ISHIDA SCALES

CCW-S-2XX SERIES
SERVICE MANUAL

' ..

ISHIDA SCALES MFG.CO., LTD.

44 SANNO-CHO SHOGOIN SAKYO-KU KYOTO 606 JAPAN
'

(
Copyright© 1987 by Ishida Scales Mfg. Co., Ltd. All Rights Reserved.
No part of this manual may be reproduced in any form, by mimeograph or any
other means, without permission in writing from the publisher.
 ;
I

TABLE OF CONTENTS

II 1 Introduction II 4 Site Engineer

1-1 OVERVIEW Procedure
1-2 THE MAIN COMPONENTS 4-1 OVERVIEW
1-5 ONE MACHINE CYCLE 4-1 SET SITE ENGINEER MODE
1-6 RCU KEY ENTRY 4-1 RETURN TO OPERATOR MODE
1-7 RCU MENUS 4-1 FUNCTION
1-7 WEIGHER OPERATION MODES 4-1 Date
1-7 INSTALLATION NOTES 4-1 Time
4-2 Feed control
(O:auto 1 :manual
2:auto time
4-2 Weight control
II 2 Start Procedure (O:minimum 1 :average
2-1 POWER ON 4-2 CALCULATION
2-1 POWER OFF 4-3 PRE ARRANGEMENT
2-1 ACTIVATE MOTOR 4-3 Target weight
2-1 ON LINE/OFF LINE 4-3 Upper limit
2-1 OPERATOR MODE MENUS 4-3 Feeder
2-2 SITE ENGINEER MODE MENUS 4-3 Dump count
2-3 INSTALLATION ENGINEER MODE 4-3 Speed
MENUS 4-4 Feed multiplier
4-4 Stagger delay
4-4 Level weight
low product
upper level
II 3 Operator 4-4
4-4
Product code
Product name
Procedure 4-5 Calculation mode
3-1 OVERVIEW (O :normal 1 :double
3- 1ZERO ADJUSTMENT 4-5 T.N.E.
3-2 PRINT MENU 4-5 SPAN ADJUSTMENT
3-2 Every print 4-6 ADJUSTMENT
3-2 Sub total print 4-6 Activate
3-2 Grand total print 4-6 Compensation
3-2 Total clear 4-6 T.H .-W.H.
3-2 Printer(O:off 1 :on ) 4-6 W.H.-P.H.
3-2 Histogram display 4-6 P.H.-R.F.
3-2 Efficiency display 4-7 Feed deviation
3-2 SUPPLY PRINTER PAPER 4-7 D.F. vib. (max-min)
3-3 PRINT FORMATS 4-7 R.F. vib. (max-min)
3-4 PRODUCTION 4-7 Transient interrupt
3-4 PRODUCTION MENU 4-7 Low product
3-5 FEEDER VALUES 4-7 Dump confirm delay
3-5 CORRECT FLOW OF PRODUCT 4-7 Motor frequency
3-6 INADEQUATE FLOW OF PRODUCT 4-7 T.H. delay
3-6 EXCESSIVE FLOW OF PRODUCT 4-8 R.S. delay
3-7 HOW TO ADJUST THE DISPERSION 4-8 R.S. pool
AND RADIAL FEEDERS 4-8 T.H. open
3-8 SYSTEM DRAINING 4-8 R.S. open

CCW-S-2XX •OPERATION• REV 4 (Table of Contents)-1

(
TABLE OF CONTENTS ,-
'

II 5 Installation II 6 Clean Up Procedure ( '"

Engineer 6-1 CLEAN INLET CHUTE

Procedure
6-1 CLEAN DISPERSION FEEDER
6-1 REMOVE POOL AND WEIGH
r·
5- 1 SET INSTALLATION ENGINEER HOPPERS
MODE 6-2 CLEAN RADIAL FEEDERS
5- 1 RETURN TO OPERATOR MODE 6-3 REMOVE DISCHARGE CHUTE
5-1 VARIANT1 6-3 Single Tube Models
5-1 Ov. sci (O:alarm
2:alarm&dump
1 :alm&stop
)
6-3 Twin and Singled Twin Tube
Models
,_..
5-2 Ov. wt (O:dump N :N stop ) 6-4 TIMING HOPPER REMOVAL
5-2 Zero (N : interval count ) 6-4 CLEAN DISMOUNTED PARTS (
5-2 Print frequency 6-4 INSTALL DISMOUNTED PARTS

5-2
(O :program N :hour
T.H. (O :off N:on
)
) II Menu Index
r
5-2 T.H . (O :no pool 1 :pool )
5-3
5-3
R.S. (O :off N:on
R.S. (O:no pool 1 :pool
)
) II Operator's Guide
5-3 Air mode
(O :off 1 :on )
5-3 Level sensor (
(O :weight 1 :photo ) -
5-3 Range (0 :4009
5-4 VARIANT2
5-4
1 :800g

Interface (O :slave 1 :master

)
c
5-4
2 :stroke on demand
Multi dump initiate
) r
(O: self 1 :sync ) (~
5-4 Multi dump confirm
(0 :first 1 :last ) (_
5-4 Manual dump initiate
(O :self 1 :sync )
5-5 Manual dump confirm (
(O :off 1 :output )
5-5 Discharge when both proper (
(O :off 1 :on )
(

(
C,

l.
C·
(
(Table of Contents)-2 CCW-S-2XX •OPERATION• REV 4
 ITABLE OF CONTENTS I
PART1 • 7 PS Unit 1
7.1 EXTERNAL VIEW
Electrical Components 7.2 MAIN FUNCTIONS
7.3 PS FUSE BOARD P-5163
LOCATION OF ELECTRICAL
COMPONENTS • 8 Transformer 301
• 1 Remote Control 8.1
8.2
EXTERNAL VIEW
MAIN FUNCTIONS
1.1 EXTERNAL VIEW 8.3 TRANSFORMER 301 CIRCUIT
1.2 MAIN FUNCTIONS DIAGRAM
1.3 RCU BLOCK DIAGRAM
1.4 RCU BOARD P-5165 • 9 Inverter
1.5 PANELBOARDP-5166 9.1 EXTERNAL VIEW
1.6 CIRCUIT BOARD REMOVAL 9.2 MAIN FUNCTIONS
PROCEDURES 9.3 BLOCK DIAGRAM
9.4 INVERTER TERMINAL
• 2 Calculation Unit
2.1 EXTERNAL VIEW • 10 Drive Motor
2.2 MAIN FUNCTIONS 10.1 EXTERNAL VIEW
2.3 CAL UNIT BLOCK DIAGRAM 10.2 MOTOR SPECS
2.4 ADC BOARD P-5185 10.3 REDUCTION GEAR SPECS
2.5 CAL CPU BOARD P-5156
2.6 HIF BOARD P-5164 • 11 Wiring Diagrams
2.7 CAL MOTHER BOARD P-5162 11.1 DIAGRAM GUIDE
11.2 PIN OUT DATA FOR 1E-6963
• 3 Relay Unit CABLESA-V
3.1 EXTERNAL VIEW Drawing
3.2 MAIN FUNCTIONS Drawing Title
No.
3.3 BLOCK DIAGRAM
3.4 SIG l/F BOARD P-5161 1E-6963 Wiring For All Components
3.5 RELAY BOARD P-5160 2E-7999 RCU Wiring
3.6 F DRV BOARD P-5158 2E-6956 CAL Unit Wiring
• 4 Drive Control Unit 2E-6955 Relay Wiring
4.1 EXTERNAL VIEW ~ower Supply Unit
4.2 MAIN FUNCTIONS 2E-6953 CAL
Circuit
4.3 BLOCK DIAGRAM 2E-7990 PS Unit Circuit
4.4 DUC BOARD P-5186
4.5 CAM SENSOR BOARD P-5167
4.6 DUC l/F BOARD P-5159
• 5 CAL Power Supply PART2
Unit Mechanical Components
5.1 EXTERNAL VIEW
5.2 MAIN FUNCTIONS LOCATION OF MECHANICAL
5.3 BLOCK DIAGRAM COMPONENTS
• 6 PS UnitO • 12 Inlet Chute
6.1 EXTERNAL VIEW 12.1 EXTERNALVIEW
6.2 MAIN FUNCTIONS 12.2 MAIN FUNCTIONS

CCW·S·2XX •SERVICE• REV 1 (Table of Contents)-1

TABLE OF CONTENTS

• 13 Dispersion Feeder • 18 Drive Unit

13.1 EXTERNAL VIEW 18.1 STANDARD DU EXTERNAL VIEW
13.2 MAIN FUNCTIONS 18.2 STD DU MAIN FUNCTIONS
13.3 ELECTROMAGNETIC COIL 18.3 STD DU ENTIRE UNIT
PROCEDURES PROCEDURES
13.4 LEAF SPRING PROCEDURES 18.4 STD DU DUC BOARD UNIT
13.5 DISPERSION FEEDER EXPLODED PROCEDURES
VIEW 18.5 STD DU LOAD CELL UNIT
PROCEDURES
• 14 Radial Feeder 18.6 STD DU CAM SENSOR
14.1 EXTERNAL VIEW PROCEDURES
14.2 MAIN FUNCTIONS 18.7 STD DU CLUTCH & BRAKE UNIT
14.3 ELECTROMAGNETIC COIL PROCEDURES
PROCEDURES 18.8 STD DU EXPLODED VIEWS
14.4 LEAF SPRING PROCEDURES 18.9 TWIN DU EXTERNAL VIEW
14.5 RADIAL FEEDER EXPLODED VIEW 18.10 TWIN DU MAIN FUNCTIONS
18.11 TWIN DU EXPLODED VIEW
• 15 Pool Hopper 18.12 TWIN DU WEIGH MECHANISM
15.1 STANDARD PH EXTERNAL VIEW EXPLODED VIEW
15.2 STD PH MAIN FUNCTIONS 18.13 CCW-S-215 DU EXTERNAL VIEW
15.3 STD PH LINK PROCEDURES 18.14 CCW-S-215 DU MAIN FUNCTIONS
15.4 STD PH SPRING PROCEDURES 1K15 CCW-S-215DUENTIREUNIT
15.5 STD PH EXPLODED VIEW PROCEDURES
15.6 CCW-S-215 PH EXTERNAL VIEW 18.16 CCW-S-215 DU DUC BOARD
15.7 CCW-S-215 PH MAIN FUNCTIONS PROCEDURES
15.8 CCW-S-215 PH SPRING 18.17 CCW-S-215 DU LOAD CELL UNIT
PROCEDURES PROCEDURES
15.9 CCW-215 PH EXPLODED VIEW 18.18 CCW-S-215DUCAMSENSOR
PROCEDURES
• 16 Weigh Hopper 18.19 CCW-S-215 DU CLUTCH & BRAKE
16.1 STANDARDWH EXTERNAL VIEW UNIT PROCEDURES
16.2 STD WH MAIN FUNCTIONS 18.20 CCW-S-215 DU WEIGH AND
16.3 STDWH LINK PROCEDURES DRIVE MECHANISM EXPLODED
16.4 STD WH SPRING PROCEDURES VIEW
16.5 STD WH EXPLODED VIEW 18.21 CCW-S-215 DU CLUTCH & BRAKE
16.6 TWINWH EXTERNAL VIEW EXPLODED VIEW
16.7 TWIN WH MAIN FUNCTIONS
16.8 TWIN WH LINK PROCEDURES
16.9 TWIN WH SPRING PROCEDURES • 19 Timing Hopper
16.10 TWINWH EXPLODED VIEW 19.1 EXTERNAL VIEW
16.11 CCW-S-215 WH EXTERNAL VIEW 19.2 MAIN FUNCTIONS
16.12 CCW-S-215 WH MAIN 19.3 ROD END PROCEDURES
FUNCTIONS 19.4 TIMING HOPPER EXPLODED
16.13 CCW-S-215WHSPRING VIEW
PROCEDURES
16.14 CCW-S-215WH EXPLODED VIEW
• 20 Timing Hopper
• 17 Discharge Chute Drive Unit
17.1 SINGLE CHUTE EXTERNAL VIEW
20.1 EXTERNAL VIEW
17.2 SINGLE CHUTE MAIN FUNCTIONS
20.2 MAIN FUNCTIONS
17.3 SINGLE CHUTE PROCEDURES
20.3 CAM SENSOR PROCEDURES
17.4 SINGLE CHUTE EXPLODED VIEW
20.4 CHAIN PROCEDURES
17.5 TWIN CHUTE EXTERNAL VIEW
20.5 TIMING HOPPER DRIVE UNIT
17.6 TWIN CHUTE MAIN FUNCTIONS
EXPLODED
17.7 TWIN CHUTE PROCEDURES
17.8 TWIN CHUTE EXPLODED VIEW

(Table of Contents)-2 CCW·S·2XX o SERVICE o REV 1

 TABLE OF CONTENTS

PART3
Troubleshooting
• 21 Troubleshooting
Electrical/Mechanical
Problems
• 22 Troubleshooting
Display Error
Messages

You can help improve this manual by calling attention to errors and recommending
improvements. Please convey your comments to the nearest Ishida Scales regional
representatives.

Thank you.

CCW·S·2XX •SERVICE• REV 1 (Table of Contents)-3

 !REVISIONS I

Section Page Revision 1: Nov 1986

Manual expanded to include service information on all

10 and 14 head CCW-S models.
Additional information added throughout the manual
to assist servicing machines.
Ch. 19 Chapter on timing hopper added.
Ch.20 Chapter on timing hopper drive unit added.
Part 3 Troubleshooting guide updated to include
information provided by engineers in the field.
Part4 Technical data added including pin out data for main
circuit boards.

(Revisions)-4 CCW-S-2XX •SERVICE • REV 1

 !SAFETY PRECAUTIONS I
This manual has been prepared for the maintenance and repair of the Ishida Scales
CCW-S-2XX series computer weighers by authorized service personnel. All service
personnel should take every safety precaution possible and observe the following
safety practices when servicing the weighers.

1. Be sure to cut the main power for servicing whenever possible.

Main power must be cut from the power switch or breaker external to the
weigher. Note that the switch at the bottom of the remote control unit is
used only as an emergency reset switch and does not cut the main power
The RCU switch cuts power only' from the RCU l_ogic circuitry. It does not cut
power to the plasma display circuitry or the the motor and drive units.
2. Various units are powered by high voltages. Check voltages!
3. If a circuit or unit is dis.connected for servicing or parts replacement, it must
be reconnected and tested before returning use of the weigher to the user.
4. Meter continuity checks should be used instead of voltage checks whenever
possible.
5. All safety devices such as guards, shields, signs, ground wires, etc. must be
restored after servicing.
6. Safety glasses should be worn when servicing the weigher.
7. Watches, rings, necklaces, bracelets and other jewelry should be removed
when servicing the weigher.
8. Care must be taken when working near moving parts. Keep hair away from
moving parts. Avoid wearing loose clothing that might be caught in the
machine. Shirt sleeves should be kept buttoned or rolled above the elbows.
Ties should be tucked in the shirt or use a tie clasp approximately 8 cm from
the end of the tie.
9. Maintain safe conditions in the area of the weigher while performing and
completing servicing.
10. Before starting the weigher, make sure fellow service engineers or customer
personnel are not in a hazardous position.

CCW·S-2XX •SERVICE• REV 1 (Safety)-5

PART 1 Electrical Components

CCW-S-2XX •SERVICE• REV 1 (PART 1)-1

1 REMOTE CONTROL UNITT

1.4 RCU BOARD P-5165

-
~

:;
-
....
:;
,.
,- a! ·-~
• I

I
0
..."' "<= 0
! ..."' 1;;
• - 5 I

; .,,,,,.. ~~ Ps1sse IS H I
0

Figure 1-3
A. FUNCTIONS
* Data display control.
* Printer control
* Bidirectional communication with calculation unit via fiber optic cable.
* Processing of statistical data.
* Dip switch values.

DIPSW4 1 2 3 4
ON Ishida Engineer Mode (Level 3) SECOND
LANGUAGE - -
OFF System Operator Mode (Level 1) English - -

1-2 CCW·S·2XX •SERVICE• REV 1

 1 Remote Control Unit

1.1 EXTERNAL VIEW

PLASMA DISPLAY--

PRINTER - -

1.2 MAIN FUNCTIONS

* Input operation values via menu selection.
* High resolution plasma display panel.
* Electrostatic data printer. .
* Bidirectional communication with calculation unit via fiber optic cable.
* Processing of statistical data.
1.3 RCU BLOCK DIAGRAM
r·-·-·;-·-·-·-~:::,;o;~o·1
r.:::,.:-:,::::",-:-,--l=b=l~ i
j ,., j

L_"'.'.'_"'. '.'"~"'_'.'.'":_'_}"=f!==1 i .... "' I

j

I
!
CAL CPU 9C•nD
(O~llCAL FIDOM

•II~ OC••O
(0~11CAL 'IUll)

L.----·-·-·-·-·-·-·-·-·.J
C"'J: ci•!•AL ~·Ol:USI•< UNIT
110-0: JIUD O'<L• "'l'<•..
~10: ~ ... l~M•••L
uo: .... l•L l~~ur
r~~· °"'"'"
OUTPUT
..... : llA•CCM •CCUI "'l'"OllT CTC: CCU""" I Tl,.111

Figure 1-2

CCW-S-2XX •SERVICE o REV 1 1-1

 1 REMOTE CONTROL UNIIT

1.5 PANEL BOARD P-5166

MOTOR

EJ QQ·Q
~x
ON
m, QQQ 4 5 6

QQQ
Q80
Figure 1-4
A. FUNCTIONS
* Mount for panel keys and LEDs.
* Input data values.

CCW-S-2XX •SERVICE o REV 1 1-3

1 REMOTE CONTROL UNJTT

1.6 CIRCUIT BOARD REMOVAL PROCEDURES

A. PRINTER BOARD

Figure 1-5

1-4 CCW-S-2XX • SERVICE •REV 1

 1 REMOTE CONTROL UNJIT

B. PANEL BOARD
-----=-=------

Figure 1-6

CCW-S-2XX •SERVICE •REV 1 . 1-5

1 REMOTE CONTROL UNITT

C. RCU BOARD

Figure 1-7

1-6 CCW-S-2XX o SERVICE• REV 1

 1 REMOTE CONTROL UNJTI

D. PLASMA DISPLAY UNIT

Figure 1-8

CCW-S-2XX •SERVICE• REV 1 1-7

 2 Calculation Unit

2.1 EXTERNAL VIEW

ADC BOARD __.-

Figure 2-1
2.2 MAIN FUNCTIONS
* Zero and span adjustment.
* Reads in weight data from each weigh unit.
* Performs combination calculation.
* Generates control signals for drive· units, relay unit and feeder units.
* Generates control signals for inverter.
* Bidirectional communication with the RCU.
* Bidirectional communication with the host computer.
2.3 CAL UNIT BLOCK DIAGRAM

Figure 2-2

2-1 CCW·S-2XX • SERVICE • REV 1

 2 CALCULATION UNIT

2.4 ADC BOARD P~5185

There are two types of chutes as listed below.
Table 2-3
ADC Specifications
P-5185 For standard models.
P-5210 For ST and high-speed T models.

A. P-5185 ADC BOARD

o=·
Ull 1

Figure 2-3
FUNCTIONS
* Reads in weight data.
* Filters out vibration components.
* Zero adjustment.

CCW-S-2XX •SERVICE• REV 1 2-2

2 CALCULATION UNIT

FILTER CONSTANTS AND GAIN RESISTORS FOR P-5185 ADC BOARD

The filter constants and gain resistors are set according to model and
weigher specifications as shown in Table 2-1 below. Be sure to check the
board #when replacing parts.
Table 2-1
1 ST STEP FILTER ~ND
STEP FILTER 3RD STEP FILTER GAIN
CONSTANT CONSTANT CONSTANT RESISTOR
# Model

R86 C169 C134 R56 C154 C120 R26 C102 C71

to to 172 to to 122 to
115 C203 174 85 168 124 55 C105 75
176 126 to 77
178 128 118 79
180 130 81
C209 182 132 86
to 184 137 88 R12 R13
217 187 139 90
189 141 92
191 143 94
193 145 96
195 147 98
197 149 100
199 151 104
100 0.47 0.22 75 0.33 0.33 91 0.47 0.33 864 10
1 KQ µF KQ KQ µF KQ KQ STD.
µF µF µF µF
100 0.47 0.22 75 0.33 0.33 180 0.47 0.32 864 16
2 KQ KQ KQ KQ KQ 215
uF uF uF uF uF uF
100 0.47 0.22 75 0.33 0.33 91 0.47 0.32 864 6.3
3 KQ uF uF KQ uF uF KQ uF µF KQ KQ -

2-3
 2 CALCULATION UNIT

B. P-5210 ADC BOARD

·~ ·~ ·~
~tt ·~ •• •••
••• . .... ....."" .
Cllt Clll Clll
'JI' .
U1T

JI-~
~.
"' ~·
Im

.
Ill~ 1111

~il-
CllS
"'
i~
CUI
y
y
m
CIU
~
CUI
.
•1, ... "J,
y
y

ClU <m
~
""
ISHIDR
y
y ~
1111
y
y
1111

P-5210
y
y
1111

Figure 2-4
FUNCTIONS
* Reads in weight data.
* Zero adjustment.
* Span adjustment.
* Includes notch filter circuit.

CCW-S-2XX •SERVICE• REV 1 2-4

2 CALCULATION UNIT

FILTER CONSTANTS AND GAIN RESISTORS FOR P-5210 ADC BOARD

The filter constants and gain resistors are set according to model and
weigher specifications as shown in Table 2-1 below. Be sure to check the
board# when replacing parts.
Table 2-2
1STSTEP 2ND STEP GAIN
3RD STEP FILTER CONSTANT
FILTER FILTER RESISTOR Mo
# CONSTANT CONSTANT
del

R86 C169 C134 R56 C154 C120 R26 C116 R131 C102 C71 C243
to 172 to to 122 to to to to
115 C203 174 85 168 124 55 C130 145 C105 75 272
to 176 126 to 77
C207 178 128 118 79
180 130 81
C209 182 132 86
to 184 137 88 R12 R13
217 187 139 90
189 141 92
191 143 94
193 145 96
195 147 98
197 149 100
199 151 104
100 0.47 0.22 75 0.33 0.33 15 30 75 1 0.22 0.47 432 10
1 KQ
uF uF KQ µF µF KQ KQ KQ uF µF uF KQ KQ
STD

2-5 CCW-S-2XX •SERVICE • REV 1

 2 CALCULATION UNIT

2.5 CAL CPU BOARD P-5156

n.•; ---
'"
~ PROMO
I
·~ PROM1
IC11
ICU ZIOA-CTC
~~

~
oT
G
,, ~·
~~
•T
G
~
"" ZaoA-CTC
...~ ,
"'~ 1ao sza

• llA!
II
l?!!
I
C.M 104
·U·
""' - ..
IQI t.DI o
ICZI U . ~ JC>O I.Sa

> '=* _,___.

u
~ ICM

ICU LS04
5* ....
• II,_. IS~
~-----'

"'° u•

Figure 2-5
A. FUNCTION
* Combination selection.
* Generates command signal for zero and span adjustment.
* Generates control signals for drive units, relay unit, and feeder units.
* Generates control signals for inverter.
* Bidirectional communication with RCU via fiber optic cable.
* Bidirectional communication with host computer via RS-232C interface.
Table 2-3

J111-Hrn Dreamo No.1-4

J125 Dispersion table load cell
J136 Host com outer RS-4221
J137 Host com outer arallel interface>
' , J138 Host com outer RS-2320
TX RCU Rx term ma I !Via t1Per oot1c cable I
Rx RCU Txterminal via tiber ootic ca bl el
J107 CAL oower sunn Iv unit + 1SV
J108 CAL oower suoolv unit + 12V + SV

CCW-5-2XX •SERVICE• REV 1 2-6

2 CALCULATION UNIT

2.6 HIF BOARD P-5164

IBHIDA
P-5164B ii•
•·
U ·o·........
•Io
"!'!""'
"l 0l•~
0. . •·•
.....

• I I I I

all ICI UUI t "' 1ucrv

*>
•• I
• t:1!i} CPU
; M>
•• M>
•
.. HUI

u PROMO
' I

a ".,.------•"*" ICI UIU

IO · - - - - - , I I
·a..- 2
11 M I
ii•I
10 LUU lb LUU ICI UH

c*"~----.,, .,•)--~1
f' ' .f* I
•• ,. . . . . . , 11'1

•' ' ,. ..
!1
LllUt!ll
IC\I u1:,· 1.~
..
ICLI LU!I ~.OJ UM ic:M II
0
PROM1 •R*.~)___,ID*,..)--~1· D* •<-)--~I
'*
'
I 1 f1 If> "i' II

. . ====:::111··o
'
. ....
ICll Cfl
• 'o-'------~'·

!.~1___.I
ICll Ult ICll un LU
PROM2 "
Q •)--~I
1 '*.~--~. R*
-i'·:::> ,,,. •..
f.' lfl"Jn- f " f' •
~---·r
!;---
E
r~------~..1.i ;;'l
ICll 1111

!-~----------'.. ,1------------'.
r~: 1 ICll Ill

j'u;:.~>_
ICUUN

c::J
__.(

---------~,·" ~
K'.11 Ill

"
.:. ·:.. if( I"" l:l:
f:f 1----------~.U Cl
• ICM 11111

E>.~>--~1s*><-----~1
**Lli*D
•k I
f"p I II
•

r"1•~
y
'' IC• JllU.

'l~ ::: "'"'Yof ~i

_.._,_
B I ICHllll
• I """'" "'I~ Ul~r,111 t,i!t--

an
H
... ""Nit-
-1111

"" • II ICH lllU I II ICMH!fl I

Ullll
-. i CU
.......
II',! ~ I

c=:::o, w,_"_'_"_"_'_,• II ICU HIM • .._,,,,_·.riir3< Ei

It
L":t 'fii"ut UI

Q*) I B*C~g*.~>--~IH*)<----~1.£*) Ii*) I ~ •

r· .r I
~ I -E I ll I .f 1 ~

i
I
•• 11111' • I If: I I

2*ti:::>:::::::::::::::( l•l·~·l IJJ f.ou MO " °""'"""""".. : . '°'

~ Jr. :·: a• a ·;· • c::::= -a1a~ I
~:=
- •• .--

. .I
"'
"" nu

""
II I
Figure 2-6
A. FUNCTION
* Bidirectional communication with host computer via RS-232C,RS-422 or
parallel interface.
* Communication with other external equipment via fiber optic cable RS-232C
interface.

2-7 CCW·S·2XX • SERVICE • REV 1

 2 CALCULATION UNIT

2.7 CAL MOTHER BOARD P-5162

P-5162aor---,,o
ISHIDA•••
r- ,0
~Hots
r:;=::;:JHo 14
i:;=::::JHOl3

~H012
~HOii
~HOIO
~V---
l
0 '_,-: 'O \: 0
~HOB ---~
'

g;;
c:=:;JHo 4 !
n
lJ
, · . o J_-_-!I
___
QH03 -~'
-n,~u
·~
QHo 2
.

t i< ! \ '.:~;;:
~NOi '1 'o ~-- t_, M~:n
~-D0
--- i-
'll_J ,L0
4'I .c•i <"1
. ~- .
Figure 2-7
A. FUNCTION
* Interconnects other circuit boards inside the CAL unit
* Contains connection terminals to the preamp board, CAL power supply unit,
RCU and host computer.
Table 2-3
Terminal Connected To
Jlll-J1L4 Preamo No_ l-4
J125 Disoersion table load cell
J130 To optional external eauioment (currently not used)
Jl31 DUC l/F board {via DUC l/F cable)
J132 Relay unit (via SIG l/F cable)
J133 Relay unit (via FDC 1/F cable)
J134 Inverter {via Inverter l/F cable)
J135 Optional 1/0 port (currently not used)
J136 Host comouter RS-4221
J137 Host comouter -·arallet interrace1
J138 Host comouter RS-232Cl
Tx RCU Rx termina tv1a r1oer oot1c ca•11et ·
Rx RCU Tx terminal (via fiber ootic cablel
J107 CAL oower suoolY unit ± 1SV
J108 CAL oower suooly unit ± 12V, ± SV

CCW-5-2XX o SERVICE• REV 1 2-8

 3 Relay Unit

3.1 EXTERNAL VIEW

RELAY 304 --\-'f'~

RELAY 30~
RELAY 306
RELAY 307
. RELAY 308 --

Figure 3-1
3.2 MAIN FUNCTIONS
* Interlock with bagmaker.
* Feed conveyor control.
* Generates error signals to external equipment.
* Inputs signal from photoelectric level sensor.
* Turns AC 200V power ON/OFF to the PS unit.
* Controls timing hopper.
* Controls feeders.
3.3 BLOCK DIAGRAM
r·-·-·-·-·-·-·-·-·-·-·-··-·1
i ti~ I' &OMIO ;

C... L UNIT
! CPU ~=]v!ll I
'"'
DFI IV"'I

CAL UN IT

l'EEOUI
CHllVER

CAI. UN l T

Figure 3-2

3-1 CCW-S-2XX • SERVICE • REV 1

 3 RELAY UNIT

3.4 SIG l/F BOARD P-5161

. •••• .•.· •.........;".i~ ct.

. R• • i
> • • D"l
!•.*ff'"- •
1111~ ICI?ll:CI i,.,.,,.'~
• TW STWU
Oll' I ™'~ u !! ..
ii!* .!f:_Jf ~ .. > I
~ l~ ! ! "" """" •

.\•1 c:::::J:::i
1".~ii''"
~
_t""1:a
111 =~t
I n 111
I
]'I
rl ~~
.
t'J l .
1~
,...·> I> I> I > I ~t.---Q.t, ~··' --
115.UCll'
• !~
"'' TDCm:lP TIU fCCJ:IO:)I'
en+ ff Ut11 > ?
.Up. Dl4 --t::f- OJP. PC7TU1itr-• Pel TLl'UJ-f
Jue. u.un • • ·cr:=i ~"JC
ISHIDA P~SISIC

Figure 3-3
A. FUNCTIONS
* Interface for bagmaker interlock.
* Interface for feed conveyor control.
* Interface for sending out error signals to external equipment.
* Interface for photoelectric level sensor signal input.
* Interface for controlling AC 200V power.
*: Interface for feeder control.
* Controls timing hopper.
3.5 RELAY BOARD P-5160

- . -
==-==========--========]
'

~=
.- .
DUMP COMPLETION
SIGNAL #1.RELAY
:!:!•M
-
AW5222

HH
~~
DUMP CDMPlETION
SIGNAL #2 RELAY . : : : ~

AW5222
""'
FEED CONTROL
"•
SIGNAL RELAY •
'
:; ;; AW5222 '
'
•
"
-
ERROR
' SIGNAL RELAY ~

AW5222

. NOT USED
AW5222

NOT USED
'
__,.
,~

--11 AW5222

ISHIDR P-5160 B

Figure 3-4

CCW-S-2XX o SERVICE• REV 1 3-2

3 RELAY UNIT

A. FUNCTIONS
* Inputs and outputs signals for bagmaker interlock.
* Outputs signal for feed conveyor control.
* Outputs error signal for user's external equipment.
* Inputs signal from photoelectric level sensor.
* Controls ON/OFF of AC 200V power.
B. PIN OUT DATA FOR EXTERNAL EQUIPMENT TERMINAL J302
Table 3-1
J302 Relay Unit LED
Signal RELAY
Pin No. Terminal No. NO.
1 DC24V{ + E2) (1) 28,29 303 303
13 Dump Completion Siqnal 1 (1 ') 50,51
14 Dump Completion Signal 2 (2) 78,79 304 304
(2') 60,61
15 Feed Control Siqnal 30,31 305 305
16 Error Siqnal 82,83 306 306
3,5,7,9 DC24V
4 Interlock Signal 1 20,21 309
6 Interlock Sicinal 2 72,21 310
8 Weigh Unit SW 22,21 311
10 Level Sensor Siqnal 25,26 312
2 DC24V
20 + SV 301
19 Motor Start
Note: Ke1ays No. ::.u/, 1~0 . .:JUl:S are not usea.
3.6 F DRV BOARD P-5158
ISHIDi:J
P-51580
•
"
........
"n • - • - •- • -• - • - • - • - •-• - • - • -• -• -
• - •
~
~.
' ' • -· ' ' '
• ' • . . • . • ' • '·
' ' • ' ' • ' • ' •' • ' •
.f D
. (] ' -' -' -' -• • - ' -' ' - ' ' -
• - • -• -• • - • - • - • • - • • - • - • -
"" '"' ""' "" lNU
"~ ZlllllO 2111111 ZNllQ INlll:J ZNllW ZNllU ?Kiili

t t t t t t t t t t t t t t t t

f'Zcil f20Z
JllO
,,., ,,~
Zo•
""' JlBI
,., { Zo• .f.Z"' F.z10 :tzn ,,. T<O ,,. ,,. ~

!_

Figure 3-5
A. FUNCTIONS
* Controls drive for dispersion feeder and radial feeders.
* Detects zero phase of AC power (zero cross signal) to switch feeders ON and
OFF.

3-3 CCW·S·2XX •SERVICE• REV 1

 4 Drive Control Unit

4.1 EXTERNAL VIEW

Figure 4-1
4.2 MAIN FUNCTIONS
* Controls drive for pool hoppers and weigh hoppers.
* Detects malfunction of brake and clutch via cam sensor.
* Built-in load cell and pre-amp detects weight.
4.3 BLOCK DIAGRAM
r-·-·-·-·-·-·---·DU 80;,,RD ·1
I I
'1
oc CPU WH1
DRIVER : DRIVE UNIT
CAL UNIT <!:::i=j u.~
::>
!D
WH2
DRIVE.A. i
PH !
DRIVER
I
I r
CAL UNIT ( i P~P i 0 LOAD CELL
' L·-·-·-·-·-·-·-·-·---·_J

Figure 4-2

CCW-S-2XX •SERVICE• REV 1 4-1

4 DRIVE CONTROL UNIT

4.4 DUC BOARD P-5186

~

JI ~

no~ w2L c.:

1 - - · - · IC0 ~~
H 3
4 I JJl2~6~.r9sPwQQql 'ti'
~ ~c2H -~----'- 6
tttttkkk j
1
"'2 ~

•'
TRAI ____ ,,_ -:;:.-:;:.::;:; 293 c5
1 1cf RS
e TRA2
.. •' '" -
g::g""n _aa.1.
,, ' -m ~lf
R7 if
H c~~
_._ CJ'""'0071 :;:'°
c::......w 0

' '"' -#{' f RIO RA4 IC3 f Rll

D 6049 UR9~...---~ ...--~~~
> MS4S37 I~
_.
o:?
~U>
I? 8~4 IRl5
,--...., XTtJ\il RAS •I I 1
Rl2 t- J3~ ~i;r:::::J JWv- JW.r
\._./ PC2 ...----~ Rl4 E ,.-.,. B

=
.. rlhCl2 H+ ~ PCI
? TLPs21-4 I? I Gi"PI IC4? 201 I+ .,.,__:rRI

!!! Cll
'? Cl3
'J l
n
1 ~J4•
-0 ·I I
•
TLPS21-4
• a>
leis ~~ +c110
~ ::
I I1
c:liZ!I PC 3 -
EMl2 Clll C20 ':-a-'
H H
czi.,..,."'

llu~
l:l

~-
.._ J205 RA7 ,1204
+c;! j l1s RIG o __J "'

Figure 4-3
Note: Rotary switch SW1 is used to set the head number.
A. FUNCTIONS
* One DUC board installed per drive unit.
* Actuates the clutch and brake which open and close the pool and weigh
hopper doors.
* Detects malfunction of brake and clutch.
* Has pre-amp which amplifies the load cell output.
4.5 CAM SENSOR BOARD P-5167
PHOTOINTERRUPTOR

CARBON RESISTOR "'- '51

Figure 4-4
A. FUNCTIONS
* For single type machines: one sensor for the weigh hopper and one for the
pool hopper.
* For twin type machines: two sensors for the weigh hopper and one for the
pool hopper.
* Detects complete cam revolutions inside the drive unit by sensing the timing
mask with a photo interrupter.

4-2 CCW·S-2XX • SERVICE o REV 1

 4 DRIVE CONTROL UNIT

B. CAM SENSOR CIRCUIT

- - - , . . - - - - - - i > - - - - - t - - - - J1-2,J2-1
RED
R ;--- -,
/ I
470.n_ I 10 I
r-
1
I IT 0--4---+'--- J1-1
BROWN

L ----- _ _ _ _ _ JI
GP-1A01
(JUMP)
c
_ __.._ _ _ _~>------~I-- J1-3,J2-2
ORANGE

Figure 4-5
4.6 DUC 1/F BOARD P-5159
I
I
I
I I 1 J324 20
\--15?1~-3' ISHIDA P-5159B

J334 ti

~[
J333

J332 ,.
J331 10

J330 10

J329

J32!1
·;[
,.
J327 .-
n f----------"~lt
I
'
Figure 4-6
__________ l~
J
'

A. FUNCTIONS
* Two boards installed at center of machine (for drive units 1-7, and 8-14)
* Junction for + SV from CAL Power Supply Unit and + 24V from PS Unit 1.
* Junction for signals between the CAL CPU board and the DUC board.

CCW·S-2XX •SERVICE •REV 1 4-3

 5 CAL Power Supply Unit

5.1 EXTERNAL VIEW

Figure 5-1
5.2 MAIN FUNCTIONS
* Supplies + 5V, ± 12V and ± 15V to the calculation unit.
* Supplies + 5V to the drive unit.
* Supplies AC100V and + 185V (for display board) to the RCU.
5.3 BLOCK DIAGRAM

~~ 2 Wh
- ·----- ·J<-oz-1
? NFI NF2 Wh
l'~+-"--'~---J402·Z RCU
AC'li;JQSV
~~ Y1,f!LJ<OZ·3 1.<>N'
z Y/Gr
NF3 FG 11C JN
Red JWJ-1
) Pias~a
t

"~ir (j B1k J4o3 -2 Display

Plasma PS DC lBSV

Wh

AC Ill (" ---·-·----···-·Blu-JW!t-·I

R....-----Blk-----···-- z
G,
;•y -Red·= I ~ )to CAL Unit
PS
~
nsv. sv
1
,,, g_
62 G1
··-·rea -_R_.,,d_:::
.,,0, .5 to DUC
-----·-J405·1)

tBlk----N'5·~)
Blk--- I 2
a s f Red- 3
to SIG I/F
--·· ·-·--.=.p~;Br_-~~:-~·'4"t.-~ )
··· - ··-----·-··-Ora·.... I " to CAL Unit
,/4nt,-4

Figure 5-2

5-1 CCW-S-2XX •SERVICE • REV 1

 6 PS Unit 0

6.1 EXTERNAL VIEW (Refer to Chapter 11 for circuit diagram.)

ELECTROMAGNETIC CONTACTOR

CIRCUIT BREAKER

FUSE HOLDER (F302 3A 2SDV)

FUSE HOLDER (F3011A 2SOV)

Figure 6-1
6.2 MAIN FUNCTIONS
* Cuts power if power leakage is detected.
* Cuts power if main body door is opened.

CCW-S-2XX •SERVICE o REV 1 6-1

'
 7 PS Unit 1

7 .1 EXTERNAL VIEW (Refer to Chapter 11 for Circuit Diagram)

ELECTROMAGNETIC CONTACTOR

THERMAL RELAY TH2

PS FUSE BOARD

Figure 7-1
7 .2 MAIN FUNCTIONS
* Provide 3-phase power for the drive motor and TH motor (via inverter).
* Provides AC200V for dispersion and radial feeders.
* Provides + 24V for clutch and brake.
* Provides + 24V for the SIG l/F board and external equipment signals.
* Controls ON/OFF for AC 200V power.
* Has built-in PS Fuse board.
7.3 PS FUSE BOARD P-5163

~ ~ ~ ~ g
~

~
•
~g ~

-
0
>
-
>
....
> ....
>
....
>
....
>
....
>
....
> ....
>
....
> -,,
I'
J314
' ' Jll3
' ' '"' ' ' J31l
' • J3t0
'I
11 II II 11

Figure 7-2
A. FUNCTIONS
*Contains PS Unit 1 fusesf311-f319.

7-1 CCW-S-2XX • SERVICE o REV 1

 8 Transformer 301

8.1 EXTERNAL VIEW

Figure 8-1
8.2 MAIN FUNCTIONS
* Primary coil inputs AC 190V,200V,208V,220V,24DV or 250V.
Secondary coil outputs AC200V 16A and AC 1DOV 4A.
8.3. TRANSFORMER 301 CIRCUIT DIAGRAM
p s
0
11-1---o
I
0

190V
200/ - - - o 200V 16A
208V
-----oo
220V
230./

'
240V
'-·

( 250V
Figure 8-2
·~..

CCW-S-2XX •SERVICE• REV 1 8-1

 9 Inverter

9.1 EXTERNAL VIEW

Figure 9-1
9.2 MAIN FUNCTIONS
* Adjusts the frequency of the power supply to the drive motor and timing
hopper motor.
9.3 BLOCK DIAGRAM

TRI?
Thermal Relay
Connector
Control
VADJ BOOST
Circuit Board
~~

External
Operation

AC Power Induction
Motor

Figure 9-2

9-1 CCW-S-2XX • SERVICE •REV 1

 9JNVERTER

9.4 INVERTER TERMINAL

Table 9-1
TERM FUNCTION
R,S,T Power Terminals.
Connect to 3-phase 180 - 240VAC, 45 - 65Hz ..
When using single phase power, connect to Rand S terminals.
E Earth Terminal.
u,v,w Output Terminals.
Connect to motor.
Note: Do not place any switch between terminals U,V,W and the motor.
1 Control Circuitry Power Terminal.
12VDC (Rated 1OOmA).
2 Speed Set (REF) Input Terminal.
Input signal within 0-10VDC. Impedance 10K-ohms.
A 0-1 OVDC signal can be obtained by using a variable resistor (Sk-ohm, 1/2W min.
rating) off of terminal 5.
Note: if an external control voltage signal is input, it can be connected directly
because the control circuit is insulated from the power source.

S pee d IOVDC Signal

5) 15)
Source
Sette~/6,
5Ka 0- IOVDC Z\ Control OUT 0-lOVDC Z\ Control
l/2W Min.~ REF.IN Circuit Board REF. IN Circuit Board
COMMON
- Rating COMMON
g)
7"
31

3 Control Circuit Common Terminal.

This is the Common Terminal (OV), NOT the Earth Terminal.
When connecting external control circuitry via shielded cables, connect all cable shield
wires to this terminal.
4 AUX Input Terminal.
Used when feedback from an external source is required.
Consult the manufacturer before using this terminal.
5 Standard 10V (Rated 20mA) Power Source Used For Setting Speed.
6 RUN Signal Input Terminal.
Completing a circuit between terminal 6 and terminal 3 will start the motor.
7 Terminal for Frequency Meter Connection.
Employs 1mA meter with an internal resistance of 185-ohms.
The full-scale-selector-switch SW2 switches between 80Hz and 120Hz but output full-
scale is always 1mA.
Note: If utilizing a meter of another manufacturer, ensure that it is a 1mA meter with
internal impedance less than 200-ohms.
+ 7
Frequency Meter
l mA full-scale
G ~
Hz COMMON
Control
Circuit Board
~

8,9 Trip Signal Contact Output Terminals.

These terminals operate as a protective circuit in the event that the electrical load or
voltage is excessive. Ter.minals 8,9 are normally open, but close if abnormal conditions
arise. The contact circuit is rated for 20.5A at 250VAC or 30VDC.

CCW-S-2XX •SERVICE• REV 1 9-2

 10 Drive Motor

10.1 EXTERNAL VIEW

------REDUCTION GEAR

~-----MOTOR

I~-- TERMINAL BOX

@ @

Figure 10-1
10.2 MOTOR SPECS
Table 10-1
Yasukawa 3-phase Induction Motor
IVlorlel Full-closed external tan FELU-7
0.4 KW
Output
200/200 v
Frenuencv 50/60 HZ
Poles 4
Snee" 150011800/1800 rom
Ratrn" Continuous
Insulation E t"""e

10.3 REDUCTION GEAR SPECS

Table 10-2
GTR
frame No.
Reduction Ratio ""
1/75
Lunncatron Grease
FinrSI' Mansel 7.5BG 4/1..5

10-1 CCW-S-2XX • SERVICE • REV 1

 11 Wiring Diagrams

11.1 DIAGRAM GUIDE

Table 11-1
Drawing
No. Drawing Title
1E-6963 Wiring For All Components
2E-7999 RCUWiring
2E-6956 CAL Unit Wiring
2E-6955 Relay Wiring
2E-6953 CAL Power Supply Unit Circuit
2E-7990 PS Unit Circuit

11.2 PIN OUT DATA FOR 1E-6963 CABLES A-V

@ Wl!lliH Sl!i:· i:A8tl! © SI~. T/~ "'81.1! @ F PS CAStE
~'"
-•z.. :rn: J'l.JZ J'U .. J2a.. PS-I
"~
' ""
-~v

z' ''"~"'''-----''
~
rJ.Rli
WHT
,,.. ew ... ,,1..1e:
·~ ,
.,, '
s"""!I .S •
]. WHT
3 /t{O
l,o. !,/fH
$ Vtt
ea~

•oz'
·ez: •
~u ... •
l NHT
3 'flt/ii>AN
-· ,
i'ICIC><>l' l

®
2 8L..IC , ..

•'
£>lie PS Cl\8LE I
'
• " 8RIV
Q_LV
~III

'Ii!
,l
~ ,• nASM.-1 ~HJ

®
7
"'""~-~""'~'"~ ,z
"
.:rns
Wtl'H Slf.
~·~ ' "'
,-
~QT

~OT 0
I
• IL..: 1"Hf)
0

I
2 ctR"
RED "f'•SV
OllT_z
I 10
UTG.llN

II "TIU/
Tll~R
t;V"'P
'NfU4ffll 11
'
I() c0 UVC P$ !A<!LE
'
3 ,....,.
,,. sw ... av: -.'sv
""'!! ,, 12 ?&II ~ 2 ll ,.. 7"DS
1-- 13
(H<>IO
~r:t,J.f/ /J
z 11• .. l)(r/. .,
s SHIEL.() S .'I<-""'" ...,.,,. s10.,,,.
, " '
• • t.S IY'tT/10: COVEl
IS. IU!i1!6LX " t~
" .e ,,.,
© '"' "' CA8tE:
© Foe ~F C11au "'' " !l!!J
C::.A.!:l~S

:rw1
~,IQOV
:nu •m
'
l~t 1"~V
,
'" ;i'Ci '
t !tHl '1c1oeV

""' ,•' ''

WHT

' HQ ·11:z:1t
• ""' '"" "'""l" iHQ

•' "'~l:i. "ll:Z: t J ~ti;)

'"
.
Yri cpr<c
',• ',• •
...,
~~/'I
11•!!( ~l!I ~
S l'H "°' • © p ~IRl. Cl'l8LE
~·
• ;r!}O/

'' ''
P$•1
9.!+ 'ftTO

·<
/(JLJTHH
_,., 7.3<.IJ
?
I WHT
•
"" ' "
S IHIY 00
?

"" "
'1 ~"'?
, UT$.\'JV
0
~-~
~.svit~!o
•'
fO
Lirl•v rsvJ <2> CELL CABLE:
11
•Z l'W! ~SV'tY«i IZ " "I flt::O T•SV
,.~,.,,.,~

SM~f)
z (;If//'/ OVT
® ·.wEeT!!_'( r1~ Mat.e: J WHT Of<O J
lf<~E-0011. ,,. sw ..~ai.x -•sv .,,.
niPS;f."'I
S Slot(LO S
•-) s
@ i!'§~I> ,., z
'
'"' CABtE.

,
•
,
- Jf/'2
OR(,
l"S>'I•""')
cs. ii!
COT I>
1
'"' 3

'"
YEL C!ITS ® FEE01'!1. cAeL.E
•
<,,

S '-Rli ~or ..
.~
,M
:or 3 '• ;TIO?
, ,,.
f.9r ~
,
II :iRV ~<)Tl @ f)IJ PS ~RLE
'l.VliT :ore ' :: :;<,\>(r ~1$V

.,.z,,."
rolll.1<
"" ,,"' '"
' "' ... ... '"' ,'
II ~,!IW 8GNf)

,z i" Zt;.l'
REO -;!.... ,.~,)
@ C.-11. l.O&lC OC Cl\8LE
J RED
13 ;~.:; "
"$.•O
,."
.J"I08 :nD1;. • '
,, ''" ¥n
is"~
P~·~iJ

ERRolt ' "'"

' m""
,,
-111.v

II• .XV "

" ., ,'
-llv

•' "'
' •
-<V

CCW-S-2XX •SERVICE• REV 1 11-1