CBE 520 Setup guide

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CBE 520 BULK BAGGER
Safety-Installation-Operation-Maintenance

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Table of Contents Page
Quick Reference Installation Information
4
Warnings and Notices
5
Grounding Recommendations and Noise
6
Recommended Spare Parts
9
Chapter 1 –General Information
10
Receipt and Inspection
11
Caution and Warnings
11
Specific Requirements
12
Dust Collection
13
Chapter 2 –Installation Guide
14
Introduction
15
Preparation
15
Site Selection
15
Uncrating
15
Re-Adjusting the Load Cell Feet
15
Load Cell Feet Checks
16
Connecting to the Supply Bin
16
Setting Conveyors
17
Installation Summary
17
Chapter 3 –Load Cell Wiring
18
Load Cell Wiring to Junction Box
19
Calibration Instructions
20
Load Cell Replacement
20
Chapter 4 –Component Description
23
CBE 520 Bulk Bag Filler Assemblies
24
Densifying Deck
26
Chapter 5 –Operational Sequence
27
Operational Sequence
28
Auto Strap Release (Optional)
29
Bag Seal Cuff (Optional)
30
Pre-Bag Inflate (Optional)
31
Powered Roller Discharge (Optional)
32
Chapter 6 –Conveyor Setup
33
Chapter 7 –PLC Timers and Adjustments
38
CBE Data Touch
40
Avery 405
40
Chapter 8 –Weigh Controller and Adjustments
43
Controllers
44
Avery 405 - Setting Target Weight
45

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Avery 405 - Adjusting Pre-Act
46
Chapter 9 –Maintenance
49
Chapter 10 - Troubleshooting
51
Controller Does Not Return to “0.00”
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Erratic Weights
52
Digital Readout Does Not Match the Floor Scale
53
Controller Does Not Light Up
53
Dirty Filling
54
Troubleshooting a Bad Load Cell
54
Chapter 11 –Standard Parts
55
PLC Timers & Adjustments
57

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QUICK REFERENCE INSTALLATION INFORMATION
1. Pneumatic Requirements: (One Hookup) Run 1/2" line to main Filter / Regulator with an output of 4
CFM operating at 80 PSI.
2. Electrical Requirements: (One Hookup) A 25 amp dedicated circuit should be supplied to the main
control panel.
3. Installing Slide gate: Install the slide to supply bin. There should be wires that are labeled from the
slide gate that need to be connected into Junction box (1) located on the filler.. The wires need be
terminated in the J-Box for the Slide gate solenoids and the reed magnet, (used for setting up the
dribble position on the slide gate).
4. See attached layout drawing for reference information.
For Technical Assistance call main: 512-352-3694
For Parts or Service needs call main number or email: [e-mail]
For New Equipment call main number or email: [e-mail]
For Used Equipment call main number or email: [e-mail]
Thank you for your Business
You are a Valued Customer

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WARNINGS AND NOTICES
WARNING
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:
1. Any personnel working directly with or on this equipment should read this manual before
proceeding with equipment use.
2. Electricians should familiarize themselves with the electrical drawings before initial start-up
of equipment.
3. Other appropriate operating and maintenance personnel should familiarize themselves with
mechanical layout and general arrangement drawings before start-up of equipment.
4. Determine location of all emergency switches.
5. Be sure all guards are in place and observe all warning signs.
6. Be sure electrical equipment is free of any accumulation of water.
7. Be sure all personnel are clear of operating mechanisms before connecting air.
8. 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:
1. 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.
2. Stop machine and disconnect power before servicing or repairing. Maintenance and
adjustments must be performed with all power disconnected unless otherwise specified in
this manual.
3. Do not attempt to defeat any safety switches. Serious injury could result.
4. 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.
5. 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.

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6. 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.
7. 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.
8. Keep fingers, hands, feet, etc. out of path of pneumatically operated components.
9. Safety glasses should be worn in equipment area.
10. Follow the safety regulations for your plant. ALWAYS USE GOOD JUDGEMENT!
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.
GROUNDING RECOMMENDATIONS AND NOISE
GROUNDING
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

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(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.
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.

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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:
1. Logic memory alteration.
2. Register alteration.
3. 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. Register and temporary I/O failure, normally result only
in nuisance failures such as operation in the wrong mode, machine glitches or incorrect or non-
existent error messages.
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.

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Recommended Spare Parts List for Model 510 /520 BBL
Qty
Description
Part Number
1
Load Cell
501-005
1
Summing Box
104-009B
2
Bag seal cuff
301704-12-1/8
1
Pilot valve
145301
1
Quick Dump Exhaust
Valve
703-014
2
Solenoid Valve
105-020
2
Solenoid valve
adapter Kit
105-020A
1
Mother Board,
O/I Board comb
Assembly
104-815S
1
Vibrator (Optional)
503-002
1
12” feedgate
(optional)
N/A
1
1
1
Slide gate(optional)
Slide gate cylinder
Magnetic reed switch
503-016
503-002
503-006
1
1
4” butterfly valve
actuator
502-707
502-704

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CHAPTER 1
General
Information

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RECEIPT AND INSPECTION
After uncrating the bulk bagger, a check should be made to see that all items ordered have been received
and that all equipment is in good condition.
Any damage incurred in shipment should be reported immediately to the delivering carrier and a claim for
the damage should be filed. Also notify Choice Bagging Equipment, Ltd. so that replacement or repair
may be initiated. If severe damage has occurred, verify the damage with written reports AND
pictures to Choice Bagging Equipment and call the trucking company or transportation provide.
1. Determine location of all switches.
2. Be sure all guards are in place and observe all warning signs.
3. Check and maintain all oil levels with proper specific oil( if equipped).
4. Be sure all electrical equipment is free of any accumulation of water before installing.
CAUTION AND WARNINGS
1. Observe extreme caution when switches are turned on. Operation may start automatically
after a time delay.
2. DO NOT open junction boxes or control panels unless you are a qualified technician. Be
sure POWER IS OFF. Except when electricians are performing maintenance, electrical
enclosures and junction boxes should REMAIN SECURELY CLOSED.
3. STOP machine and disconnect power supply before servicing or repairing. Maintenance
and adjustments must be performed with all electrical power supplies disconnected unless
otherwise specified in this manual.
4. READ COMPLETELY any information associated with this bulk bagger. There is an
additional manual included for the GSE controller.
5. DO NOT attempt to defeat any safety switches. Serious injury could result. (If applicable)
6. 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. (if applicable)
7. 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.
8. High-pressure air systems are dangerous. DO NOT service or trouble-shoot 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.

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9. Keep fingers, hands, feet, clothing, etc., out of the path of pneumatically operated
components.
10 Safety glasses should be worn in equipment area.
11. Follow the safety regulations for your plant. ALWAYS USE GOOD JUDGEMENT.
SPECIFIC REQUIREMENTS
1. Voltage
The system is designed for one location hookup. If the unit is equipped with a vibratory table
or power conveyors, 3 phase voltage will be required. The control voltage will be
maintained through a step-down transformer in the control panel. If the unit is only equipped
with the digital controller and solenoid operated controls, only 110 Volt single phase power
is required.
2. Air Requirements
The system is designed for one location hookup. The maximum air requirements when the
machine includes all available functions is approximately 3.9 CFM @ 80 PSI per fill cycle.
3. Solenoids / Pneumatics.
All pneumatic components (air valves & cylinders) are self-lubricating and additional lubricated air
is not required. If lubricated air is used then lubricated air must be used for the life of all the
cylinders.
Connect high-pressure airline to filter regulator, located on back
side of packer. A suitable source of supply is a (1/2” pipe
connection).
It is recommended that an extra water trap (not supplied with
machine) be installed prior to the regulator in the high-pressure
airline and the packer. Drain trap as required.
Connect air hoses to cylinder of bag chair for automatic bag
discharge (optional equipment). If the machine was ordered
from the factory with options, this will already be done. If the
machine was not originally ordered with an option, the manifold
should be pre-plumbed for one option at a later time.
Connect all air hoses which were disconnected for shipment.
All hoses and related fittings are correspondingly color coded
for ease of re-assembly.

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DUST COLLECTION
A 4” dust hookup is located on the upper filler pipe. This pipe should be connected to dust
collection piping with a damper so the amount of volume of air can be adjusted to the fill head. If
you have too much draw, material will be drawn up from the stream along with the dust during the
filling cycle.

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CHAPTER 2
INSTALLATION
GUIDE

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INTRODUCTION
Carefully read these instructions to assure proper installation and performance of the scale.
PREPARATION
Standard preparation of the floor scale consists of the following steps:
1. Select a site
2. Check levelness and smoothness of the site
3. Uncrating the Bulk Bagger
4. Adjust the four leveling feet on the scale
5. Connect cable to junction box and indicator (if required)
6. Calibrate the unit
SITE SELECTION
Be careful to select a location that will prevent accidental overloading of the 520 series. Avoid
installing the scale in areas where damage may occur such as impacts from heavy machinery,
wheels, forklift tines or shock damage from falling objects.
The interface cable between the 520 series and the indicator must be secured to the floor or wall
and protected against crushing, cutting or water damage. If the site has such potential dangers, a
method of protection such as running the cable in conduit is recommended.
UNCRATING
Remove the crate and inspect the Model 520 for any visible damage caused during shipment. If
damage is present, notify your freight carrier and CBE immediately to register a claim. Take
pictures if damage is visible when crate arrives physically damaged.
RE-ADJUSTING THE LOAD CELL FEET
The base of the Model 520 has built in forklift pickup pockets. Using the forklift pockets, elevate the
Model 520 and locate the four (4) load leveling feet. They are stored inside the frame for transport.
Each load leveling foot should be screwed out to the same length (so the frame is 2” from the floor).
Once the unit is in final position, the unit should be leveled and solid on all 4 corners.

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LOAD CELL FEET CHECKS
1. Be sure when leveling the BB, the load feet are resting securely on the floor
and thread bolt engagement is a minimum of 50% in the load cell prior to
jamming the lock nut. Be careful not to over tighten.
2. Be sure there is a clearance of 1” min and 2” max between the floor and the
bottom of bulk bag frame.
NOTE: Do not over tighten the jam nut. This may cause reading errors, causing
erratic weights.
3. Secure the load cell cable to the floor or wall. Take care not to stretch or bind
cable as this will effect weight readings.
4. In most cases the controller frame and main enclosure are strapped to a
pallet which is strapped to the vibratory deck of the bulk bagger. However, on
occasions they are disconnected for shipment, and you may have to
reconnect the load cell cable and disconnect cable back to the weight
indicator. Reference the indicator User and Installation Guide for proper
connections.
Note: Depending on the model and configuration, your indicator may come pre-connected to
the scale.
CONNECTING TO SUPPLY BIN
The Model 520 Bulk Bag Filler can be fed via slide-gate valve, butterfly valve, auger, rotary
vane feeder or air lock feeder. In a typical installation, one of these feed devices will be
fastened directly to the customers supply bin. An 8" flex connector hose is installed to the outlet
side of the chosen feed device down to the bulk bag filler head. Care must be taken to ensure
that there is a minimum of 6” of flex hose between the feeding valve assembly and the inlet to
the filling head of the Bulk Bagger, if not adjusting for various Bulk Bagger heights. If the filler
head of the bagger needs to be adjusted, then more flex hose will be required between the feed
device and the head. The flexibility between valve/feeder and scale is necessary to minimize
vibration to scale during the filling cycle, which can be detrimental to bag weight accuracy.
Note: Be sure the flex connector hose is long enough so you do not influence
the scales.

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SETTING CONVEYORS
Once the BB is in place and anchored, use a chalk line to layout any conveyors to the system.
Refer back to layout drawing to set remaining conveyors. If the BBL is equipped with a powered
conveyor, this will come secured to the BBL structure. Layout a line parallel line to the powered
discharge conveyor, maintaining a 1/2" clearance between all conveyors to ensure the conveyor
units are not touching the scale conveyor.
INSTALLATION SUMMARY
Place the 510 series in the selected site.
Align with your discharge spout and connect with flexible collar( supplied by customer)
NOTE: Assure that each leveling load foot is securely resting on the floor before jamming
the load cell nut. Be sure the Bulk bagger does not rock and is level. Be sure to have
a minimum of a ¼” maximum of ½” clearance between the frame and the floor.
CAUTION:
If more than 1/2" clearance to floor is needed, the bottom of the leveling load foot must be shimmed.
Be sure the leveling load foot bolt thread engagement is a minimum of 50% into each of the load
cells.
Tighten leveling foot lock nut against load cell being careful not to over tighten. This may cause
reading errors, which will require re-calibration.
NOTE: If removing the controller from the equipment, secure the controller to the desired location
and then the load cell cable to the floor or wall. Re-connect the load cell cable to the weight
indicator. Reference the indicator User and Installation Guide for proper connections. Take
care not to stretch or bind cable as this will affect weight readings.
NOTE: Depending on the model and configuration, your indicator may come pre-connected to
the scale.

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CHAPTER 3
LOAD CELL WIRING

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LOAD CELL WIRING TO JUNCTION BOX
The four (4) load cells are each wired to their respective terminals in the junction box according to
the corner numbering system shown in Figure 1 below. See Figure 2 (below) for junction box
layout and wiring connections. If equipped, tighten the strain relief hubs on the junction box with a
wrench to assure proper seal.
Figure 1: Load Cell Configuration
Figure 2: Junction Box Connections
Take the cable coming from the junction box of the 500 series and wire it to the controller indicator
as follows:

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Table 1: Connector Wiring
WIRING DESIGNATION
WIRE COLOR
(+) Excitation Red
Red
(-) Excitation
Black
(+) Signal
Green
(-) Signal
White
(+) Sense
Blue
(-) Sense
Brown
Ground or Shield
Clear
CALIBRATION INSTRUCTIONS
1. Calibrate the scale to controller indicator per instructions supplied (See Chapter 4 for Calibration
Instructions).
2. After calibration has been completed, take a known weight (ideally 25% of 10,000 # capacity)
and check each corner. Place weight between center of scale and each corner one at a time as
shown in Figure 1: Load Cell Configurations. Use the same calibrated weight in each corner.
3. If the indicator weight reading deviates from the known weight, use the junction box trim pot for
that corner and adjust as needed. A qualified service technician is highly recommended to
perform this procedure. Call CBE to schedule a service technician to assist you with installation
of your system.
4. To adjust the corner weight readings, use the trim pot designated for that corner which is
numbered the same as the corner you need to adjust. Turning the pot clockwise increases the
weight reading. Refer to Figure 2: Junction Box connections for the correct location.
5. After each corner has been checked and calibrated, make a final check of your calibration in all
corners and center of the scale.
6. The scale is now calibrated and ready for use.
LOAD CELL REPLACEMENT
Should a load cell become damaged due to an overload condition, replacement load cells can be
ordered from CBE. The part number for the load cell can be found on the Recommended Spare
Parts List in this manual.
1. Unbolt the defective load cell, and then remove leveling load foot from the load cell.
2. Disconnect load cell cable from junction box and attach a chase wire to the load cell cable.