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OPERATORS MANUAL

AS675 LP GAS CYLINDER FILLING SYSTEM

OPERATORS MANUAL

Document No. 80424-21.MAN

This manual applies to AS670 software No. 60144 version 1.6x – 1.80

Issue Date: October, 2006

Designed by:

actronic

Kosel Industries reserves the right to make changes to the Kosel Industries range of products without prior notice and assumes no liability in connection with the use of any Kosel Industries branded product

© 2006, Kosel Industries

AS675 OPERATORS MANUAL

© 2006, Kosel Industries 80424-21.MAN

Contents

1. Introduction ................................................................................................................... 1

2. System Description ....................................................................................................... 2

3. The Indicator .................................................................................................................. 3

4. The Keyboard ................................................................................................................ 4

5. Filling Instructions ........................................................................................................ 5

5.1 Quick guide for cylinders with a Cat No. ...................................................................... 5 5.2 Quick guide for cylinders with no Cat No. .................................................................... 6 5.3 Detailed Filling Instructions for Cylinders with a CAT No. ............................................ 8 5.4 Detailed Filling Instructions for Cylinders with no CAT No. ........................................ 10

6. Cylinder Category Entry (CYL CAT, FW AND TW) ................................................... 14

7. Zero .............................................................................................................................. 15

8. Anti-theft Function ...................................................................................................... 15

9. Totalisers ..................................................................................................................... 16

9.1 Totaliser No. 1 - Valid Fill Totals ................................................................................ 16 9.2 Totaliser No. 2 – All Fill Totals. .................................................................................. 16 9.3 Multiple User Mode .................................................................................................... 17 9.4 Category Totals ......................................................................................................... 18

10. Error Messages ........................................................................................................... 20

11. Access Codes .............................................................................................................. 23

12. Appendix ...................................................................................................................... 24

Operators Manual AS 675

© 2006 Kosel Industries / Doc 80424-21.MAN 1

1. Introduction

LP Gas under pressure (in a cylinder) is a liquid. As a liquid, its volume will increase (expand) if heated. A full cylinder left in the sun, or exposure to heat will, under the pressure of the expanding liquid, cause the pressure relief valve to operate, with potentially dangerous results. To avoid this situation, a LP Gas cylinder must never be filled more than 80% by volume.

To fill a cylinder with a known safe amount of LP Gas three figures must be obtained to calculate how much LP Gas to add. These are:

1. The capacity or volume of the cylinder, expressed as either its water capacity (WC) in kg or lb, or its gas capacity, expressed as the maximum safe weight of gas, in kg or lb, that the cylinder will hold. The relationship between these figures is given by: Safe Weight of Gas = 0.42 x WC where the filling factor of 0.42 allows for a vapour space in the cylinder and takes into account the specific gravity of the LP Gas (Propane).

2. The empty weight of the cylinder. This is made up of two components; the weight of the bare cylinder (Tare Weight) plus the weight of any fitting or valve permanently attached to it.

3. The residual weight of gas in the cylinder. This is determined by weighing the cylinder and from this weight subtracting the empty weight figure (“2” above).

The Water Capacity (WC) and Tare Weight (TW) are normally stamped on the cylinder and can be expressed in either kg or lb. On some cylinders only the tare weight (TW) is marked on the cylinder and the weight of the fitting (cylinder valve assembly) must be obtained and added to the TW figure to derive the EW figure.

The AS675 can fill cylinders to either the Safe Gas Capacity or to a Nominal Gas Capacity. The safe gas capacity is as described above. The Nominal Gas Capacity is a nominated capacity equal to or a little less than the safe gas capacity. This is used so that a range of cylinders can be used to provide a standard quantity.

AS675 Operators Manual

2 © 2006 Kosel Industries / Doc 80424-21.MAN

2. System Description

The AS675 system consists of:

1. An AS670 digital control unit and weigh indicator that has the following functions:

i) Processes the signal from the load cell in the weighing platform and converts it to a weight reading to be displayed on the LCD display.

ii) Calculates and displays the maximum gross weight of the cylinder to be filled.

iii) Controls the LP Gas flow by controlling the solenoid valve (or valves).

iv) Communicates weight and cylinder information with a remote computer if available.

2. An AS574 power supply unit, which has the following functions:

i) Provides the power requirements of the AS670

ii) Contains the relays that control the pump and valve(s).

iii) Provides an intrinsically safe communications interface between the AS670 and the computer.

3. A load cell based weighing platform containing a single point load cell.

The full-scale weight capacity of the system is 99.9 kg

The purpose of AS675 system is to safely fill cylinders to their nominal (gas) capacity (“Cylinder Category Filling”) and in some cases their safe gas capacity (“No Cat Filling”).

The cylinder to be filled is placed on a weighing platform and filled to either a safe nominal weight or to a safe weight based on the water capacity (WC) of the cylinder. By controlling solenoid-operated valves and in some cases a pump, the LP Gas from the main reservoir is dispensed into the cylinder. The indicator calculates and displays the maximum allowable cylinder weight and the amount of LP Gas contained in that cylinder.

Caution: The safe filling of cylinders is dependent on the operator entering the correct category number and TW figure, or the correct WC, TW or EW figures and using the correct units of weight (kg or lb) for the cylinder to be filled.



3. The Indicator

Gross Weight

Max Full weight

Gas Weight

LED Indicators Keyboard

GROSS WEIGHT DISPLAY: displays gross weight on platform and, during data entry, cylinder Cat No.

MAX FULL WEIGHT DISPLAY: shows the calculated maximum full weight of the cylinder and, during data entry, the cylinder fitting weight.

GAS WEIGHT DISPLAY: shows the net weight of gas in the cylinder and, during data entry, the cylinder water capacity and tare weight.

LED INDICATORS: enunciates the displays and the various stages of the filling operation.

KEYBOARD: used to enter data and control the filling operation.

Gas WeightLED Indica tors



4. The Keyboard

There are 20 keys on the keyboard providing the following functions:-

CYL CAT

Used to select and display the cylinder Category No.

TARE WEIGHT

Used to enter and display the Tare Weight data.

CONFIRM WEIGHT

Used to check weigh the cylinder before filling begins and complete the data entry process.

START FILL

Starts the filling if cylinder data and weights are correct.

STOP

Turns the solenoid valves off, and if pressed twice completes the filling operation.

ZERO

If the gross weight on the platform is less than 2 kg, when pressed, will zero the gross weight display.

ENT & PIN

i) Used during cylinder cat data entry to accept numerical data and,

ii) Used to enter PIN numbers when multiple user mode is selected.

lb to kg

Enables lb to kg conversion when entering cylinder data in lbs.

CLR & NO CAT

i) Clears numerical data entries to zero and

ii) Selects the NO CAT cylinder filling procedure.

NUMBER KEYS (0 - 9) and DP

Used to enter numerical data.

DP & LAST FILL

Used to display “LAST FILL” information up to the time new filling data is entered.

MODEL AS670STOPSTARTFILLZE RO



5. Filling Instructions

5.1 Quick guide for cylinders with a Cat No.

For a detailed description see Section 5.3

1. Check Zero (see Section 7).

2. Check cylinder for:

i) last test date.

ii) rust, dents and other damage

iii) TW or EW figure

iv) CAT No.

3. If the multiple totalisers feature is enabled, (see Section 9), and the middle display does not indicate Usr nUsr nUsr nUsr n (where n=1 to 9), enter a valid “PIN No” as follows:

i) Press the ENT key

ii) Enter 4-digit PIN number

4. Place the cylinder on the platform centre.

5. Press CYL CAT and enter the cat number for this cylinder.

6. Press TW / EW and enter the TW figure obtained from this cylinder.

7. Press CONFIRM WEIGHT – keep hands clear of the cylinder.

8. Attach the filling valve, and open the fill valve. Ensure the hose does not touch any fixed part of the frame or cabinet.

9. Press START FILL – keep hands clear of cylinder.

10. After the FILLING LIGHT turns on, open cylinder valve – and the cylinder begins to fill.

11. When the FILL COMPLETE light comes on, compare the calculated weight on the middle display (Maximum Full Weight) with that shown on the top display (Gross Weight). For safety, the Gross Weight must be equal to or less than the Maximum Full Weight. The Net Weight and Maximum Full Weight are displayed until the weight on the platform is disturbed (unstable) when these displays blank.

12. Close the fill valve and the cylinder valve, then disconnect the fill

CONFIRM

WEIGHT

TW

EW

CYLCAT

PIN No.

ENT

STARTFILL



valve.

13. Remove the cylinder from the platform.

14. By pressing the LAST FILL key the gross weight, maximum full weight and net weight are again displayed. This can be done any time up until data is entered for the next filling sequence.

5.2 Quick guide for cylinders with no Cat No.

For a detailed description see Section 5.4

1. Check Zero (see Section 7).

2. Check cylinder for:

i) last test date.

ii) rust, dents and other damage

iii) WC and TW or EW figures

PIN No.

ENT

3. If the multiple totalisers feature is enabled, (see Section 9), and the middle display does not indicate Usr nUsr nUsr nUsr n (where n=1 to 9), enter a valid “PIN No” as follows:

i) Press the ENT key ii) Enter 4-digit PIN number

4. Place the cylinder on the platform centre.

CYLCAT

5. Press either CYL CAT followed by NO CAT or just NO CAT. Enter the WC figure obtained from this cylinder

EITHER (where the tare weight and fitting weight are known) :

TW

EW

6. Press TW / EW and enter the TW figure obtained from this cylinder.

CONFIRM

WEIGHT

7. Press CONFIRM WEIGHT and enter the fitting weight if known, or use the default figure displayed on the middle display.

OR (where the empty weight is known and the fitting weight is taken as zero) :

TW

EW

8. Press TW / EW and enter the EW figure obtained from the cylinder.

LAST FILL

CLRNO CAT



CONFIRM

WEIGHT

9. Press CONFIRM WEIGHT and for the fitting weight enter zero, if it is not the default value.

THEN:-

CONFIRM

WEIGHT

10. Press CONFIRM WEIGHT again – keep hands clear of the cylinder while the weight is checked…

11. Attach the filling valve and open the fill valve. Ensure the hose does not touch any fixed part of the frame or cabinet.

STARTFILL

12. Press START FILL – keep hands clear of cylinder while it checks weights again.

13. After the FILLING light turns on, open the cylinder valve – and the cylinder begins to fill.

14. When the FILL COMPLETE light comes on, compare the calculated weight on the middle display (Maximum Full Weight) with that shown on the top display (Gross Weight). For safety, the Gross Weight must be equal to or less than the Maximum Full Weight. The Net Weight and Maximum Full Weight are displayed until the weight on the platform is disturbed (unstable) when these displays blank.

15. Close the fill valve and the cylinder valve, then disconnect the fill valve.


LAST FILL

17. By pressing the LAST FILL key the gross weight, maximum full weight and net weight are again displayed. This can be done any time up until data is entered for the next filling sequence.

IMPORTANT: During filling the operator must not touch the cylinder or the filling nozzle, to avoid the measured weight being affected, resulting in an invalid or aborted filling operation.



5.3 Detailed Filling Instructions for Cylinders with a CAT No.

Before a filling operation begins and with the platform empty, the displays on the AS670 will show the following:

Top Display: 0.00 kg (current weight on platform)

Middle Display: - - - kg (no meaning until data entered)

Bottom Display: - - - kg (no meaning until data entered or filling)

Note: If the multiple totals feature has been enabled, (see Section 9 for details), the middle display will show Usr nUsr nUsr nUsr n, where n indicates a user number from 1 to 9.

The weight shown on the top display should normally be 00.00 with the ZERO indicator light on. If the reading is not zero, but within -0.5 to +3.5 kg of the original calibration, the scale can be "zeroed" by pressing the ZERO key (see Section 7).

The CYL CAT number assigned to a cylinder defines the nominal gas capacity and fitting weight for the cylinder and also includes an approximate Tare Weight (TW) value for self-checking purposes. (See section 6 for CYL CAT data entry).

Before starting a cylinder filling sequence, the cylinder category number (CYL CAT) and tare weight (TW) must be obtained for the cylinder to be filled and entered into the system via the keyboard. If the multiple totalisers feature is enabled, (see Section 9), and the middle display does not indicate Usr nUsr nUsr nUsr n (where n = 1 to 9), enter a valid “PIN No” as follows:

1. Press the PIN key (ENT key)

2. Enter a user 4 digit PIN number. The message Usr nUsr nUsr nUsr n (where n = 1 to 9) is displayed on the middle display.

If the cylinder to be filled does not have a CYL CAT number, the WC (water capacity) and EW (empty weight) or TW (tare weight) data obtained from the cylinder, must be entered instead (see Section 5.4 – No Cat Fill).

1. Place the cylinder to be filled on the platform centre.

2. Press the CYL CAT key, followed by a number key corresponding to the cylinder cat number. The top display will show the number selected, the middle display will show the weight of the fitting assigned to that Cat No. and the FITTING kg light will be on. The bottom display will show (flashing) the nominal gas capacity for this cylinder.

3. Press the TW/EW key. The bottom display will show - - - and the TW/EW light will be on. Use the keyboard to enter the TW figure obtained from the cylinder. Pressing the CLR key will clear

the entry to 0.0.

If this data is in lbs, the lb to kg key must be pressed just prior to or just after the numbers are keyed in. These numbers appear on the bottom display as keyed in. If lbs were



selected, the UNITS IN lb light will be on. (At this point pressing the lb to kg key again will toggle the units back to kg and the light will stop flashing but the displayed number will remain the same). Data is entered to one decimal place. If the cylinder data is given to two decimal places, and the last decimal place is keyed in, the least significant digit is ignored.

4. Press the CONFIRM WEIGHT key - this accepts the TW figure just entered and the cylinder is now check weighed - the indicator “beeps” at a 1 second rate while it waits for the cylinder to become stable. When stable, the bottom display initially blanks and then displays (flashing) the weight of the residual gas in the cylinder and the NET light is on. The middle display now shows the calculated maximum full weight allowable for this cylinder. The top display continues to show the cylinder Cat No.

Pressing either the CYL CAT key or the TW/EW key again will show the fitting weight on the middle display, and either the nominal gas capacity or TW on the bottom display. The CYL CAT No. and TW can be edited at this time. Press the CONFIRM WEIGHT key again to check weigh as described in “4” above.

5. Attach the filling valve and hose to the cylinder and open the fill valve. Ensure that the hose does not touch any part of the surrounding frame or cabinet.

6. Press the START FILL key. The cylinder is again weighed - the indicator “beeps” until the weight is stable - and then Maximum Full Weight figure on the middle display is adjusted to include the weight of the hose and fitting. The top display shows the live gross weight on the platform and the bottom display shows the net weight of gas in the cylinder and the NET light is on. The FILLING light comes on and the solenoid valve opens. Open the cylinder valve and the cylinder begins to fill.

If required, the filling can be “halted” by pressing the STOP key once. The valves close and the FILLING light flashes slowly. The weights shown on the top and bottom displays remain “live”. Filling can be resumed by pressing the START FILL key. Pressing the STOP key again “completes” the fill.

7. Filling continues until the net weight of gas reaches the nominal gas capacity of the cylinder. The valve closes and when the weight on the platform is stable, the FILL

COMPLETE light comes on. If the cylinder has been over-filled by more than 3% of the Max Full Weight, the message oFiLLoFiLLoFiLLoFiLL shows flashing on the top display while the displays remain “live”.

8. When the FILL COMPLETE light comes on, compare the calculated weight on the middle display (Maximum Full Weight) with that shown on the top display (Gross Weight). For safety, the Gross weight must be equal to or less than the Maximum Full Weight. The Net weight and Maximum Full Weight are displayed until the weight on the platform is disturbed (unstable) when these displays blank.

9. Close the valves and remove the hose and fill valve.


11. By pressing the LAST FILL key (shared with the DP key) the gross weight, maximum full weight and Net weight are again displayed. This can be done any time up until data is entered for the next filling sequence.



If during filling, the cylinder is “lent” on forcing the measured weight above the calculated maximum full weight, the filling is stopped and cannot be restarted. The fill, however, is not “completed” or recorded until the platform has become stable, when it will record and display the actual weight on the platform and the net weight of gas in the cylinder. In this case, to completely fill the cylinder if it was stopped early, the cylinder has to be first removed from the platform and then the data has to be re-entered as if it was a new filling operation.

The filling operation can be "completed" by three methods:

1. Automatically, when the content of the cylinder equals the nominal cylinder capacity.

2. By pressing the STOP key twice. (The first press HALTS the filling, but can be restarted.)

3. Where communications exist with a computer, the computer can stop and "complete" the filling operation.

The platform weight returning to less than 0.5 kg marks the end of the filling sequence and:

1. The TARE is cancelled. (The NET light turns off.)

2. The TW entry is cancelled.

3. The displays revert to their pre-filling state.

At the end of the filling sequence when the cylinder is removed from the platform, the top display shows the live gross weight on the platform and bottom display shows - - - until new data is entered. The middle display will show - - - or, if multiple totalisers are enabled, Usr nUsr nUsr nUsr n (where n=1 to 9).

The weight on the platform must return to less than 0.5 kg before another filling operation can begin.

If another cylinder is filled within a time period (set during installation), the last Cat No. will be retained allowing the operator to directly enter the TW/EW data saving the time of entering the cylinder Cat No.

NOTE: If, during a filling operation, the weight on the platform is reduced to less than 50% of the Confirm Weight value, the filling operation is aborted and an error message is displayed.

5.4 Detailed Filling Instructions for Cylinders with no CAT No.

(If the cylinder to be filled has a CYL CAT number refer to Section 5.3).

Before a filling operation begins and with the platform empty, the displays on the AS670 will show the following:

Top Display: 0.00 kg (current weight on platform)

Middle Display: - - - kg (no meaning until data entered)

Bottom Display: - - - kg (no meaning until data entered or filling)



Note: If the multiple totals feature has been enabled, (see Section 9 for details), the middle display will show Usr n , where n indicates user number 1 to 9.

The weight shown on the top display should normally be 0.0 with the ZERO indicator light on. If the reading is not zero, but within -0.5 to +3.5 kg of the original calibration, the scale can be "zeroed" by pressing the ZERO key (see Section 9).

Before starting a cylinder filling sequence, the cylinder water capacity (WC) and empty weight (EW) must be obtained for the cylinder to be filled and entered into the system via the keyboard. Note: EW = TW (tare weight) plus FW (fitting weight)

If the multiple totalisers feature is enabled, (see Section 9), and the middle display does not indicate Usr nUsr nUsr nUsr n (where n = 1 to 9), enter a valid “PIN No” as follows:

1. Press the PIN key (ENT key).

2. Enter a 4 digit PIN number. The message, Usr n Usr n Usr n Usr n (where n = 1 to 9) is displayed on the middle display.

1. Place the cylinder to be filled on the platform centre.

2. Press either the CYL CAT key, followed by the NO CAT key, or press the NO CAT key directly. The top display will show no CAtno CAtno CAtno CAt, the middle display will show a default fitting weight (determined in an engineering set-up), and the FITTING kg light will be on. The bottom display will show - - - awaiting data entry for this cylinder and the WC light will be on and flashing, prompting for WC data.

3. The Water Capacity data is read from the cylinder to be filled in either kg or lb, and entered via

the keyboard. If this data is in lbs, the lb to kg key must be pressed just prior to or just after the numbers are keyed in. These numbers appear on the bottom display as keyed in. If lbs were selected, the UNITS IN lb light will be on. (At this point pressing the lb to kg key again will toggle the units back to kg and the light will stop flashing but the displayed number will remain the same). Data is entered to one decimal place. If the cylinder data is given to two decimal places, and the last decimal place is keyed in, the least significant digit is ignored. Incorrect

entries can be cleared to 0.0 by pressing the CLR key. The data is accepted by pressing the TW/EW key. For water capacities above 99.9 Kg and 99.9 lb, data is entered as whole units only. (no D.P.)

Note: WC and TW/EW data must be entered using the same units. Mixed units will not be accepted.

4. The bottom display will now show - - - and the TW/EW light will be on and flashing, prompting for TW/EW data. The UNITS in lb light will remain on if previously selected. The numbers appear on the bottom display as keyed in. If the cylinder data is given to two decimal places, and the last decimal place is keyed in, the least significant digit is ignored. Incorrect entries

can be cleared to 0.00 by pressing the CLR key.

Note: Where cylinders have their EW value marked on them, the fitting weight is entered



as zero and the value entered is the EW figure obtained from the cylinder - this includes the fitting weight.

5. The entry can be accepted two ways: i) by pressing the NO CAT key again (the bottom display will show the entered WC data, and the middle display will show the default fitting weight). ii) by pressing the CONFIRM WEIGHT key.

6. The top display continues to show no CAtno CAtno CAtno CAt, the bottom display shows (flashing) the nominal gas capacity that the system has assigned to this cylinder and the middle display shows the default fitting weight. The FITTING kg light is on and flashing, prompting for an actual fitting weight. A new fitting weight can be entered and accepted by pressing the CONFIRM WEIGHT key or the default figure can be accepted the same way. If the EW figure has been used in “4” above the fitting weight must be zero.

7. On pressing the CONFIRM WEIGHT key for the second time, the cylinder on the platform is check weighed. (The indicator “beeps” until the weight is stable) The bottom display initially blanks and then displays (flashing) the weight of the residual gas in the cylinder and the NET light is on. The middle display now shows the calculated maximum full weight allowable for this cylinder. The top display continues to show no CAtno CAtno CAtno CAt.

8. The data entries can be checked and edited if required at this point by repeating the above steps.

9. Attach the filling valve and hose to the cylinder and open the fill valve. Ensure that the hose does not touch any part of the surrounding frame or cabinet.

10. Press the START FILL key. The cylinder is again weighed and the Maximum Full Weight figure on the middle display is adjusted to allow for the weight of the hose and fitting. The top display shows the live gross weight on the platform and the bottom display shows the net weight of gas in the cylinder and the NET light is on. The FILLING light comes on and the solenoid valve(s) open. Open the cylinder valve and the cylinder begins to fill.

If required the filling can be “halted” by pressing the STOP key once. The valves close and the FILLING light flashes slowly. The weights on the top and bottom displays remain “live”. Filling can be resumed by pressing the START FILL key. Pressing the STOP key again “completes” the fill.

11. Filling continues until the net weight of gas reaches the safe gas capacity of the cylinder. The solenoid valve closes, and when the weight on the platform is stable, the FILL

COMPLETE light comes on. If the cylinder has been over filled by more than 3% of the Max Full Weight, the message oFiLLoFiLLoFiLLoFiLL shows flashing on the top display while the displays remain “live”.

12. When the FILL COMPLETE light comes on, compare the calculated weight on the middle display (Maximum Full Weight) with that shown on the top display (Gross Weight). For safety, the Gross weight must be equal to or less than the Maximum Full Weight. The Net weight and Maximum Full Weight are displayed until the weight on the platform is



disturbed (unstable) when these displays blank.

13. Close the cylinder and fill valves.

14. Remove the hose and fill valve.


16. By pressing the LAST FILL key (shared with the DP key) the gross weight, maximum full weight and Net weight are again displayed. This can be done any time up until data is entered for the next filling sequence.

If during filling, the cylinder is “lent” on forcing the measured weight above the calculated maximum full weight, the filling is stopped and cannot be restarted. The fill, however, is not “completed” or recorded until the platform has become stable, when it will record and display the actual weight on the platform and the actual net weight of gas in the cylinder. In this case, to completely fill the cylinder if it was stopped early, the cylinder data has to be re-entered as if it was a new filling operation.

The filling operation can be "completed" by three methods:

1. Automatically, when the contents of the cylinder, equals the nominal cylinder capacity.

2. By pressing the STOP key twice (the first press HALTS the filling).

3. Where communications exist with a computer, the computer can stop and "complete" the filling operation.

The platform weight returning to less than 0.5 kg marks the end of the filling sequence and:

1. The TARE is cancelled (the NET light turns off).

2. The WC and TW entries are cancelled.

3. The displays revert to their pre-filling state.

At the end of the filling sequence when the cylinder is removed from the platform, the top display shows the live gross weight on the platform and the middle and bottom displays show - - - until new data is entered.

NOTE: If, during a filling operation, the weight on the platform is reduced to less than 50% of the “Confirm Weight” value, the filling operation is aborted and an error message is displayed.



6. Cylinder Category Entry (CYL CAT, FW AND TW)

Cylinders that have common sizes and fitting weights can be classified into one of 10 categories.

A CAT no. (category number) when assigned to a cylinder, defines for that cylinder, its Nominal Gas Capacity, the weight of the cylinder valve fitting and a “Nominal TW” figure. The TW figure is for self-checking purposes and ensures that grossly incorrect tare weight data cannot be used. The CAT no. details should be entered only by a suitably qualified operator as errors in this data may cause overfills or inaccurate filling.

NOTE: The Nominal Gas Capacity assigned to a cylinder must equal to or be less than the Safe Gas Capacity as calculated by: SGC = WC x Filling Factor.

(Filling Factor for Propane = 0.420)

The Nominal Gas Capacity, fitting weight and a nominal (estimated) Tare Weight values are assigned to categories 0 to 9. These values are entered as follows:-

1. Enter access code: STOP 9 6 3 within 0.5 seconds between key presses.

2. The top display will show: CAt1CAt1CAt1CAt1

3. The middle display will show, flashing, the message FitFitFitFit meaning fitting weight.

4. The bottom display will show 0.0 or the weight of the fitting weight assigned to Cat 1.

5. A new fitting weight can now be entered via the keyboard, or accept the current value and press ENT. This figure will be added to the tare weight figure, entered by the operator, to determine the true, empty weight of the cylinder. This is used in determining the weight of residual gas and the amount of gas to add to correctly fill the cylinder. The limits for the fitting weight are- min, 0.0 kg and max, 4 kg.

6. After pressing ENT the middle display will show, flashing, GASGASGASGAS and the bottom display will show the current value for this category.

7. Enter the nominal gas capacity (in kg) via the keyboard (the limits for the nominal gas capacity are; min, 4.5 kg and max 45 kg), or accept the current figure and press the ENT key to accept.

8. After pressing ENT the middle display will show, flashing, tArEtArEtArEtArE and the bottom display will

show 00 or the current value. Enter the nominal or estimated tare weight of the cylinder. This figure is used as a guide to prevent the accidental use of the wrong CAT No. Enter the TW estimate using the numeric and DP keys and press ENT to accept. (The limits for this are: min, 1 kg and max, 45 kg). A figure in the mid-range of known tare weights for this category should be used.

9. The top display will now show: CAt 2CAt 2CAt 2CAt 2 and the data for CAT 2 cylinders will be displayed as for “CAT 1” above.



10. Pressing the ENT key (three times per category) will scroll through all the cylinder category data for viewing, adding or editing. Wrong entries can be cleared by use of the CLR key.

11. Any CAT number can be accessed directly while in this set-up mode by pressing the CYL CAT key and then the desired number. Previously entered data can then be edited.

12. Exiting from this CAT set-up routine at any point can be achieved by pressing the STOP key. Changes or additions made, up until the last time the ENT key was pressed, will be saved.

A table shown in the Appendix has been provided for the convenient recording of stored category numbers.

7. Zero

Before any filling operation begins, the indicator must be checked for ZERO i.e. the weight showing

on the top display is 0.00 and the ZERO light is on. If there is any residual weight on the platform or

“zero” drift in the system, the indicator may be reading other than 0.00 . To set this back to zero press the ZERO key. A shift in zero of up to -0.5 and +3.5kg from the original calibration point can be corrected for. (If the shift is greater than this, when the ZERO key is pressed an error message

is displayed - Error 36. Contact your service representative.)

If the indicator has not “seen” a zero reading for more than a specified time set in an engineering

function, on attempting to enter data for a new filling operation, an error message (Error 38) is displayed and filling is inhibited until the scale is re-zeroed.

8. Anti-theft Function

If, during filling after 10 seconds from when START FILL is pressed, the rate of increase in weight

on the platform is below a pre-set minimum, the system will go into the “HALT” state and Error 40 will be displayed. The filling can be resumed by pressing the START FILL key again.

However if the fill rate is still below the pre-set minimum, the filling will stop and Error 41 will be displayed. All functions will be inhibited until a secret code is entered to re-enable the system. The system remains “locked out” even if power is turned off and on. This code is issued to authorised personnel only.



9. Totalisers

The AS670 has totalisers to record the LP gas dispensed, the residual LP gas, the number of filling operations for all cylinders filled and for the cylinders filled by up to nine individual users (includes all categories).

These cylinder fills are stored as two groups of totals:

(1) Valid Fill Totals - filling operations that have been filled correctly and resulted in a FILL COMPLETE signal from the AS670 display unit

(2) All Fill Totals - all the filling operations that including those from (i), above, and also those which have not been filled correctly, (for example, where the cylinder is removed from the platform before the FILL COMPLETE signal).

The difference between these two totals represents the number of cylinders, the gas dispensed, and the residual of filling operations that were not completed correctly, (non-valid fills).

The totals are not lost when power is removed from the system and roll over to zero beyond their maximum value.

The totals can be reset to zero by pressing STOP 7 7 7 .

9.1 Totaliser No. 1 - Valid Fill Totals

During every filling operation when a valid FILL COMPLETE is achieved, the following is added to three separate totals:

i) On the top display the total weight in kg of the gas dispensed. Max No. 99999 kg.

ii) On the middle display the total weight in kg of the residual gas in the cylinders. Max No. 9999 kg.

iii) On the bottom display the fill number - this increments every valid “FILL COMPLETE”. Max No. 999.

These totals are displayed by pressing STOP 7 8 9 when the system is not in a filling sequence.

The weight totals are accumulated to the nearest 0.1kg but are displayed rounded down to the nearest kg.

9.2 Totaliser No. 2 – All Fill Totals.

This accumulates the totals of i), ii) and iii) above but also includes the maximum weight recorded during a filling operation, residual gas and an incremental fill number of filling operations that do not end with a valid FILL COMPLETE indication. For example, when a cylinder is removed before the



target weight is reached, or removed too quickly before a stable reading is achieved. These totals are displayed by pressing STOP 4 5 6 . This “No. 2” total is the grand total of all gas dispensed.

9.3 Multiple User Mode

When this mode is enabled, one of nine separate sets of “User” totals (corresponding to one of 9 users) must be selected before a cylinder can be filled. When the Multiple User mode has been selected the middle display shows USrUSrUSrUSr---- .

Before the start of the filling sequence, a user PIN is entered. Attempting to fill a cylinder

without a user number selected results in the error message UsrUsrUsrUsr and Error 16 being displayed.

Selecting the user number:

1. Press the PIN (ENT) key. If the Multiple User function is enabled, the top display will

show PIN and the other displays will be blank.

2. Enter the 4-digit user PIN number. These appear as dashes on the middle display. If the PIN number is correct the middle display will show UUUUssssrrrr nnnn where n = the user’s totaliser number. Any filling operation will now be recorded in Totaliser Number n. This User Number stays selected until there has been a period where no keyboard operations occur for the time set by the engineering function E5 (Time out for no data entry).

3. The User Number can be cancelled by:

i) pressing the PIN (ENT) key then the STOP key

ii) entering another PIN number

iii) timed out after a pre-defined time period of no filling activity

User 9 (Select by PIN No.)

Dispensed kg xxxxx

xxxx

xxx

xxxxx

xxxx

xxx

Valid Fills“STOP 789”

All Fills“STOP 456”

Residual kg

Number of Fills

Dispensed kg xxxxx

xxxx

xxx

“STOP 789”

Residual kg

Number of Fills


Dispensed kg xxxxx

xxxx

xxx

xxxxx

xxxx

xxx



Residual kg

Number of Fills


Dispensed kg xxxxx

xxxx

xxx

xxxxx

xxxx

xxx



Residual kg

Number of Fills

All users (Select by “PIN STOP”)

Dispensed kg xxxxx

xxxx

xxx

xxxxx

xxxx

xxx



Residual kg

Number of Fills



PINs are assigned to each user through engineering set-up functions. They are not displayed during entry and cannot be recalled. However if a PIN has been forgotten, a new PIN can be entered.

For every valid fill the standard (All users) set of totals increment as well as the selected set of user totals.

When Multiple User mode is disabled, the standard (All users) totalisers (dispensed quantity, residual quantity, and fill number) function as previously described.

9.4 Category Totals

This feature records the total LP gas dispensed, the total residual LP gas and the number of filling operations for each cylinder category for all users.

These numbers are stored as two groups of totals:

(1) Valid Fill Totals - filling operations that have been filled correctly and resulted in a FILL COMPLETE signal from the AS670 display unit

(2) All Fill Totals - all the filling operations that including those from (i), above, and also those which have not been filled correctly, (for example, where the cylinder is removed from the platform before the FILL COMPLETE signal).

The difference between these two totals represents the number of cylinders, the gas dispensed, and the residual of filling operations that were not completed correctly, (non-valid fills).

The Category Totals can be read from the display by selecting a category, then pressing STOP 7 8 8 (Valid Fills only) or STOP 4 5 5 (All Fills).

Example:

i) Press the CYL CAT key

ii) Select the category (number 0 to 9)

iii) Press STOP 7 8 8 (valid fills only) or STOP 4 5 5 (all fills)

The word GAS will appear on the bottom display and the dispensed gas total will appear on both the middle and top displays – the first four least significant digits on the middle display and up to 5 most significant digits on the top display. (Maximum displayed number is 99999999.9kg)

This number remains for about 5 seconds (or press ENT) before stepping onto the residual total. The word rESrESrESrES will appear on the bottom display and the residual gas total will appear on both the middle and top displays – the first four least significant digits on the middle display and up to 5 most significant digits on the top display. (Maximum displayed number is



99999999.9kg).

This number also remains for about 5 seconds (or press ENT) before stepping onto the number of fills total. The word FiLFiLFiLFiL will appear on the bottom display and the number of fills total will appear on both the middle and top displays – the first four least significant digits on the middle display and up to 5 most significant digits on the top display. (Maximum displayed number is 999999999kg).

Repeat for other categories.

If Multiple User totals are selected (see above), a user PIN number will need to have been entered before the category can be selected.



10. Error Messages

Error messages will be displayed if the required conditions for calibration or successful filling are not met. The word Error is shown on the top display and the error number is shown on the middle display.

The following table lists the error message numbers the probable cause and suggested operator response.

More detailed descriptions of the errors are outlined in the AS675 Installation, Set-up, Calibration and Spare Parts Manual.

Top

Display

AS675 Error Message No.:

Probable Cause Suggested User Response

Error 1- Error 8

Fault with electronics during calibration and engineering set-up

Call for service

Error 11- Error 14

Fault with filling station electronics or interconnecting cabling

Check cabling or call for service

UsrUsrUsrUsr Error 16 User ID (PIN number not entered

correctly) Only when multiple totalisers selected.

Enter PIN number. See AS675 Technical Manual for instructions

tarEtarEtarEtarE Error 17 The entered TW differs from the estimated TW by more than figure set in Engineering set-up (E10)

Enter correct tare weight and / or check cylinder master file data.

CAPCAPCAPCAP Error 18 The cylinder CAT or WC data has

not been entered. Enter data in manual mode and / or check cylinder master file data.

tarEtarEtarEtarE Error 19 The TW data has not been entered.

Enter TW and / or check cylinder master file data.

2 biG2 biG2 biG2 biG Error 20 The calculated “Maximum full weight” figure is too large for system. This makes an allowance for the weight of the hose and nozzle.

Re-enter cylinder data and / or check cylinder master file data.

StAbLStAbLStAbLStAbL Error 21 On pressing “CONFIRM

WEIGHT”, the weight on the platform is not stable - this message occurs after a delay of 10 seconds.

Allow cylinder to stabilise on platform before filling.

tooLotooLotooLotooLo Error 22 The calculated amount of gas to dispense is too small – i.e.. less than 1 kg.

Check contents of the cylinder.

Is it already full?



Top

Display



CYLCYLCYLCYL Error 23 On pressing “Confirm Weight”,

the weight on the platform is less than the calculated E.W. figure


inhibinhibinhibinhib Error 24- Error 25

The filling has been inhibited by the computer (if available and the function has been enabled.)

Check computer system.

ConFConFConFConF Error 26 The weight on the platform has not been “confirmed”.

In manual mode, ensure the confirm weight key is pressed in the proper sequence.

StAbLStAbLStAbLStAbL Error 27 On pressing “START FILL”, the weight on the platform is not stable - this message occurs after a delay of 10 seconds.

Allow cylinder to stabilise on platform before filling.

tooLotooLotooLotooLo Error 28 On pressing “Start Fill”, the weight on the platform is less than the calculated E.W. figure.


tooLotooLotooLotooLo Error 30 The weight on the platform is less than the “confirmed” weight.

Fill the correct cylinder.

inhibinhibinhibinhib Error 32 The START FILL key is pressed when the computer has inhibited the filling

CYLCYLCYLCYL Error 33 The cylinder is removed from the platform before “Fill Complete”.

Wait for the “Fill Complete” light before touching cylinder.

StAbLStAbLStAbLStAbL Error 34 At the end of the fill while waiting to go “FILL COMPLETE” the platform is not stable.

Check platform & cylinder for movement. (rocking or vibration)

2 FAr2 FAr2 FAr2 FAr Error 36 When the “ZERO” key is pressed and the shift from zero calibration is too large.

Check for free movement of platform scale top - or load cell may be damaged.

----SAFESAFESAFESAFE Error 37 When entering new cylinder data in auto mode, the nominal gas capacity entered is greater than the safe gas capacity calculated from the water capacity entered.

Check cylinder data, then re-enter.



Top

Display



2Ero2Ero2Ero2Ero Error 38 Scale has not seen “ZERO” for a certain time since the last filling operation as set in an engineering function (E31)

Re-zero scale using the ZERO key. Ensure the platform is clear of obstructions and hose.

rAnGErAnGErAnGErAnGE Error 39 Hose weight too large or too small The limits are set in engineering functions (E17 and E19).

Check hose and fitting valve weight.

Ensure hose has easy and unobstructed path to the cylinder

2 SLo2 SLo2 SLo2 SLo Error 40 The filling rate is too slow. Check that the gas supply is OK

The minimum "fill rate" may need to be reduced in an engineering set-up

2 SLo2 SLo2 SLo2 SLo Error 41 The filling rate is too slow after restarting the filling system after “ERROR 40”. Further filling is inhibited until a “release code” is entered via the keyboard at which point a “FILL COMPLETE” occurs and the amount of gas dispensed (if any) is sent to the computer. Removing power from the unit will not release the inhibit function.

Enter reset code if available. Otherwise call for service. Check that the gas supply is OK The minimum "fill rate" may need to be reduced in an engineering set-up



11. Access Codes

A number of functions can be accessed by the use of a four-character code. When entering these codes, the time between key presses must not exceed ½ second. No key beep sounds.

These codes are listed below:

STOP 1 1 1 Displays the software and version numbers

STOP 4 4 4 Select product number (1 to 9 then ENT)

STOP 6 6 6 Turn On/Off ID reader (Any number key toggles then ENT)

STOP 4 5 6 Display “All Fills” totals (STOP to exit or timeout)

STOP 7 1 9 Turn On/Off polling blips (Any number key toggles then ENT)

STOP 7 7 7 Reset all totals to zero (then ENT)

STOP 7 8 9 Display “Valid Fills” totals (STOP to exit or timeout)

STOP 8 8 8 Turn ON/Off Auto Data Mode (Any Number key toggles then ENT)

STOP 9 6 3 Cylinder category set-ups (STOP to exit)



12. Appendix

Ca

t #

NG

CF

W(k

g)

No

m T

W(k

g)

MF

W*

(kg

)N

om

TW

(lb

)

Data

Re

quired for

Pro

gra

mm

ing:

Fill

ing F

acto

r:

Defa

ult F

.W. fo

r N

oC

at (k

g):

Max T

.W. E

rror

(%):

Cate

gory

Data

Entr

y W

ork

sheet

*MF

W (

w/o

Hose a

nd N

ozzle

) =

NG

C +

FW

+ T

W. T

his

valu

e is

ca

lcula

ted

and

dis

pla

ye

d d

uri

ng

fill

ing

.

Ne

t G

as W

t =

MF

W -

Re

sid

ual G

as

For

NoC

at: N

GC

= W

C x

Fill

ing F

acto

r

lb =

kg

/0.4

54

1 2 3 4 5 6 7 8 9

10

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