCRIPTION
PROXIMITY SENSOR LEVEL SENSOR ADJUST PLATE
83
Ultra-Count Stand
PN: TA-UCSTAND
ITEM NO 1 2 3 4 5 6 7
QTY
1 1 4 4 1 1 1
PART NO.
TP-T10MA0202 TP-T10MA8032 TP-110764 TP-T10MA0204 TP-T10MA0203 TP-T10MA8027 TP-
T10MA8021
DESCRIPTION
BASE WELD SUPPORT SHELF LEVELING MOUNT LOWER COLUMN UPPER COLUMN BASE FOR 24″
BOWL WELDMENT SUPPORT ANGLE
Note: Stand is optional on multiple UC-2400 systems.
84
85
Ultra-Count 3000 System Layout
PN: T-UC3000
ITEM NO.
1 2 3 4 5 6 7 8
PART NO
TA-UC3STAND TA-UC1000-DC TA-UC2000-DC TA-UC2400, UC5000 UC-3000 TA-UC5560 TA-
UC6500-1 TA-UC7030
DESCRIPTION
STAND ASSEMBLY ELECTRONICS ASSEMBLY CABLE ASSEMBLIES V-TRACK & ACCUMULATOR IOP
ASSEMBLY OPTICAL EYE ASSEMBLY SUPPLY HOPPER ASSEMBLY 30″ CCW BOWL ASSEMBLY
QTY.
1 1 1 1 2 1 1 1
Page No.
88 59 61 63, 75 71 77 79 92
Note 1: If you purchased the UC-3000 with the Short V-Track configuration, your part numbers are the same as those listed above, with the following exception: Item 4 V-Track is replaced with TAUC2400-SDC.
ULTRA-COUNT STAND
86
PN: T-UCSTAND
87
ITEM NO.
1 2 3 4 5 6 7 8 9 10 11 12 13
UC-3000 Stand Assembly
PN: TA-UC3Stand
QTY.
4 1 1 1 1 2 1 1 1 1 1 1 1
PART NO
TP-110740 TP-T10MA3001 TP-T10MA3002 TP-T10MA8032 TP-T10MA3004 TP-T10MA3003 TP-
T10MA3006 TP-T10MA3008 TP-111215 TP-T10MA3010 TP-T4MA5123 TP-T10MA3007 TP-
T10MA3005
DESCRIPTION
SEISMIC VIBRATION-DAMPING MOUNTS BASE WELDMENT LOWER COLUMN SUPPORT SHELF BOWL
BASE UPPER COLUMN MODULE BRACKET VERTICAL PROX POST JOINING TEE HORIZONTAL
PROX POST CLAMP BLOCK PROX MOUNT TOUCH SCREEN MOUNT
ULTRA-COUNT 3000 SYSTEM LAYOUT
88
PN: TA-UC3000
89
ITEM NO.
1 2 3 4 5 6 7 8 9 10 11 12
UC-3000 Supply Hopper Assembly
PN: TA-UC6500-1
QTY.
1 2 1 1 2 1 1 8 1 2 2 1
PART NO
TP-T10MA6501 TP-T10MA6502 TP-T10MA6504 TP-T10MA6505 TP-T10MA6506 TP-
T10MA6503-30 TP-T10MA6508-30 TP-120150 TP-224005 & (4) TP-110761 TP-109104
TP-109105 TP-T10MA6507
DESCRIPTION
HOPPER ANGLE MOUNT VIBRATOR SHELF PAN VIBRATORY TRAY HOPPER GATE VERTICAL
SUPPORT TUBE VERTICAL SUPPORT TUBE U-BOLT 1/4-20 VIBRATORY DRIVE & MOUNTS
THUMB SCREW KNOB NYLON PAD CLAMP BAR
90 UC-3000 SUPPLY HOPPER ASSEMBLY TA-UC6500-1
91
ITEM NO.
1
2
3
Thirty-Inch Counter Clockwise Bowl Assembly
PN: TA-UC7030
QTY.
1 1 1
PART NO
TP-720123 TP-T10-MA0043-30 TP-109161
DESCRIPTION
30 INCH BOWL & DRIVE SKIVER CLAMPING KNOB
92
Upper V-Track Assembly
PN: TA-UC2400SCD1
ITEM NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
QTY.
1 1 1 1 2 1 1 1 1 1 1 2 2 2 4
PART NO
TP-T10MA8011-S TP-T10MA8014 TP-T10MA8012RH TP-T10MA8012LH TP-T10MA8013 TP-
T10MA8018LHS TP-T10MA8017LHS TP-T10MA8018RHS TP-T10MA8017RHS TP-T10MA8023-S
TP-T10MA8024-S TP-T10MA8025 TP-T10MA8015 TP-T10MA8016 TP-504104
DESCRIPTION
CONVEYOR PLATE ANGLE MOUNT ROLLER BLOCK ROLLER BLOCK IDLER ROLLER UPPER GUARD
LOWER GUARD UPPER GUARD LOWER GUARD BELT SUPPORT ANGLE BELT SUPPORT FLAT BELT
SUPPORT BLOCK ADJUSTER ROLLER SHAFT BEARING
93
94
110 VAC Electrical Drawing
95
FPG I/O Electrical Drawing
96
Analog Control Electrical Drawing
97
DB9 Electrical Drawing
UC24-E7_FP0RDA4
98
DB25 Electrical Drawing
99
Aux Interface Electrical Drawing
100
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101
Appendix
A. Ultra-Count System Detailed Setup Procedure I. Counter Setup II. Procedure
III. Troubleshooting Inaccurate Counts IV. Setup Procedure Summary
102
A. Ultra-Count System Detailed Setup Procedure
The following sections provide detailed, step-by-step instructions on how to
set up the UC-2400 and UC3000, perform parts tests, adjust eye settings, and
troubleshoot inaccurate counts.
C. I. Counter Setup
The setup procedure for the Ultra-Count Parts Counter is a two-part process:
- Bowl Setup and 2) Eye Setup.
Bowl Setup refers to mechanical and touch screen settings that cause parts in the bowl to flow properly. More specifically, these settings and adjustments cause the parts to feed so that one part passes through the eye at a time with a consistent separation of parts. Do not proceed to Eye Setup procedures if parts are jamming or multiple parts are passing through the eye with no or insufficient separation.
Eye Setup refers to touch screen and optical frame pot settings that affect the accuracy of counts. The Eye Test Screen allows for testing to ensure accurate counts. Pot settings on the eye will also affect the accuracy of counts.
Due to the highly technical nature of these procedures, more experienced setup personnel may be required. Bowl and Eye Setup processes require sufficient testing, over a period of time, to ensure that each process is accurate.
D. II. Procedure
Step 1: Ensure proper and consistent level of parts in the bowl. The correct level of parts in the bowl is the level that allows most of the center cone (floor) to be free of parts. Because of the cone shape, parts will feed to walls of the bowl. The Hopper Settings screen provides for hopper timing and vibration levels. The position of the level sensor in the bowl can also be adjusted to cause the proper level of parts in the bowl.
Note: The level of parts must not be at a high level to prevent parts from falling off the slide drawers.
Step 2: Ensure proper parts separation in the bowl. The proper parts flow is the flow that allows only one part to fall on the V-track belt at a time as the parts exit the bowl. Wipers are provided to brush off parts that stack and drawers are provided to reduce the width of the bowl track so that only one line of parts goes around the bowl.
Improperly set wipers can also cause parts to jam. This is a delicate setting that requires a lot of testing to prevent jamming and wiping off of parts. Additionally, vibration levels in the Settings screen can be adjusted (Fast/Slow bowl speed) to cause separation.
Note: You MUST have good parts flow from the bowl before attempting any setup of the counting eye. The parts must be dropping from the discharge of the bowl onto the V-track belt one at a time, every single time, with a minimum 4″ gap on the V-track belt between each part. If this is not done correctly you may experience inaccurate counts. If the parts are overlapping or stacked on top of each other you also may experience inaccurate counts.
Step 3: Ensure the eye is clean. Use a cotton cloth and a mild glass cleaning agent. Spray the cleaning agent on the cotton cloth, not directly on the eye.
103
Step 4: Perform single part testing. Single part testing is used to ensure
that for every single part that passes through the eye, a count of one is
achieved. The single part test is also performed to assist with determining
the Min and Max settings, which are set on the Eye Settings Screen. Most parts
will run fine with a Belt Speed of 99. Any changes to the Belt Speed will
change the readings from the eye and will make it necessary to restart the
testing procedure. Adjust the belt speed to 99 on the Settings screen to
perform this test. Speeds lower than 99 may be required if parts continue to
move after the belt stops. APPI recommends as high a belt speed as possible to
increase the gap between parts. The eye must be set to the most sensitive pot
setting, but output must NOT stay on continually.
From the Main Menu, press the Settings menu button, then the Eye Setting menu
button, then the Eye Test menu button. Press the Start toggle button to start
the belt. At this point, the belt will run, but the bowl will not. When all
parts are off the belt, press the Reset button. Then drop one part onto the
V-track belt while looking at the Eye Test screen. One part must be detected
as one part before dropping any further parts. The Eye Test screen will show
the test results from the last nine parts dropped. Every time a part is placed
on the conveyor, one part must be detected.
Drop one part at a time, but drop them in every possible orientation so the
eye has a chance to see them from every angle. Observe the Min and Max
readings at the bottom center of the screen. Continue to drop parts (one at a
time) onto the V-track belt until you no longer see any change in the Min or
Max readings. If the Min or Max values change, continue to drop one part at a
time, again, until these two values do not change.
Note: While the Eye Test screen shows you the last nine part readings, there
is no limit to the number of parts that can be used while performing the Eye
Test.
Note: The purpose of dropping parts by hand ensures that there is no scrap in
the parts dropped onto the belt. Additionally, dropping one part at a time
ensures that there is proper separation and no overlapping occurs. Overlapping
could produce improper Min / Max results.
If no part is detected, or one part is detected as two inputs, then eye pot
settings must be adjusted. Normally the pot settings do not need to be changed
from MOST SENSITIVE and LEAST DURATION.
Pot Setting Sensitivity: Sometimes one part is counted as two because the
eye is too sensitive. By turning DOWN the sensitivity, the eye may ignore any
leading or trailing smaller parts. The goal is to have the part detected as
one part. You can test for sensitivity of the eye by using an Allen key.
Starting with 1/8″, with the key on the centerline of the field, perpendicular
to the detection field, pass the key the entire length of the eye. At the most
sensitive setting, the output should remain ON the entire time the key is in
the detection field.
Pot Setting Duration: Sometimes a small part sends a very short output to
the counter PLC which may not be detected by the PLC. The duration pot can
increase the length of the output so that the PLC detects in the eye output
every time. However, if the output is too long, a second part may not be
detected causing an overcount.
Step 5: Perform single part testing after eye pot settings adjustments. After
pot settings are adjusted, perform the single part test as described in Step
4. Continue to perform the Single Part Test until you are absolutely sure that
one part dropped onto the belt is always counted as one part. You will notice
that the part length Min / Max values will increase as the duration setting is
increased.
104
Step 6: Perform part gap testing (two parts): A gap test can be performed to
ensure that duration pot setting is optimal (not too long a period of time)
and also determine how close parts can be on the belt to ensure proper
accuracy of counts.
While still on the Eye Test screen, stop the V-track belt, press the Reset
button and place two parts on the stopped belt with a 1/4″ gap between the
parts. Start the belt, and then check to make sure the counter saw exactly two
parts. If the counter saw the two parts as one part, stop the belt and place
the parts further apart. Continue to test, increasing the gap, until the count
results are two. Adjust the Duration Pot to increase or reduce the gap, as
required.
If the duration output is too high, the output will still be ON when the
second part starts to pass through the eye. This will cause overcounts since
the first pulse being sent from the eye to the PLC overlaps the second pulse,
causing it to look like one larger part instead of two smaller parts.
Turn the duration potentiometer down so that a minimal gap between parts is
achieved and both parts are counted.
Note: If Eye Pot settings (Sensitivity or Duration) are changed, Step 4 must
be repeated.
Step 7: Perform gap testing (five parts). Perform the same gap test as
described in Step 6, but this time with five parts. Carefully place them at
the minimum distance determined to ensure the duration setting does not cause
parts to be ignored by having too long an output. Then, start the belt and
ensure that five parts are detected.
Note: As stated in Step 6, the gap test will determine the minimum gap
required between parts to ensure that two parts passing through the eye at the
minimum gap will always be counted as two. APPI recommends that the duration
pot setting be the minimum required, but sufficient so that the PLC can detect
even the shorted inputs from the eye.
Step 8: Adjust Min / Max settings. Min / Max settings are provided to 1)
filter parts and 2) deal with overlapping parts. Access the Eye Settings
screen and adjust the Min / Max settings as required.
The Min setting can be used to filter parts such as scrap. However, if the
good parts are less than 0.5″, then you should not attempt to filter scrap as
the part itself may be seen as scrap and thus not counted, causing an
overcount. If your parts are clean and free from scrap, then the Min value
should be set to zero (0). This will allow all parts to be counted; no
filtering.
The Max setting can be used to count overlapping parts as two instead of one.
However, if your parts are less than 1″, then you should not attempt to count
parts as two as this will cause undercounts. If your parts flow well and do
not overlap, then set the Max setting to the highest value of 9.99 (no adding
of counts).
If you wish to add a count whenever the maximum size is exceeded, toggle the
ON / OFF button on the Eye Settings screen to ON. However, when turned on, the
Double Count function may cause an undercount condition if the maximum setting
is too low and one part is counted as two parts. To disable the Double Count
function, toggle the ON / OFF button to OFF. This will set the Double Count
setting to zero. However, if the Double Count function is turned off, an
overcount condition may occur if parts
References
- Poly Bags, Bagging Machines & Automated Systems - Advanced Poly Packaging
- Poly Bags, Bagging Machines & Automated Systems - Advanced Poly Packaging