OK International CW1-RC Series User manual

CW-1RC SERIES CHECKWEIGHER
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CW1-RC SERIES
CHECKWEIGHER
Operation Manual
This manual is intended for use by qualified personnel operating the machine and
carrying out maintenance work on the machine.
All rights reserved. No part of this manual may be reproduced without the
permission of O/K INTERNATIONAL CORP.
O/K INTERNATIONAL CORP. reserves the right to modify components or
specifications at any time, without prior notice to the purchaser. The contents of
this manual may likewise be amended.
For information concerning maintenance or repairs not covered by this manual,
please contact the Service Department of O/K INTERNATIONAL CORP.
This machine is subject to continuous improvement, so your machine may differ
slightly from the specifications in this manual. O/K INTERNATIONAL CORP.
cannot accept responsibility for any deficiencies in this manual or any
consequences arising therefrom.
VERSION : CW1-RC Checkweigher Operation Manual
DATE : 7-10-2020
MACHINE S/N : GENERAL
O/K International Corp.
73 Bartlett Street
Marlborough, MA 01752, U.S.A.
Phone : [phone]
Fax : [phone]
E-mail: [e-mail] Information: www.okcorp.com

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O/K INTERNATIONAL CORP.
73 Bartlett Street
Marlborough, MA 01752, USA
Phone : [phone]
Fax : [phone] E-mail : [email protected]

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CONTENTS
1. INTRODUCTION ......................................................................................................................5
1.1 GENERAL ..............................................................................................................................................5
1.2 WARRANTY ...........................................................................................................................................5
1.3 TECHNICAL SPECIFICATIONS ..................................................................................................................6
1.4 ENVIRONMENT PROTECTION ...................................................................................................................6
2. SAFETY WARNINGS AND INSTRUCTIONS .........................................................................7
3. MACHINE COMMISSIONING ..................................................................................................8
3.1 UNLOADING ...........................................................................................................................................8
3.2 ELECTRICAL AND PNEUMATIC SUPPLY ....................................................................................................8
3.3 PRE-START POWER AND SAFETY CHECKS ..............................................................................................9
3.4 COMMISSIONING WEIGH SCALES ......................................................................................................... 10
3.4a Removing Over-travel Bolts (Machines Equipped with Actuating Scale Conveyors Only) ........... 10
3.4b. Initial Calibration ............................................................................................................................ 10
4. MACHINE PARTS AND DESCRIPTIONS ............................................................................ 11
4.1 CW1-RC CHECKWEIGHER OVERVIEW ........................................................................................... 11
4.2 CW1-RC SUPERFILLER CONTROL COMPONENTS OVERVIEW ................................................................ 13
5. MACHINE OPERATION ....................................................................................................... 14
5.1 METHOD OF OPERATION ..................................................................................................................... 14
5.2 STARTING AND STOPPING THE CW1-RC.............................................................................................. 15
5.2.1 Set-Up and Run Ready Condition ................................................................................................. 15
5.2.2 Cycle Starting / weighting .............................................................................................................. 15
5.2.3 Cycle Stopping .............................................................................................................................. 15
5.2.4. Emergency Stopping .................................................................................................................... 15
5.3 TOWER LIGHT INDICATORS .................................................................................................................. 16
6. TOUCHSCREEN OPERATION ............................................................................................ 17
6.1 MAIN SCREEN (HOMEPAGE) [ACCESS LEVEL 0] ............................................................................... 17
6.2 SCALE DASHBOARD [ACCESS LEVEL 1]........................................................................................ 21
6.3 ADVANCED MENU [ACCESS LEVEL 0] ............................................................................................. 22
6.4 RECIPE MANAGER [ACCESS LEVEL 1] ............................................................................................ 23
6.5 SCALE CALIBRATION [ACCESS LEVEL 2] ....................................................................................... 25
6.5.a Machines Equipped with Actuating Scale Conveyors ................................................................... 25
6.5.b Machines Equipped with Roller Scale Conveyors ........................................................................ 25
6.6 MAINTENANCE MODE [ACCESS LEVEL 1] ........................................................................................ 26
6.7 ALARM HISTORY [ACCESS LEVEL 0] ............................................................................................... 27
6.8 SYSTEM ALARMS ................................................................................................................................ 28
6.9 NOTIFICATION MESSAGE DISPLAY ....................................................................................................... 29
7. MAINTENANCE .................................................................................................................... 30
7.1 INTERVALS ......................................................................................................................................... 30
7.1a Daily ............................................................................................................................................... 30
7.1b Monthly ........................................................................................................................................... 30
7.2 FREQUENCY DRIVE SETTINGS ............................................................................................................. 31
7.2a Standard Drive Parameters ............................................................................................................ 31
8. SPARE PARTS ..................................................................................................................... 32

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9. COMPONENT DRAWINGS .................................................................................................. 33
9.1 CW1-RC ........................................................................................................................................... 33
9.2 WEIGH SCALE CONVEYOR (STATIC POWERED ROLLER SYSTEM) .......................................................... 34
9.3 WEIGHING PLATFORM (DROP DOWN SCALE CONVEYOR SYSTEM) ......................................................... 35
9.4 ELECTRICAL PANEL (SIEMENS) ............................................................................................................ 36
9.5 ELECTRICAL OPERATOR CONTROLS (PRO-FACE) ................................................................................. 37
9.6 MAIN AIR PREPARATION STACK & PNEUMATICS (NORGREN) ................................................................. 38

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1. INTRODUCTION
1.1 General
Thank you for choosing the OK CW1-RC CHECKWEIGHER. We appreciate your
business and look forward to a long relationship with you.
In the design and construction of this machine we take the greatest care to ensure
quality and durability, combined with a high level of user-friendliness and easy
maintenance. This manual contains a lot of information necessary for safe and
efficient use of the machine. Please read it carefully before starting to use the
machine. Carrying out the maintenance as recommended by a qualified engineer will
ensure proper and efficient operation of the machine.
If you have any enquiries, please provide the machine model and serial number.
If you have any problems with regard to this manual or the machine, please contact:
O/K INTERNATIONAL CORP.
73 Bartlett Street
MARLBOROUGH, MA 01752
Tel: [phone]
Fax: [phone]
E-mail : [email protected]
1.2 Warranty
O/K INTERNATIONAL CORP. warrants this machine in accordance with their
standard Terms and Conditions of Sale.
The warranty does not cover normal wear and tear and becomes void:
a. When not following the operating and maintenance instructions
b. When using the machine outside normal operating conditions
c. When the machine is operated or maintained by non-qualified personnel
d. When modifications to the machine are made without the written approval of
O/K INTERNATIONAL CORPORATION
e. When original factory parts have been replaced by generic parts

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1.3 Technical Specifications
 Electrical Supply: North America: 480V, 3Ø + Earth, 60Hz
Europe & Asia: 380V, 3Ø + Earth, 50Hz
 Pneumatic Supply: 80-100psi (5-7 bar). dry, non-lubricated
 Noise Level: < 80 dB
 Ambient Temperature: 10°C - 30°C
 Humidity: Max 75% without condensation
 Protection Level: IP66 (Excluding Operator Touchscreen, IP65)
See below for further details on protection level
1.4 Environment Protection
The CW1-RC is manufactured for exposure to a wash-down environment. All frame members
are constructed of stainless steel and all welds are continuous. Components within the
checkweigher such as enclosures, gear motors, load cells and photoeyes are rated at or
above IP66 and are therefore wash-down ready. Care should be taken with regards to the
operator touchscreen when wash-down is being performed. At a protection rating of IP65 the
touchscreen can withstand incidental contact with a wash-down stream, however it should
never be exposed to direct contact with the wash-down stream. Doing so will result in
permanent damage of the screen.

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2. SAFETY WARNINGS AND INSTRUCTIONS
Read the safety and operating instructions carefully before using the machine.
All operating and maintenance personnel must be familiar with the contents of the operating manual and
must follow it accurately.
Welding on or near the machine can cause damage to certain components (such as the PLC).
Only qualified personnel aware of all safety regulations should carry out service and maintenance on
the machine.
Before starting maintenance or repair operations the main electrical disconnect switch must be in the off
position and locked. The pneumatic shut-off valve located on side of the lower enclosure should be
closed and locked.
A qualified electrical technician should only carry out service on the electrical systems on the machine.
The machine uses compressed air, be aware that if skin is near to an active compressed air outlet, air
embolism may occur which can result in death.
Do not wear rings, watches, jewelry or loose clothing when operating or maintaining equipment.
The safety labels on the machine must be clear and legible. Damaged or illegible labels should be
repaired or replaced.
Do not operate this machine without all the safety switches, doors, covers and other safety devices in
place and in proper operating conditions.
All safety switches, doors, covers and other safety devices must be regularly checked for correct position
and operation.
If an unforeseen event in the surrounding environment occurs that puts the machine in an unsafe state,
the machine should be stopped. Power and air should be disconnected until an authorized engineer has
inspected the machine, rectified any faults that has put it in an unsafe condition, and fully tested it and
approved it for use.
Do not use the machine for anything other than its designed purpose.
Any attempt to move, dismantle or dispose of the machine or any component thereof should be made
only by a qualified person with correct attention paid to safety.

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3. MACHINE COMMISSIONING
3.1 Unloading
The CW1-RC will arrive on one pallet. Remove all anchoring straps holding the equipment
to the pallet. Carry out a visual inspection for signs of damage that may have occurred
during shipping.
Note: On machines equipped with
actuating scale conveyors, it is
recommended to leave the scale
conveyor blocks strapped in-place
until the machine is in place and
air is supplied. Without air
pressure the scale conveyors will
settle down, exposing the weighing
rails increasing the risk for
inadvertent load cell damage.
Lift each piece of equipment off the palette, being careful to avoid cable trays and junction
boxes, and affix leg levelers provided in one of the included packed boxes. Set main
checkweigher dual conveyor system into place first and then bolt on the reject roller
conveyor. The checkweigh scale is blocked up off of its load cell to prevent load cell
damage during shipping. Carefully remove strapping and block and gently place scale
conveyor onto load cell. Note that the ½” (12mm) spacer provided, must be located
between the load cell and the scale conveyor base tube. Secure with four M8 hex bolts
provided. When torqueing bolts, apply counter-pressure to the scale conveyor in opposite
direction to prevent excessive force on the load cells.
WARNING! Overloading load cell will result in permanent damage and require
replacement!
3.2 Electrical and Pneumatic Supply
Before connecting the electrical mains supply to
the rotary disconnect switch ensure that it is in the
off position. Only after verification should the
connection be made. The connection of the mains
should only be carried out by a qualified electrical
technician. If the feed is supplied with a neutral,
terminate it in the provided terminal block next to
the disconnect switch. The machine does not make use of a neutral connection.

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Connect an airline to the air shut
off ball-valve located on the side
of the reject pusher support base.
The machine requires clean dry,
non-lubricated air at a rate of 1L
per case (when rejecting). The
minimum diameter of hose should
be no less than 1/2" (12mm).
3.3 Pre-Start Power and Safety Checks
After the machine is energized, the safety system should be checked to ensure proper operation. Please refer to
the table below outlining the start-up procedure. Only when these actions have been completed successfully,
should the machine be released for production.
If the machine fails to stop when the emergency stop button is pressed, contact O/K International Corp.
immediately and do not run the machine.
Action Result
1. Before turning the main disconnect switch
to the on position, check for proper voltage
with a voltmeter.
Voltmeter reading should not vary more than
10% from the specified voltage for the
machine
2. Turn the machine on by rotating the main
disconnect switch to the on position.
Machine will power up. The touchscreen will
read “Safety Circuit Activated”
3. Release emergency stop button. Press
the RESET button.
The safety relay will energize the main power
contactors. The blue lamp of the RESET
button will turn off. The message display will
read “Please Wait…Machine Powering Up”
4. Press emergency stop pushbutton The main contactors will de-energize and the
display will read “Safety Circuit Activated”

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3.4 Commissioning Weigh Scales
3.4a Removing Over-travel Bolts (Machines Equipped with Actuating Scale Conveyors Only)
After the machine is in place and the air supply has been connected the weigh scales can
be commissioned. Start by removing all strapping material from the scale conveyor and
weighing pedestals. During shipping, the over-travel protection bolts are set in such a
manner to prevent damage to the load cells. Refer to Figure 3.4a.1 - Weigh Scale Assembly
for location. The 4 corner bolts need to be removed before running.
It is important to note that once the over-travel bolts are removed, great care should be taken
when working around the scales/load cells. This is especially true when the air supply to the
machine is off and the conveyor is actuated down leaving the weigh rails exposed. The load
cells can be overloaded from excessive side loading and/or compressive and torsional
forces, resulting in permanent damage.
Figure 3.4a.1 - Weigh Scale Assembly
3.4b. Initial Calibration
For powered roller conveyor scale systems, after scale conveyor is mounted to load cell, it
is recommended that the scale is calibrated. For drop down style scale conveyor systems,
after removing the over-travel bolts it is recommended that the scales be calibrated. Refer
to section 6.5 Scale Calibration for an explanation on how to calibrate the scales.
Corner Over-travel
Bolt

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4. MACHINE PARTS AND DESCRIPTIONS
4.1 CW1-RC CHECKWEIGHER Overview
Please refer to Figure 4.1 - CW1-RC CHECKWEIGHER Overview which points out the
main components of the CW1-RC CHECKWEIGHER accompanied by brief descriptions.
The CW1-Roller Conveyor version is shown.
Figure 4.1 – CW1-RC OVERVIEW
A
B
E
C
D

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A. Weigh Scale Roller Conveyor – Receives boxes filled with product and weighs them to
check if weight is within range. Please note that this conveyor is mounted directly to a
load cell. Use caution when working around or manually placing cases on/off to avoid
damaging load cells.
B. Reject Pusher – Pushes out of range weighed boxes from the Weigh Scale Roller
Conveyor to the Reject Roller Conveyor.
C. Reject Roller Conveyor – Accumulates out of range weighed boxes (usually 3 to 4
boxes depending on size).
D. Electrical Panel/Operator Controls Station – Houses touch screen, emergency stop,
control buttons and all electrical components including CPU, frequency drives, fuses,
etc.
E. Outfeed Roller Conveyor – Allows boxes filled with product with in-range weight to exit
the machine.

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4.2 CW1-RC Superfiller Control Components Overview
Please refer to Figure 4.2 – CW1-RC Superfiller Control Components OVERVIEW which
points out the major controlling devices. The CW1-RC version is shown.
Figure 4.2 – CW1-RC CHECKWEIGHER CONTROL COMPONENTS OVERVIEW
A. Weigh Scale Roller Conveyor Photoeye – Detects that a box is staged on the roller
conveyor scale and ready to be weighed.
B. Reject Pusher Photoeye – Detects that an out of weight range box is placed in front of
the reject pusher before being pushed onto the reject roller conveyor
C. Outfeed Roller Conveyor Photoeye– Detects that an in-weight range box is ready to exit
the machine.
D. Reject Roller Conveyor Photoeyes – Detect that there is enough space on the reject
roller conveyor to reject another box.
E. Weigh Scale Conveyor Motor – Drives the infeed conveyor transport rollers.
F. Outfeed Conveyor Motor – Drives the outfeed conveyor transport rollers.
A
E
B
C
F
D

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5. MACHINE OPERATION
5.1 Method of Operation
The CW-1RC is a checkweigher combined with a reject system used to verify the weight of a case.
If the measured weight is within allowable range then the case is allowed to exit the checkweigher.
If the measured weight is outside of the allowable range it is automatically rejected onto an
accumulation conveyor, thereby keeping it from exiting to downstream processes.
When the system is ready for production and the machine is cycle started, the checkweigh scale is
zeroed. When a new case enters, it comes to a stop on the center of the checkweigh scale. After
a delay to allow the scale to stabilize, the weight of the case is measured; this is the gross weight
(i.e. the weight of the case, plastic liner and product). The net weight (i.e. the weight of product) is
calculated by subtracting the entered tare weight (i.e. weight of the case and plastic liner) from the
gross weight. The net weight is then compared to the allowable limits configured by the user to
determine if it is acceptable or not acceptable. If acceptable, the scale conveyor will start allowing
the case to exit scale position, pass by the reject system and exit the machine. If the weight is not
acceptable, it will exit the scale position and stop at the reject position. Once stopped, it checks
that there is space on the reject accumulation conveyor to be rejected. If space is available the
reject pusher will push the case onto the accumulation conveyor and operation will resume. If no
space is available, the system will notify the operator and wait to reject the case until space becomes
available. The machine will continue this process until cycle stopped or if an alarm condition occurs.

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5.2 Starting and Stopping the CW1-RC
5.2.1 Set-Up and Run Ready Condition
In order to start filling, the following conditions must be met.
1. The operator must ensure that there are no boxes on either conveyor. (Note:
The only time boxes should remain on either conveyor is following an emergency
stop.)
2. The emergency stop pushbuttons pulled out, press the RESET pushbutton.
3. The checkweigher must receive permission-to-operate confirmation from the
plants master controller (if interface is applied).
5.2.2 Cycle Starting / weighting
Press the START pushbutton.
The checkweigher will begin to accept cases from upstream equipment.
It will checkweigh boxes as long as no error conditions occur and the machine has
permission to run from the plant’s master control system (if interface is applied).
5.2.3 Cycle Stopping
Press the STOP pushbutton at any time
The boxes in the checkweigh station will be weighed and accepted or rejected
depending on their weight. No new boxes will enter the machine will stop.
5.2.4. Emergency Stopping
Push in either EMERGENCY STOP pushbutton if an emergency condition arises.
When an emergency stop is initiated all machine functions cease. That is, weighing
and rejecting stops and all PLC outputs de-energize.
To recover from an emergency stop, make sure EMERGENCY STOP pushbuttons
are pulled. Press blue RESET pushbutton to re-energize system. Proceed with
normal machine operation.

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5.3 Tower Light Indicators
The Red-Amber-Green tower light atop of the Weigh Scale Roller Conveyor gives
the operator a visual indication of certain machine operations. Refer to Figure 5.6.1
- Tower Light Indications below for a listing of Tower Light indications.
Figure 5.6.1 – Tower Light Indications
BUZZER
Intermittent
(0.5s On
/
2.5s Off)
Reject Accumulation Conveyor Full
Intermittent
(1s On
/
1s Off)
Checkweight - Failed
RED
Steady Safety Circuit is Activated
Slow-Flash Cycle Stopped
Fast-Flash Cycle Stop in Progress OR
Checkweight
-
Failed
AMBER
Steady Outfeed (Downstream) Blocked
Slow-Flash Reject Accumulation Conveyor Full
Fast-Flash No Function
GREEN
Steady Running Production
Slow-Flash No Function
Fast-Flash Checkweight - Passed

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6. TOUCHSCREEN OPERATION
6.1 Main Screen (Homepage) [Access Level 0]
{LOADED RECIPE} - Displays the name of the recipe currently loaded. See section 6.4
Recipe Manager for details on recipe creation.
{GROSS} Weight Display - Displays the real-time weight value, in kilograms, measured by
the scale. Press anywhere on the displayed value area and the screen will be replaced
with the zoomed in screen as shown below.
.
The values displayed here are the same as found on the home screen. This is simply a
zoomed in view, useful when the machine is running to see checkweight results easier.
The only difference is the addition of a lightbar on top of the page. It will flash green on a
good checkweight, and flash red on a bad checkweight. This gives an easily viewed

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indicator of outcome of checkweight. Press anywhere on the screen to return back to
home screen.
{TARE WEIGHT} – Displays tare weight of the case as defined by the recipe. See section
6.4 Recipe Manager for further details.
{CHECKWEIGHT (NET)} – Displays the measured net weight, in kilograms, of the last
case.
[ADVANCED MENU] – Pressing this button takes the user to the Advanced Menu screen.
See section 6.3 Advanced Menu.
[LOAD RECIPE] – Pressing this button pop-up the "Load Recipe" window. Once open,
press radio buttons 1-8 to load the corresponding recipe.
[SCALE DASHBOARD] - Pressing this button, will take the user to scale dashboard
screen. See section 6.2 Scale Dashboard for further details.
{DATE & TIME} - Current date and time is displayed in the format of YY/DD/MM and
HH:MM respectively.
{CURRENT USER} - "OPERATOR", "SUPER" or "ENGINEER" will be displayed
depending on what level the user has logged on to. Pressing will pop-up the Security
Access window.

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[LOGIN] – When pressed, the user will be prompted to enter in a username and password.
A successful login, permits the user to access higher level functions within the display. The
table below identifies the different levels of access.
[LOGOUT] - When pressed, the user level will be restored to OPERATOR access.
[SECURITY MANAGER] – When pressed, the change password dialog box opens
allowing a user to change their password or a lower level user’s password. Additionally,
new users can be added and existing users can be deleted.
Access Levels and Privileges
All screens described in this manual have different levels of access. A screen that has
Operator level access can be accessed at any time by any user, and therefore operators
are not required to log in. A user logged in as SUPER has additional access to the Recipe
Manager. A user logged in as ENG has full access to all areas of the user display. Non-
operator users will retain their current access privilege until they log out or until 30 minutes
of display inactivity elapse. Refer to Figure 6.1.1 - User Log-In Information below which
shows log-in information.
Figure 6.1.1 – User Log-In Information
User
Level
Username
Password
O
perator
0
-
-
Supervisor
1
SUPER
12345
Engineer
2
ENG
54321

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{MESSAGE DISPLAY BOX} (Located on Bottom of Screen)
The message display box will display various status messages based on normal machine
operation. Refer to Figure 6.1.2 Message Display Information below for a list of the
messages that may be displayed and a description of why.
Figure 6.1.2 – Message Display Information
Message Description
Safety Circuit Activated Displays when an e-stop has been pressed or a guard door has
been opened and the machine hasn’t not been reset
Please Wait…Machine
Powering Up
Displays after the reset pushbutton has been pressed. During
this time the drives power-up and the main air to come up to full
pressure
Machine Ready
Displays after the power-up period and after cycle stopping as
long as fill station is clear and customer has given permission to
run. Pressing “START” will start the machine
Machine Running Is displayed after the machine has been started and during
normal machine production
Cycle Stop Initiated Is displayed after the user presses “STOP” button during
production.
Machine Holding – Outfeed
Blocked
Is displayed when the “outfeed blocked” photoeye is blocked.
No cases will be release from the machine until the photoeye is
cleared.
Clear Cases Before Starting
Is displayed if case is blocking “case in checkweigh” position
photoeye when machine is reset, but not started. Machine
cannot be started if case is on scale and requires operator to
remove the before starting.
Machine in Alarm An alarm was generated during production and the machine is
automatically cycle stopped.