CBE 230 Guide

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Customer Name
Project#: INPAK SYSTEMS/CERTIS USA
Customer PO#: 0130369-3
Serial#: 140726
Model: 230 Auger Packer/ Certis USA Project
Controller: Avery ZM405
Electrical Controls: 220/440/ other_
Electrical Motors:
Air Requirements:
Special Features: CLASS 2, Division 2, Group 2 Electrical

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CBE 230 AUGER PACKER
Safety - Installation - Operation - Maintenance
_________________________________________________________________

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Table of Contents
FOREWARD......................................................................................................................................................................5
IMPORTANTNOTICE.....................................................................................................................................................5
WARNINGS.......................................................................................................................................................................6
BEFOREOPERATINGEQUIPMENT:...........................................................................................................................6
WHENOPERATINGEQUIPMENT:..............................................................................................................................6
ELECTRICALNOISECONSIDERATIONS..................................................................................................................9
BACKGROUNDNOISE...................................................................................................................................................9
EFFECTSOF ELECTRICALNOISE ..............................................................................................................................9
GROUNDINGRECOMMENDATIONS ......................................................................................................................10
ACPOWERCONSIDERATIONS.................................................................................................................................10
RECOMMENDED 230SPARE PARTS LIST..........................................................................................................................11
CHAPTER 1........................................................................................................................................................................12
RECEIPT ANDINSPECTION .......................................................................................................................................13
ASSEMBLYPROCEDURES.........................................................................................................................................13
SOLENOIDS/PNEUMATICS.......................................................................................................................................14
SUPPLYBINCONNECTIONS......................................................................................................................................14
CHAPTER 2........................................................................................................................................................................15
INSTALLATIONPROCEDURES.................................................................................................................................16
PNEUMATICCONNECTIONS.....................................................................................................................................16
ELECTRICALCONNECTIONS ...................................................................................................................................16
FINALIZATION OF INSTALLATION......................................................................................................................................17
CHAPTER 3........................................................................................................................................................................18
PRINCIPLEOF OPERATION........................................................................................................................................19
SEQUENCEOFOPERATION.......................................................................................................................................19
PHASEONE.....................................................................................................................................................................19
PHASETWO....................................................................................................................................................................20
CHAPTER 4........................................................................................................................................................................21
MAINFRAMEASSEMBLY..........................................................................................................................................22
FRONTPOST ASSEMBLY............................................................................................................................................22
AUGERSCREW DRIVETUBEASSEMBLY.............................................................................................................22
AUGERMOTOR.............................................................................................................................................................22
BELTDRIVEASSEMBLY............................................................................................................................................22
FEEDSYSTEMASSEMBLY ........................................................................................................................................22
AUGERBARRELHOUSING........................................................................................................................................23
AUGERSEALASSEMBLY...........................................................................................................................................23
INLETHOPPERASSEMBLY .......................................................................................................................................24
HOPPERSEALASSEMBLY.........................................................................................................................................24
BELTGUARD ASSEMBLY..........................................................................................................................................24
BAGCLAMPASSEMBLY............................................................................................................................................24
INFLATABLEVALVEBAGSEAL..............................................................................................................................24
BAGCHAIRASSEMBLY..............................................................................................................................................24
DUSTCOLLECTORASSEMBLY................................................................................................................................25
PNEUMATICCONTROLS............................................................................................................................................25
ELECTRICALCONTROL.............................................................................................................................................25
ATTACHMENTSANDOPTIONALFEATURES......................................................................................................26

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CHAPTER 5........................................................................................................................................................................27
PNEUMATICADJUSTMENTS....................................................................................................................................28
MAIN LINE PRESSURE................................................................................................................................................28
BAG SEAL REGULATOR.............................................................................................................................................29
POWERED BAG CHAIR FLOW CONTROLS...........................................................................................................29
AIR PURGE STUFFING BOX PRESSURE.................................................................................................................29
MECHANICALADJUSTMENTS.................................................................................................................................30
AUGER 30
BAG CHAIR POSITION.................................................................................................................................................31
MOTOVIBRATOR BAG CHAIR SETTLER POSITION...........................................................................................31
MAINTENANCE, LUBRICATION, & ADJUSTMENTSTO MOTOVIBRATOR................................................32
INTENSITY OF THE VIBRATOR................................................................................................................................32
NOISE LEVEL.................................................................................................................................................................32
MAINTENANCE.............................................................................................................................................................33
LUBRICATION...............................................................................................................................................................33
CHAPTER 6........................................................................................................................................................................34
NON-INFLUENCINGSPOUT.......................................................................................................................................35
COMPONENTSOF ANON-INFLUENCINGSPOUT...............................................................................................35
CHANGINGTHEISOLATORSEALONAN EXISTINGNON-INFLUENCINGSPOUTASSEMBLY ............36
DETAILEDLAYOUTOF COMPONENTSOFTHEASSEMBLY...........................................................................37
CHAPTER 7........................................................................................................................................................................38
PLC&TIMERADJUSTMENTS...................................................................................................................................39
PLC SCREEN...................................................................................................................................................................39
ADJUSTING THE TIMER.............................................................................................................................................39
PLC ...........................................................................................................................................................................40
INPUT/OUTPUT SCREEN ............................................................................................................................................40
VIBRATORY/DENSIFIER ON DELAY......................................................................................................................40
CHAPTER 8........................................................................................................................................................................41
GENERALMAINTENANCE........................................................................................................................................42
MAINTENACEGUIDE..................................................................................................................................................43
MAINTENANCE TIPS...................................................................................................................................................46
CHAPTER 9........................................................................................................................................................................47
GENERALTROUBLESHOOTING..............................................................................................................................48
TROUBLESHOOTINGGUIDE.....................................................................................................................................48
ILLUSTRATED PARTS...................................................................................................................................................53
CHAPTER 10......................................................................................................................................................................67
465CONTROLLERUSER’S GUIDE..........................................................................ERROR!BOOKMARK NOT DEFINED.
SCHEMATICS & DRAWINGS....................................................................................................................................109
GENERAL ARRANGEMENT DRAWING................................................................................................................112

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FOREWARD
This manual has been prepared to assist you with your Choice Bagging Equipment, Ltd. bag packaging
equipment.
The text contains instructions for installation and operation of your packing equipment, as well as
directions for adjustment and maintenance.
Following the text is the reference section which contains drawings; bills of materials, recommended
spare parts, manufacturers' bulletins and any other information necessary to the successful operation of
your equipment.
If further information or assistance is needed, please contact us at:
Choice Bagging Equipment, Ltd.
4804 North Main Street, Taylor, TX. 76574
Phone: [phone], Fax: [phone]
Parts Email: [e-mail]
Equipment Website: www.choicebagging.com
IMPORTANT NOTICE
READ THIS MANUAL COMPLETELY before installing, starting-up, or operating this equipment. Be
certain all personnel concerned with this machinery are fully alerted to the possible HAZARDS of the
equipment and its utilities (electrical and pneumatic) before any operation is allowed.
Choice Bagging Equipment, Ltd. cannot emphasize enough the importance of good safety practices in the
use of this equipment.
Sound engineering and design practices have been applied to minimize the possibility of accidents.
However, while using equipment of this type, good judgment and extreme caution are necessary on the
part of all personnel.
The purpose of this section is to alert operating and maintenance personnel to the possible dangers of
this type of equipment. Serious injury and/or equipment damage could result from not heeding these
safety precautions.
If any clarification is required -- ASK US.

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WARNINGS
The purpose of this section is to alert operating and maintenance personnel to the possible dangers of
this type of equipment. Serious injury and/or equipment damage could result from not heeding these
safety precautions.
BEFORE OPERATING EQUIPMENT:
Any personnel working directly with or on this equipment should read this manual before proceeding
with equipment use.
Electricians should familiarize themselves with the electrical drawings before initial start-up of
equipment.
Other appropriate operating and maintenance personnel should familiarize themselves with mechanical
layout and general arrangement drawings before setting up and doing start-up on equipment.
Determine location of all emergency switches.
Be sure all guards are in place and observe all warning signs.
Be sure electrical equipment is free of any accumulation of water.
Be sure all personnel are clear of operating mechanisms before connecting air line.
Never start equipment without first checking for loose objects, tools and trash. All persons in the
immediate area of the equipment should be alerted prior to starting.
WHEN OPERATING EQUIPMENT:
Observe extreme caution when switches are turned on. On some equipment, the operation may begin
automatically after a time delay.
Do not open junction boxes or control panels unless you are a qualified electrician. Be sure power is off.
Except when electricians are performing maintenance, electrical enclosures and junction boxes should
always be securely closed.
Stop machine and disconnect power before servicing or repairing. Follow all LOCK OUT / TAG OUT
PROCEDURES when performing maintenance and adjustments on this equipment. A disconnect is
provided that has a place for LOCKOUT.

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Do not attempt to defeat any safety switches. Serious injury could result.
While machine control power is on, do not activate limit switches manually. Serious injury and/or
machine damage could result. Disable machine before attempting any maintenance or manual testing of
components.
Motors will get warm to the touch and should not cause concern for equipment reliability and operation.
A temperature rise is normal per new NEMA specifications.
If additional wire runs are added to any junction box or control panel, wiring practice should be such as
to maintain prevailing electrical hazard classification.
High-pressure air systems are dangerous. Do not service or troubleshoot systems with air supply on. Be
sure to bleed off any trapped air before working on components since it is possible to have high
pressures trapped in airlines and cylinders, etc.
Keep fingers, hands, feet, etc. out of path of pneumatically operated components.
Safety glasses should be worn in equipment area.
Follow the safety regulations for your plant. ALWAYS USE GOOD JUDGEMENT!

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WITHIN THE TEXT OF THIS MANUAL:
"WARNING" indicates possible injury to personnel.
"CAUTION" indicates possible damage to equipment.
"NOTE" is an informational comment.
Before you begin production AND as you continue working daily with the machine, these points should
be observed for continuous service. Service parts such as belts, stuffing box material, bearings, gears, fill
spouts, etc. are available for replacement and stock supplies through Choice Bagging Equipment.

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ELECTRICAL NOISE CONSIDERATIONS
A major consideration in the installation of a successful system is the problem created by electrical noise.
The following paragraphs provide information to help the user avoid electrical noise problems. Though
many potential problems are presented, few, if any, will be encountered in an actual application using a
suitably installed PLC system, even in a relatively harsh industrial noise environment.
BACKGROUND NOISE
Electrical noise is defined as any unwanted electrical signal which enters the control equipment. Noise
signals cover the entire spectrum of frequencies and may have any wave shape. The largest single
difficulty with noise is that it is not always present. Continuous, or frequent, periodic noises are generally
easy to detect and accommodate. Intermittent noise sources that produce short, high energy bursts at
irregular and widely spaced intervals cause the majority of problems. Noise has a number of different
pathways into the control equipment. It can be conducted through signal or power wiring or it can be
radiated by electromagnetic waves. Conducted noise is typically coupled into the signal or power wiring
either electro-statically or magnetically. Electrostatic coupling occurs through parasitic capacitance
between the noisy line and the signal/power line. This typically would be the case for long wire runs in
the same conduit. Magnetic coupling occurs through parasitic mutual inductances between lines. This
requires high currents or high currents or high rate of change of current as well as significant mutual
inductance, which may result from proximity or wiring. Electromagnetically radiated noise is typically
high frequency (radio waves). The control system and its wiring may act as antennas in picking up noise
signals. This pathway is least likely to present problem levels of noise to a PLC, and its sources are rare
industrial applications. The dominate sources of noise in industry are those devises (and their wiring)
that produce and switch high voltages and currents. Typical examples include large motors, welders, and
contactors that switch heavily inductive loads such as brakes or clutches. Other examples of noise
sources are Triac/SCR motor control and power invertors.
EFFECTS OF ELECTRICAL NOISE
The predominant effect of noise on the system is to cause “soft” failures; that is, failures which do not
damage the system but do cause it to function improperly.
Three main types of soft failures are encountered:
Logic memory alteration.
Register alteration.
Momentary I/O failure.
Logic memory alteration presents the most significant potential problem in that it may, in some cases,
result in improper machine operation. Both register and momentary I/O failures normally result only in
nuisance failures such as operation in the wrong mode, machine glitches or incorrect/non-existent error
messages.

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GROUNDING RECOMMENDATIONS
A good grounding system is a major consideration in planning any electrical system. However, it is
essential for proper operation of the electronics that a low-impedance path to earth ground exist. All
filtering devices internal to the PLC require a good earth ground return. The structural ground present in
many industrial environments does not provide an adequate ground return. A supplementary grounding
electrode should be used to reduce the impedance of the earth ground return when direct-wire
connection to the power system is not feasible. As a minimum, a No. 12 AWG stranded copper wire
should be used to connect to the copper grounding electrode. The connection should exhibit very low DC
resistance (0.05 OHM) and low high-frequency impedance (such as copper lugs). Minimum wire sizes,
color coding, and general safety practices should comply with American National Standards and the
National Electrical Code.
Other earth ground sources are not as desirable as a copper ground stake. Green wire earth grounds
(safety grounds) brought into the control system from plants distribution networks tend to be very noisy.
In most plants, the green wire earth ground system is characterized by ground loops, multiple
terminations to different references, and long wire runs adjacent to motor power and other high-power
wiring. Conduit as an earth ground has even more problems. Though many installations use these
ground references successfully, the practice should be avoided.
AC POWER CONSIDERATIONS
Electrical devices should not be operated at the low end of their input power voltage rating for extended
periods of time. When input voltage is low, current input is forced higher to provide the devise with the
power of needs. Additional current means additional heating. When a system is to be installed where
long brownouts are known to occur, the user is advised to supply the PLC with power from a voltage
regulating transformer. Use of this type of transformer will provide normal voltage to the devices and
keep current within normal range.