CBE 510 Setup guide

1
CBE 510 BULK BAGGER
Safety-Installation-Operation-Maintenance

2
TABLE OF CONTENTS
Topic Page
Quick Reference Information…………………………………………………………………..…… 3
Before Operating Equipment………………………………………………………………..……… 4
When Operating Equipment………………………………………………………………….…….. 4
Recommended Spare Parts List…………………………………………………………………… 7
CHAPTER 1 General Information…………………………………………………………….. 8
Receipt and Inspection
Cautions and Warnings
Specific Requirements
CHAPTER 2 Installation Guide………………………………………………………..……. 12
Introduction
Preparation
Site selection
Uncrating
Installation
Connecting to supply bin
Installation Summary
CHAPTER 3 Load Cell Wiring ……………………………………………………….…….…. 17
Load Cell Wiring to Junction Box
Load Cell Replacement
Load Cell Connection Guide
Load cell information / Capacity
CHAPTER 4 Component Descriptions……………………………………………………… 22
CHAPTER 5 Optional Equipment…………………………………………………………….. 24
Butterfly/slide gate valve
VibratoryDeck
Bag Pre-inflate/ Exhaust
Inflatable Bag Cuff
CHAPTER 6 Setup and Operating Procedures……………………………………………. 26
Principal of Operation
Timers
Operational Sequence
Phase 1
Phase 2
CHAPTER 7 Maintenance………………………………………………………………………. 35
Bag Seal Cuff & Gauge
CHAPTER 8 Trouble Shooting……………………………………………………………..…. 38
Controller doesn’t return to Zero
Erratic weighs
Digital readout does not match the floor scale
Controller does not lite up
Dirtyfilling

3
QUICK REFERENCE INSTALLATION INFORMATION
1. PneumaticRequirements:(OneHookup)Run1/2"linetomainFilter/ Regulatorwithanoutput
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 labeledfrom
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.
5. ForTechnical Assistance call main # 512.352.3694.
6. For parts you can email [e-mail]
6. For Equipment Sales call main office or email [e-mail]
If any clarification is required -- ASK US!
WARNINGS
WARNING
The purpose of this section is to alert operating and maintenance personnel to the possible dangers
of this type of equipment. Serious injuryand/or equipment damage could result from not heeding
these safety precautions.

4
BEFORE OPERATING EQUIPMENT:
1. Any personnel working directly with or on this equipment should read this manual before
proceeding with equipment use.
2. Electricians shouldfamiliarize themselves with the electrical drawings before initial start-up of
equipment.
3. Other appropriate operating and maintenance personnel shouldfamiliarize themselves with
mechanical layout and general arrangement drawings before start-up of equipment.
4. Determine location of all emergency switches.
5. Be sure allguards are in place and observe all warning signs.
6. Be sure electrical equipment is free of any accumulation of water.
7. Be sure allpersonnel areclear of operating mechanisms beforeconnecting air.
8. Never start equipment without first checking for loose objects, tools and trash. All persons in
the immediatearea ofthe equipment should bealerted 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, electricalenclosures
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.
6. If additional wire runs areadded to any junction boxor 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 anytrapped 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.

5
Safety glasses should be worn in equipment area.
Follow the safetyregulations 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
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 typicallycoupled into the signalor power wiring either electro-statically or magnetically. Electrostatic

6
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 proximityor wiring. Electromagneticallyradiated 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 topresent problem levels of noiseto 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 inductiveloads suchas brakes or clutches. Other examples of noise sources areTriac/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:
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, normallyresult only in nuisance failures such as
operation in the wrong mode, machine glitches or incorrect or non-existent error messages.
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 internalto
the PLC require a good earth ground return. The structural ground present in manyindustrial 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 andthe 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,
thegreenwireearthgroundsystemischaracterizedbygroundloops,multipleterminationstodifferentreferences,
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 supplythe PLC with power from a voltage regulating transformer. Use of this
type of transformer will provide normalvoltage to the devices and keep current within normal range.

7
Recommended Spare Parts List for Model 510 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
110 volt AC
105-020
2
Solenoid valve adapter Kit
105-020A
1
Vibrator motor (Optional)
513-002
1
Solenoid valve
24 volt DC
2600-070

8
CHAPTER 1
GENERAL
INFORMATION

9
RECEIPT AND INSPECTION
After uncrating the packer,a check should be made to see that all items ordered have been receivedand that
all equipment is in good condition.
Anydamageincurredin shipment should be reported immediately to the delivering carrierand a claim forthe
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 thetrucking company or transportation provide.
1. Determine location of all switches.
2. Be sure allguards are in place and observe all warning signs.
3. Check and maintain all oil levels with proper specific oil ( if equipped).
4. Be sure allelectrical equipment isfree 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. Exceptwhen electriciansare 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 informationassociatedwith 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 machinedamage could result. Disable machine before attempting anymaintenance or
manual testing of components. (If applicable)
7. If additional wire runs are added toany junction boxor control panel, wiring practice should be
such as to maintain prevailing electrical hazard classification.

10
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.
9. Keepfingers, hands,feet,clothing,etc., outofthepathofpneumaticallyoperated components.
10 Safety glasses should be worn in equipment area.
11. Follow the safetyregulations for your plant. ALWAYS USE GOOD JUDGEMENT.
Specific Requirements
1. Voltage
The system is designedfor one location hookup. If the unit is equipped with a vibratorytableor
power conveyors, three phase voltage will be required. The control voltage will be maintained
through a step-down transformer in the controlpanel. Ifthe unit is only equipped with the GSE
controller, 110 Volt, single phase is required.
2. Air Requirements
The system is designed for one location hookup. The maximum air requirements when all
options are selectedare approximately 3.9 CFM@ 80 PSI per bag 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.

11
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.
Connectair 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. Allhosesand relatedfittingsarecorrespondingly
color coded for ease of re-assembly.

12
Chapter 2
INSTALLATION

13
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. Unpack the scale
4. Adjust the four leveling feet on the scale
5. Connect cable to junction box and indicator
6. Calibrate the unit
SITE SELECTION
Be careful toselect a location that will prevent accidental overloading of the 510 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 510 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 asrunning the cable in conduit is recommended.
UNCRATING
Remove the packing material and inspect the 510 series for any visible damage caused during
shipment. If damage is present, notify your freight carrier immediatelyto register a claim.
INSTALLATION
A. Lifting and moving the 510 series can be done using a forklift, inserting theforks thru the two
forklift channels provided in the deck.
B. Using the fork channels, raise the main deck of the510 BB and locatethe 4 load cells, 1 on
each corner. The leveling feet are run and jammed for shipping purposes. Loosen the jam
nut, and run the leveling pad out 2”. All feet need must to be run out the same distance, so
the deck will be solid when setting on the floor.
C. If the deck is not solid when the unit is set on thefloor, you must loosen the leveling footthat
is not securely resting on the floor and re-tighten the jam nut. Adjust each foot so the deck is
level and the feet are solid tothe floor.

14
CONNECTING TO SUPPLY BIN
Our 510 series Bulk Bag Fillers can be fed via slidegate valve, butterfly, valve, auger, rotary air lock.
The valveisfasteneddirectlytothecustomer supplybin. An8"flexconnectorhose hasbeensupplied
to install from the outlet side of the valve to the bulk bag filler head. Care must be taken to ensure that
there is a minimum of 6” of flex house between the feeding valve assembly and the inlet to the filling
head ofthe filler. If not, thelack offlexibilitybetween valve/feeder andscale can be detrimental to bag
weight accuracy
Note: Be sure the flex connector hose is long enough so you do not influence the scales.
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 surethe 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.
Tightenlevelingfootlocknutagainstloadcellbeingcarefulnottoovertighten.Thismaycause
reading errors, which will require re-calibration.

15
Note:
Ifremovingthecontroller from theequipment, securethe controllertothedesiredlocationandthenthe
load cell cable to the floor or wall. Re-connect the load cell cable to the weight indicator. Reference the
indicator User and Installation Guidefor 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.

16
Chapter 3
LOAD CELL
WIRING

17
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 on page 14 for junction box layout
andwiringconnections.Tightenthestrainreliefhubsonthejunctionboxwithawrenchtoassureproper
seal.
Figure 1: Load Cell Configuration
Figure 2: Junction Box Connections
Take the cable coming from the junction box of the 510 series and wire it to the indicatorconnector as
follows:

18
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 indicator per instructions supplied with your indicator.
2. After calibration has been completed, take a known weight (ideally 25% of capacity) and check
each corner. Place weight between center of scale and each corner one at a time as shown in
Figure 2: Junction Box Connections. Use the same calibrated weight in each corner.
3. If the indicator weight reading deviates from the known weight the junction box trim pot for that
corner should be adjusted. A qualified Scale Technician should perform this procedure. Call your
GSE Distributor for service.
4. Toadjustthecornerweightreadings,usethetrimpotdesignatedforthatcornerwhich isnumbered
thesameasthecorneryouneedtoadjust.Turning thepotclockwiseincreases theweightreading.
Refer to Figure 1: Load Cell Configuration 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 Choice Bagging Equipment according to the part number ( see spare parts list)?
1. Unbolt the defective load cell, and then remove leveling load footfrom the load cell.
2. Disconnect load cell cable from junction box and attach a chase wire to the load cell cable.

19
WARNING: DO NOT CUT THE LOAD CELL CABLE!
3. Pull the load cell cable out of the formed frame channels. The chase wire will be used to pull the
newload cell cable through the formed channel.
4. Install the new load cell by reversing the preceding steps. Reference the wiring diagram in Table 1
on page 19.
5. To verify correct load cell/junction box terminal connections, see the numbers on the terminals
inside the junction boxand the corner numbering diagram in Figure 1: Load Cell Configuration.
6. Position load cells with load cell alignment arrow pointing up toward the deck. With the torque
wrench, tighten all mounting bolts to 75 ft. /lbs.
7. Route the load cell cables in each corner so that the cable is free from possible contact with the
load cell or load foot. Pull cable tight towards junction box, coil up extra length with cable ties and
securely store inside channel. (See figure 3: 510 bottom view)
8. Pass end of load cell cable through cable fittings in the NEMA 4X junction box.
Calibration is necessary after load cell replacement. Follow the calibration instructions in quick
reference in chapter 4.

20
Figure 3: 510 Series Bottom View
LOAD CELL CONNECTION GUIDE
SHIELD CLEAREXCITION + BLACK
EXCITION + RED SIGNAL - WHITE
SIGNAL + GREEN SENSE - BROWN
SENSE + BLUE