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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VERSION : CW1-RC CheckWeigher Operation Manual_v0
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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