A&D AD-4961-2KD-2035 User manual

AD-4961-2KD-2035
CHECKWEIGHER
INSTRUCTION MANUAL
1WMPD4002855

WARNING DEFINITIONS
The warnings described in this manual have the following meanings:
A potentially hazardous situation which, if not avoided, could result in
death or serious injury.
A potentially hazardous situation which, if not avoided, may result in
minor or moderate injury or damage to the instrument.
This symbol indicates caution against electrical shock. Do not touch
the part where the symbol is placed.
This symbol indicates the ground terminal.
This symbol indicates that an operation is prohibited.
Note Information or cautions to use the device correctly.
© 2014 A&D Company, Limited. All rights reserved.
No part of this publication may be reproduced, transmitted, transcribed, or translated into any
language in any form by any means without the written permission of A&D Company, Limited.
The contents of this manual and the specifications of the instrument covered by this manual are
subject to change for improvement without notice.

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Contents
1. Introduction ................................................................................................................................................ 6
1.1. Features .............................................................................................................................................. 6
1.2. Safety Precautions .............................................................................................................................. 7
2. Description of Individual Parts ................................................................................................................... 8
2.1. Whole View ......................................................................................................................................... 8
2.2. Display................................................................................................................................................. 9
2.2.1. Description of individual parts ...................................................................................................... 9
2.2.2. Connecting the USB memory .................................................................................................... 10
2.3. Control Box.........................................................................................................................................11
3. Operating the Screens ............................................................................................................................. 12
3.1. Icons.................................................................................................................................................. 12
3.2. Entering the Numerical Values.......................................................................................................... 12
3.3. Pulldown Selection............................................................................................................................ 13
3.4. Entering the IP Address .................................................................................................................... 13
3.5. Entering the Characters .................................................................................................................... 14
3.6. Entering the Password ...................................................................................................................... 15
4. Basic Operations...................................................................................................................................... 16
4.1. Operation Outline .............................................................................................................................. 16
4.2. Turning the Power ON....................................................................................................................... 17
4.3. Turning the Power OFF..................................................................................................................... 18
4.4. Weighing Operation........................................................................................................................... 19
4.4.1. Changing the weighing value display ........................................................................................ 19
4.4.2. Adjusting zero ............................................................................................................................ 20
4.4.3. Starting / Stopping the weighing operation ................................................................................ 21
4.5. Management Level and User Edition/Login ...................................................................................... 22
4.5.1. Management level...................................................................................................................... 22
4.5.2. Changing the user...................................................................................................................... 23
4.5.3. Registering the user................................................................................................................... 24
4.5.4. Changing the user information...................................................................................................25
4.5.5. Deleting the user........................................................................................................................ 26
4.6. Selecting the Product / Changing the Detect Function Settings ................................................................. 28
4.6.1. Registering the product.............................................................................................................. 28
4.6.2. Setting the target, high limit and lower limit values.................................................................... 30
4.6.3. Setting the product length, processing number and belt speed ................................................ 31
4.6.4. Setting the tare value ................................................................................................................. 32
4.6.5. Setting the digital output (DO).................................................................................................... 33

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4.6.6. Setting the delay and hold time. ................................................................................................34
4.6.7. Changing the product to be weighed ......................................................................................... 36
4.6.8. Measuring the product length ....................................................................................................37
4.6.9. Registering the product image...................................................................................................39
4.6.10. Copying the product settings ..................................................................................................... 40
4.6.11. Deleting the product settings ..................................................................................................... 41
4.7. Summary of Weighing Results.......................................................................................................... 42
4.7.1. Weighing history......................................................................................................................... 42
4.7.2. Histogram................................................................................................................................... 43
4.7.3.
X
control chart ........................................................................................................................ 44
4.7.4.
R
control chart ......................................................................................................................... 46
4.7.5. All summary ............................................................................................................................... 47
4.7.6. OK summary .............................................................................................................................. 48
4.7.7. Number of samples summary .................................................................................................... 49
4.7.8. Number of OK samples summary.............................................................................................. 50
5. Adjustment Operations ............................................................................................................................ 51
5.1. Calibrating the Checkweigher Using a Weight.................................................................................. 51
5.2. Adjusting the Belt Speed ................................................................................................................... 53
5.3. Setting the Date/Time........................................................................................................................ 56
5.4. Setting LAN ....................................................................................................................................... 57
6. Output ...................................................................................................................................................... 58
6.1. Outputting to the USB memory ......................................................................................................... 58
6.1.1. Outputting the weighing history .................................................................................................58
6.1.2. Weighing history output example............................................................................................... 59
6.1.3. Outputting the histogram, control chart, summary results PDF files .................................................... 60
6.2. Outputting to the Printer .................................................................................................................... 61
6.2.1. Outputting to the printer ............................................................................................................. 61
6.2.2. Histogram printing example ....................................................................................................... 62
6.2.3. Control chart printing example ................................................................................................... 63
6.2.4. Summary results printing example............................................................................................. 64
7. External Devices ...................................................................................................................................... 65
7.1. Formatting the USB Memory............................................................................................................. 65
7.2. Connecting a LAN ............................................................................................................................. 67
7.3. Connecting a Printer ......................................................................................................................... 67
7.3.1. LAN connection.......................................................................................................................... 67
7.3.2. USB connection ......................................................................................................................... 67
7.4. Connecting to the Serial Interface..................................................................................................... 68
7.4.1. Setting SWs ............................................................................................................................... 68
7.4.2. Inserting a cable......................................................................................................................... 68

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8. Detailed Description of the Setting Values............................................................................................... 69
8.1. Product Name/Product Code ............................................................................................................ 71
8.1.1. Product name............................................................................................................................. 71
8.1.2. Product code.............................................................................................................................. 71
8.2. Judgment Basis................................................................................................................................. 71
8.2.1. Target value ............................................................................................................................... 71
8.2.2. High limit value........................................................................................................................... 71
8.2.3. Lower limit value ........................................................................................................................ 71
8.2.4. Reject Over ................................................................................................................................ 71
8.2.5. Consecutive fail stop.................................................................................................................. 71
8.2.6. Consecutive fail number ............................................................................................................ 71
8.2.7. Product length............................................................................................................................ 71
8.2.8. Processing number .................................................................................................................... 72
8.2.9. Speed ......................................................................................................................................... 72
8.3. DO Map ............................................................................................................................................. 72
8.3.1. Outputting requirements ............................................................................................................ 72
8.4. DO Behavior...................................................................................................................................... 73
8.4.1. Delay time .................................................................................................................................. 73
8.4.2. Hold time.................................................................................................................................... 73
8.4.3. Polarity ....................................................................................................................................... 73
8.5. Detect Parameter .............................................................................................................................. 73
8.6. Revision............................................................................................................................................. 73
8.6.1. Tare value................................................................................................................................... 73
8.6.2. Auto zero.................................................................................................................................... 74
8.6.3. Auto zero range ......................................................................................................................... 74
8.6.4. Dead zone timer......................................................................................................................... 74
8.6.5. Monitoring timer ......................................................................................................................... 74
8.6.6. Averaging time ........................................................................................................................... 74
8.6.7. Dynamic compensation.............................................................................................................. 74
8.6.8. Dynamic compensation value .................................................................................................... 74
8.7. Statistical ........................................................................................................................................... 75
8.7.1. Number of samples.................................................................................................................... 75
8.7.2. Sample size (Sub samples) .......................................................................................................75
8.7.3.
X
.............................................................................................................................................. 75
8.7.4.
R
............................................................................................................................................... 75
8.7.5. Class width................................................................................................................................. 75
8.8. Weighing Capacity ............................................................................................................................ 75
8.8.1. Weighing capacity ...................................................................................................................... 75
8.8.2. Decimal point position................................................................................................................ 75

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8.8.3. Minimum division ....................................................................................................................... 75
8.8.4. Unit............................................................................................................................................. 75
8.9. Stability Detect................................................................................................................................... 76
8.9.1. Stable mass range ..................................................................................................................... 76
8.9.2. Stable time range ....................................................................................................................... 76
8.10. Zero Revision .................................................................................................................................... 76
8.10.1. Zero adjustment range............................................................................................................... 76
8.10.2. Zero tracking mass range .......................................................................................................... 76
8.10.3. Zero tracking time range ............................................................................................................ 76
8.11. Calibration ......................................................................................................................................... 76
8.11.1. Calibration weight value............................................................................................................. 76
8.11.2. Zero point................................................................................................................................... 76
8.11.3. Span ........................................................................................................................................... 77
8.12. Main Unit ........................................................................................................................................... 77
8.12.1. Weighing conveyor length.......................................................................................................... 77
8.12.2. Curb chattering .......................................................................................................................... 77
8.12.3. Rotation direction ....................................................................................................................... 77
8.12.4. Conveyor mode.......................................................................................................................... 77
8.13. Display............................................................................................................................................... 78
8.13.1. Language ................................................................................................................................... 78
8.13.2. Mass display mode .................................................................................................................... 78
8.13.3. Negative mass value.................................................................................................................. 78
8.13.4. Displaying data selection ........................................................................................................... 78
8.13.5. Standby mode ............................................................................................................................ 78
8.13.6. Brightness .................................................................................................................................. 78
8.13.7. Reading Confirmation dialog...................................................................................................... 78
8.14. Connection ........................................................................................................................................ 79
8.14.1. Serial mode................................................................................................................................ 79
8.14.2. Output mode .............................................................................................................................. 80
8.14.3. Modbus ...................................................................................................................................... 80
8.14.4. Slave address ............................................................................................................................ 80
8.14.5. Baud rate.................................................................................................................................... 80
8.14.6. Parity .......................................................................................................................................... 80
8.14.7. Stop bits ..................................................................................................................................... 80
8.14.8. Data bits ..................................................................................................................................... 80
8.14.9. Flow control................................................................................................................................ 80
8.15. Digital Input (DI) ................................................................................................................................ 81
8.15.1. DI1 to DI8................................................................................................................................... 81
8.15.2. Delay time .................................................................................................................................. 83

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8.15.3. Chattering................................................................................................................................... 83
8.15.4. Polarity ....................................................................................................................................... 83
8.16. External Devices ............................................................................................................................... 83
8.16.1. Monitoring the rejector ............................................................................................................... 83
8.16.2. With metal detector .................................................................................................................... 83
8.16.3. Printer IP address ...................................................................................................................... 83
8.16.4. Printer connection method ......................................................................................................... 83
8.17. Date/Time.......................................................................................................................................... 83
8.17.1. Date............................................................................................................................................ 83
8.17.2. Time ........................................................................................................................................... 83
8.18. LAN ................................................................................................................................................... 84
8.18.1. IP address .................................................................................................................................. 84
8.18.2. Subnet mask .............................................................................................................................. 84
8.18.3. Default gateway ......................................................................................................................... 84
8.19. Speaker ............................................................................................................................................. 84
8.19.1. Volume ....................................................................................................................................... 84
8.19.2. Start/Stop sound......................................................................................................................... 84
8.19.3. Fail judgment sound................................................................................................................... 84
8.20. USB Memory..................................................................................................................................... 84
8.20.1. Operational history..................................................................................................................... 84
8.20.2. Weighing history......................................................................................................................... 84
9. Modbus Communication .......................................................................................................................... 85
9.1. Modbus RTU ..................................................................................................................................... 86
9.2. Modbus TCP ..................................................................................................................................... 86
9.3. Reference Number............................................................................................................................ 87
9.4. Address ............................................................................................................................................. 87
10. General Purpose External Input/Output................................................................................................... 95
10.1. Connection ........................................................................................................................................ 96
10.2. Terminal Arrangement ....................................................................................................................... 97
11. Maintenance............................................................................................................................................. 98
11.1. Checkweigher Errors......................................................................................................................... 98
11.1.1. List of error messages ............................................................................................................... 98
11.2. Storing the System Data ................................................................................................................... 99
11.3. Restoring the System Data ............................................................................................................. 101
11.4. Initializing the System Data............................................................................................................. 102
12. Specifications ......................................................................................................................................... 103
13. External Dimensions .............................................................................................................................. 104

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1. Introduction
1.1. Features
The AD-4961 is a checkweigher developed for checkweighing products.
Display
・ Excellent and easy operability with 7-inch touch sensitive panel
Dustproof・waterproof construction
・ Waterproof construction complying with IP65
Conveyor construction
・ The gear-driven conveyor mechanism allows easy removal of conveyor and maintenance.
Functions
・ The AD-4961 checkweigher divides the products into ten groups and can register a maximum of 100 products for
each group (a total of 1000 products).
・ Product images can be uploaded from USB memory.
・ The user registration function is provided to assign a management level appropriate to each user. This ensures a
safe operation of the system.
・ Serial communication or TCP/IP communication allows communications with Modbus-enabled devices without
using communications program.
External output/input
・ General purpose input, rejector output, alarm output, RS-232C/RS-485 input/output TCP/IP are provided as
standard

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1.2. Safety Precautions
To use the AD-4961 checkweigher safely, read the following precautions before use.
Hazard of rotating object
・ Keep hands and fingers away from the rotating part while the checkweigher is running.
・ If the product accumulates, falls over or spills on the checkweigher, stop the checkweigher immediately, turn the
power off and take necessary actions.
Hazard of electrical shock
・ Be sure to turn the power off before removing the display cover or control box cover for inspection.
・ Keep the power turned off during the inspection.
・ Turn the power on after the installation has been complete.
Precautions for installation
・ Install the checkweigher on a solid surface away from sources of vibration.
・ Install the checkweigher in an area where it is not exposed to direct sunlight.
・ Install the checkweigher in an area where it is not subject to direct flow from the window, electric fan or air
conditioner.
Grounding
・ Be sure to ground the checkweigher to avoid electrical shock, fire or malfunction.
Precautions for use
・ Do not apply shock or excessive external force to the infeed and weighing conveyors.
・ Do not apply a load exceeding the weighing capacity to the weighing conveyor.
・ Do not modify or disassemble the checkweigher. Do not change the parts.
・ Be sure to level the checkweigher.
・ Feed the product to be weighed into the checkweigher at a constant interval.
Cooling the checkweigher
To avoid the checkweigher overheat, be sure to allow enough clearance from other devices.
If the temperature surrounding the checkweigher exceeds the specified operating temperature range, take
necessary measures such as cooling the checkweigher using a fan.

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2. Description of Individual Parts
2.1. Whole View
Fig.1 Whole view
No. Name Description
1 Infeed conveyor Conveys the product to the weighing conveyor.
2 Photosensor/Reflector Detects the product.
3 Weighing conveyor Weighs the product.
4 Display Used to operate the checkweigher and display various screens.
5 Control box Used to control the weighing operation and connect to external devices.
6 Power switch Turns the checkweigher on or off.
7 Rejector (Option) Separates the product according to the weighing results.
8 Rejector conveyor (Option) Conveys the weighed product.
1. Infeed conveyor 3. Weighing conveyor
7. Flipper type rejector
(
O
p
tion
)
8. Rejector conveyor
(Option)
5. Control box 6. Power switch4. Display
2. Photosensor/
Reflector

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2.2. Display
2.2.1. Description of individual parts
Fig.2 Display
No. Name Description
1 Operation panel Displays the Weighing screen and other screens.
Used to change the settings and operate the checkweigher.
2 STOP button Finishes the weighing operation and stops the conveyor.
3 START button Starts the weighing operation and starts the conveyor.
4 USB terminal cover Waterproof cover for the USB terminal.
A USB terminal is installed.
2. STOP button
3. START button
4. USB terminal cover
1. Operation panel

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2.2.2. Connecting the USB memory
With the AD-4961 checkweigher, the USB memory can be used to
register the product images and save the weighing data.
Remove the USB terminal cover on the display by turning the screws.
Insert the USB memory into the USB terminal
When the USB memory is recognized, the USB mark appears on the
upper right side of the screen.
Note:
Only USB memory formatted in FAT32 can be used.
When a USB memory other than FAT32-formatted ones is used, format the memory before use.
When the USB mark does not appear even if the USB memory is inserted, refer to “3.3.2. Connecting the display” of
the assembly guide and check the USB cable connection.
When the USB mark does not appear even if USB cable connection is correct, the file system may not be compatible.
Refer to “7.1. Formatting the USB Memory” and format the USB memory.
Fig.3 USB terminal

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2.3. Control Box
Fig.4 Control box
No. Name Description
1 General purpose output terminal Outputs the weighing results.
2 General purpose input terminal Inputs data from external devices.
3 LAN connector Used to connect a printer or for Modbus communication.
4 Serial interface Used for cyclic printing or for Modbus communication.
1. General purpose
output terminal
2. General purpose
input terminal 3. LAN connector
4. Serial interface

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3. Operating the Screens
This chapter describes basic operations of the screens that appear on the operation panel.
3.1. Icons
This section describes the functions of the icons commonly used in various screens.
Other icons are described as they appear.
Icon Name Description
HOME key Returns to the Weighing screen.
RETURN key Returns to the previous screen.
Returns to the Weighing screen when touched repeatedly.
Left arrow key Shifts the screen to the left when items are too many to display in
one screen.
Right arrow key Shifts the screen to the right when items are too many to display
in one screen.
3.2. Entering the Numerical Values
When a numerical value is required, the numerical value entry dialog box appears.
Fig.5 Numerical value entry dialog box
Name Description
Numerical value field Displays the value entered.
BS key Deletes a numerical value before the cursor.
CLR key Deletes all the numerical values entered.
ESC key Exits from the dialog box without confirming the value entered.
Input
keys
ENT key Confirms the value entered.
The value out of the input range will not be confirmed.
Numerical value field
Input keys

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3.3. Pulldown Selection
When an item selection is required, the pulldown selection dialog box appears.
Fig. 6 Pulldown selection dialog box
1. Select an item and touch the OK button. The selected item is confirmed.
3.4. Entering the IP Address
When an IP address is required for the checkweigher or the printer, the IP Address entry dialog box appears.
Fig.7 IP Address entry dialog box
Name Description
IP address setting item Selects the item to be set and enter numerical values.
BS key Deletes a numerical value before the cursor.
CLR key Deletes all the numerical values entered.
ESC key Exits from the dialog box without confirming the value entered.
Input
keys
ENT key Confirms the value entered as an IP address.
Scroll bar
Item to be selected
IP address setting item
Input keys

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3.5. Entering the Characters
When a character is required, the character entry dialog box appears.
Fig.8 Character entry dialog box
Name Description
MODE key Switches the characters to be input.
BS key Deletes a character before the cursor.
CLR key Deletes all the characters entered.
ESC key Exits from the dialog box without confirming the characters entered.
Input
keys
ENT key Confirms the characters entered.
Input keys
MODE key

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3.6. Entering the Password
When a password is required for a user login or user registration, the Password entry dialog box appears.
Fig.9 Password entry dialog box
Name Description
Password input field The entered password will be indicated by (asterisks).
BS key Deletes a character before the cursor.
CLR key Deletes all the characters entered.
ESC key Exits from the dialog box without confirming the characters entered.
Input
keys
ENT key Confirms the characters entered as the password.
Password input field
Input keys

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4. Basic Operations
This chapter describes the basic operations of the checkweigher.
4.1. Operation Outline
This section outlines the operations. The work flowchart below shows the daily operation. For details on each
operation, refer to the relevant section.
*1: For details about the user registration, refer to “4.5. Management Level and User Edition/Login.”
Before shipment, the user with the user name, Admin, and with the management level of Administrator has been
registered.
Starting up the checkweigher
Refer to “4.2. Turning the Power ON”
Registering a product
Refer to “4.6.1. Registering the product”
Changing the management level (*1)
Refer to “4.5.2. Changing the user”
To register and weigh a new productTo weigh the registered product
Only for the management level o
f
quality manager or above
Weighing a product
Refer to “4.4.3. Starting/Stopping the weighing operation”
Checking the weighing results
Refer to “4.7. Summary of Weighing Results”
Stopping the checkweigher
Refer to “4.3. Turing the Power OFF”
To change the product
Selecting a product
Refer to “4.6.7. Changing the
product to be weighed”

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4.2. Turning the Power ON
1. Turn the power switch 90 degrees clockwise to the ON (I)
position.
2. After the checkweigher startup, the Weighing screen
appears.
Fig.11 Weighing screen (Initial screen)
Fig.10 Power switch

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4.3. Turning the Power OFF
1. Turn the power switch 90 degrees counterclockwise to turn
off and stop the checkweigher.
Note:
For emergency stop, perform the above operation.
In that case, before turning the power ON again, be sure to
resolve the cause of the stop.
Fig.12 Power switch