DACS-G

PRODUCT
GUIDE

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The purpose of this document is to depict the available DACS-G Checkweigher product range.
The guide provides information on DACS-G models and configurable options, the guide will be
updated periodically to reflect range development.

Following the initial product definition content a tutorial is provided, this provides an introduction
to fundamental Checkweigher uses as well as more detail about the options depicted in the
initial configuration tables.

The guide, which due to the anticipated update frequency is supplied in PDF format only,
is provided as an Ishida internal reference document only.

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DACS-G Key features
• Compact and modular design
• Multi-range (DACS-G-S015, 600g or 1500g)
• 7” Colour LCD screen, touch key pad with command dial button
• 200 presets standard. Up to 500 as an optional upgrade
• Quick-release conveyors in a wide range of dimensions
• Smooth frame design for fast and easy cleaning
• Ishida-made, high-speed, high-sensitivity load cell
• Anti Floor Vibration (AFV) compensation cell
• Load cell - excessive load protection through Dislocating Force Limiter (DFL)
Connectivity
• Ethernet
• USB
Options
• Special reject systems
• Feedback control
• Metal detector
• Printer
• Reject confirmation

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Reading the codes How to read
the name:
• The model name contains information about the machine specifications
• You can tell the maximum weight, conveyor width and length, type of
in-feed conveyor, finish and display unit

DACS-G-S 015 - 2 4 - SS - I - S
Max Weigh Weigh In-feed
Code Finish Display unit
weight Conveyor width Conveyor length conveyor
015 1,500g 1 - 160 mm SS - Stainless Steel I - Infeed S - Standard command dial
060 6,000g 2 - 240 mm 2 - 250 mm WP - Water Proof N - No Infeed H - High grade colour touch screen
3 - 320 mm 3 - 350 mm CE - Ceia MD**
4 - 400 mm 4 - 450 mm S - Safeline MD
5 - 550 mm
6 - 650 mm

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3 2
Checkweigher benefits
applications DACS-G Command Dial DACS-G CTS

• Feedback to hand packers

• Feedback to a volumetric filler 4
• Feedback to an auger filler 5
• Feedback to the baking process
1 Screens
S H
2 Data Storage

3 Printer S Standard command dial

High grade colour touch screen (CTS) -

4 Metal detector H
this is the most advanced option

5 The reject system

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DACS-G-S015/S060
Model
Model(s) Infeed (mm) Weight (mm) Reject (mm) Model(s) Infeed (mm) Weight (mm) Reject (mm)
DACS-G-S015-12* 450 250 550 DACS-G-S060-22* 450 250 550
DACS-G-S015-13* 350 350 550 DACS-G-S060-23* 350 350 550
DACS-G-S015-14* 350 450 550 DACS-G-S060-24* 350 450 550
DACS-G-S015-22* 450 250 550 DACS-G-S060-33* 450 350 550
DACS-G-S015-23* 350 350 550 DACS-G-S060-34* 450 450 750
DACS-G-S015-24* 350 450 550 DACS-G-S060-35* 450 550 750
DACS-G-S015-33* 350 350 750 DACS-G-S060-36* 550 650 750
DACS-G-S015-34* 350 450 750 DACS-G-S060-44* 545 445 845
DACS-G-S015-35* 450 550 750 DACS-G-S060-45* 445 545 845
DACS-G-S060-46* 545 645 845
Specifications
Option Rules/Comments S015 S060
Languages Up to 3 off
Manuals (Paper or CD) Up to 3 off
Line Height 850mm 100 ±
Leg Extension Straight 950mm 100 ±
Leg Extension Flared 1100mm 100 ±
SS Stainless Steel
Environment
WP Water Proof *DACS G-S060 22/23/24 size not available
Left to right
Direction of Travel
Right to left
S Standard Command Dial
Display
H High Grade CTS Caution - ensure required language is available
Non approved
Approval
MID
Standard Not bolt down
Feet Bolt Down
Caster
None
CEIA THS/SL21E 3F Aperature size to be confirmed, product dependent

Metal Detector CEIA THS/SLMS21 Aperature size to be confirmed, product dependent

Integration CEIA THS/MS21 Aperature size to be confirmed, product dependent
Safeline Dual Frequency Aperature size to be confirmed, product dependent
Safeline Signature Aperature size to be confirmed, product dependent

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Reject Options
Reject Method Direction (Front or Rear) Direction (Front or Rear inline) Direction (Front and Rear) Reject Bin S015 S060
Standard Air 2 zone 3 zone 3 zone Confirm quantity
HD Air 2 zone 3 zone 3 zone Confirm quantity
Pneumatic Arm 2 zone 3 zone 3 zone Confirm quantity
Reject Options Rules
Reservoir Kit Included with HD Air; selectable with other options
Reject Confirmation Only selectable with reject bin(s)
Bin Full Only selectable with reject bin(s)
Bin Locked Only selectable with reject bin(s)
Product Buildback Sensor Only selectable with reject bin(s)

Upgrade Options
Machine Upgrade Options Rules S015 S060
Extended Infeed (excludes combination units) Extended Infeed Conveyor at 50mm increments - original infeed length stated + up to 400mm maximum
Printer
Beacon
E Stop Facility
Belt Gap Transfer Plates If selected, all conveyors
Infeed Guides Infeed conveyor only, not full length of conveyor
Windshield Fixed Lockable Hatch Included as standard when selecting reject confirmation. Material Polycarb only
Windshield Fixed Interlocked Hatch Material Polycarb only
Undercover Material Polycarb only
Reject Bin Over Cover Included as standard with reject confirmation (all bins)
Communication Options (up 3 maximum per m/c) Rules
Host Interface Ethernet / RS232 / RS422/485
Preset Communications Ethernet / RS232 / RS422/485
Weight Data Output Ethernet / RS232 / RS422/485
Serial Print Ethernet / RS232 / RS422/485
IDCS II Ethernet / RS232 / RS422/485
Modbus Ethernet / RS232 / RS422/485
Software Options Rules
Reference Weight Renewal
Extended Presets 200 Standard, 500 Extended
Average Start
Proper Count Software (with Paddle) Hardware included (paddle assembly)
Proper Count Software (without Paddle) No hardware supplied
Feedback Control Hardware included (additional module)
Pre-set Selection via Handheld Barcode Excludes hardware (barcode scanner)
Random Checking Software Not to be used in conjunction with any other communication or software option (including IDCS II)

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DACS-G-S015-24 (SNACKS)
Model
Model(s) Infeed (mm) Weight (mm) Reject (mm)
DACS-G-S015-24-SS-I-N-S 350 450 450
DACS-G--S015-24* 350 450 550

Specifications
Option Configuration DACS Snacks
Languages Up to 3 off
Manuals (Paper or CD) Up to 3 off
Line Height 850mm 100 ±
Leg Extension Straight 950mm 100 ± N/A
Leg Extension Flared 1100mm 100 ± N/A
SS Stainless Steel
Environment
WP Water Proof N/A
Left to right
Direction of Travel
Right to left
S Standard Jog Dial
Display
H High Grade CTS
Non approved
Approval
MID
Standard Not bolt down
Feet Bolt Down
Caster N/A

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Reject Options
Reject Method Direction (Front or Rear) Direction (Front or Rear inline) Direction (Front and Rear) Reject Bin DACS Snacks
Standard Air 2 Zone 3 Zone 3 Zone Confirm Quantity
HD Air 2 Zone 3 Zone 3 Zone Confirm Quantity
Pneumatic arm* 2 Zone 3 Zone 3 Zone Confirm Quantity N/A
Reject Options Rules
Reservoir Kit Included with HD Air; selectable with other options
Reject Confirmation Only selectable with reject bin(s)
Bin Full Only selectable with reject bin(s)
Bin Locked Only selectable with reject bin(s)
Product Buildback Sensor Only selectable with reject bin(s)
* Only available on 550mm reject conveyor

Upgrade Options
Machine Upgrade Options Rules DACS Snacks
Extended Infeed (excludes combination units) Extended Infeed Conveyor at 50mm increments - original infeed length stated + up to 400mm maximum N/A
Printer
Beacon
E Stop Facility
Belt Gap Transfer Plates If selected, all conveyors
Windshield Gravity Held Included as standard with 015 model. Material Polycarb only
Windshield Fixed Lockable Hatch Included as standard when selecting reject confirmation. Material Polycarb only
Windshield Fixed Interlocked Hatch Material Polycarb only
Undercover Material Polycarb only
Reject Bin Over Cover Included as standard with reject confirmation (all bins)
Communication Options (up 3 maximum per m/c) Rules
Host Interface Ethernet / RS232 / RS422/485
Preset Communications Ethernet / RS232 / RS422/485
Weight Data Output Ethernet / RS232 / RS422/485
Serial Print Ethernet / RS232 / RS422/485
IDCS II Ethernet / RS232 / RS422/485
Modbus Ethernet / RS232 / RS422/485
Software Options Rules
Reference Weight Renewal N/A
Extended Presets 200 Standard, 500 Extended
Average Start
Proper Count Software (with Paddle) Hardware included (paddle assembly)
Proper Count Software (without Paddle) No hardware supplied
Feedback Control Hardware included (additional module)
Pre-set Selection via Handheld Barcode Excludes hardware (barcode scanner)

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Retail Code of Practice - Standardisation Guide
Model
Model(s) Infeed (mm) Weight (mm) Reject (mm) Model(s) Infeed (mm) Weight (mm) Reject (mm) Model(s) Infeed (mm) Weight (mm) Reject (mm)
DACS-G-S015-12* 450 250 550 DACS-G-S015-34* 350 450 750 DACS-G-S060-35* 450 550 750
DACS-G-S015-13* 350 350 550 DACS-G-S015-35* 450 550 750 DACS-G-S060-36* 550 650 750
DACS-G-S015-14* 350 450 550 DACS-G-S060-22* 450 250 550 DACS-G-S060-44* 545 445 845
DACS-G-S015-22* 450 250 550 DACS-G-S060-23* 350 350 550 DACS-G-S060-45* 445 545 845
DACS-G-S015-23* 350 350 550 DACS-G-S060-24* 350 450 550 DACS-G-S060-46* 545 645 845
DACS-G-S015-24* 350 450 550 DACS-G-S060-33* 350 350 750
DACS-G-S015-33* 350 350 750 DACS-G-S060-34* 350 450 750

Specifications
Option S015 S060
Reject Bin Lockable
Reject Bin Door Status

Reject Bin Full

Status Monitoring

Fixed Tunnel
Lockable Access

Fixed Tunnel
(optional) (optional)
Interlocked Access

Reject Confirmation
Product Detection Sensor
Reject Confirmation Sensor
Product Build Up Sensor
Audible/ Visual Reject
Confirmation of
Successful Reject
Enhanced Product Tracking
Metal Detector Fault

Reject System Failure

(Metal) Low Air

Bin Lock Open Status

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Checkweigher
overview and benefits
• Automatically checks the weight of every pack
• Only correctly weighted packs continue
down the line
• A small saving of a couple of grams per pack
can add up to a lot of money

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Used for both
weighing and counting packs
WEIGHING COUNTING
1 2 3 4
PRE-PACKING PACKING MULTI-PACKING CARTONS & CASES

1 2 3 4
Pre-packing Packing Multi-packing Cartons & cases
Make sure the right amount Make sure the pack contains Make sure the right Make sure the correct
of product is there before the correct amount of product amount of each item number of items is in
it is packed once packed/sealed is in the multi-pack the carton or case

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Core parts 1 In-feed conveyor

of the checkweigher • Helps stabilise the product as it moves to the weigh conveyor
• Regulates pack spacing
2 Weigh conveyor

• Weighing takes place on the weigh conveyor

• Disturbances impact the accuracy - a windshield may be used
• Accuracy influenced by the time that the product is on the weigh conveyor
3 Reject conveyor

• The reject conveyor belt has a special coating which makes it slippery -
product moves smoothly as it leaves the checkweigher
3

2
In-feed AA
1 conveyor
A Optimal stable time

B As product length increases,

stable time decreases. B
B
The longer the product, the less
space there is on the weigh
conveyor relative to the product,
so the slower the conveyor must
move for the product to be stable
long enough for an accurate
reading from the weigh sensor CC

C As line speed increases,

stable time decreases

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Reject system
The difference between two and
three zone reject systems:
• Two Zone - sends both under- and overweight packs into the same zone.
This configuration is known as Two Zone as product can either continue
in line if correctly weighted (First Zone) or be rejected off the line into the
bin (Second Zone).

• Three Zone - separates underweight and overweight packs.

Three Zone is similar to Two Zone except there are two reject zones.

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The reject system
Use these technical specifications to help guide your choice
Rejection system Speed Drive Zones Product Weight Limitation

Not suitable for thin packs

120-130 Machine Limit
or small bags which
Arm packs per Pneumatic 2 or 3 Solid or bags - product
can get caught in the gap
minute dependent
between arm and belt

200 Machine Limit

Needs to push all the
Airjet packs per Pneumatic 2 or 3 Solid or bags - product
way to remove product
minute dependent

Arm rejector • Used for packs that are between the Air jet rejector • The most common option
machine limits
• Uses an air jet to blow rejected products
• Sorts products into separate under off the line.
and overweight bins
• Suitable for separating lightweight products
• It is best used for thick solid products which on a high-speed line, and is a double
do not get damaged very easily reject system

• Suggested use on bags of crisps, open trays • Suggested use on bags of crisps, yoghurt
of meat and cereal boxes pots and cereal boxes

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Reject modes
The DACS can be operated
in four reject modes:
• Normal
This mode does not involve the requirements of the “Three packers Rules”.*

• T1-T2 Control - Mode

This mode fulfills rules #2 and #3 of the “Three Packers Rules”.* This is:
- The actual quantity may be less, on the average than the marked quantity.
- No more than 2.5% (1 in 40) of the packages shall be Non-Standart
(less than the normal weight).
- No packages shell be inadequate (less than the Apostolate Tolerance Limit).

• Average Control Mode * Three Packer’s Rules

1. The actual contents of the packages shall not be less, on average, than the nominal quantity.
Satisfies rules #1 and #3 of the Three Packers’ Rules.* That is: 2. Not more than 2.5% (1 in 40) of the packages may be non-standard, i.e., have negative errors larger than the TNE** specified for the nominal quantity.
- The actual quantity may not be less, on the average than the marked quantity. 3. No package may be inadequate, i.e., have a negative error large than twice the specified TNE**.
**TNE = Tolerable Negative Error
- Non-standard packages may exceed 2.5% (1 in 40)
- No packages shell be inadequate

• Average T1-T2 Control Mode

Satisfies rules all of the Tree Packer’s rules.* That is:
- The actual quantity may not be less, on average than the marked quantity.
- No more than 2.5% (1 in 40) of the packages shall be non-standard.
- No package shall be inadequate

In average T1-T2 control the checkweigher will automatically adjust

its lower limit to comply with average weight e-prepackage and the T1 and T2 ranges for a 400g pack
3 packers rules:
The average of all packs must not
• Packs that are less than the nominal weight, but still within the TNE** Nominal weight 400g
be less than 400g
• Packs that are less than the TNE** and are non-standard
TNE** 12g
• Packs that have less than twice the TNE** and are inadequate
T1 1 in 40 may weigh
388g
We use the terms T1 and T2: (Nominal weight - TNE**) between 388g and 376g
• T1 is the nominal weight minus the TNE** - packs in this zone are non-standard T1 No pack may weigh less
376g
• T2 is the nominal weight minus twice the TNE** - packs in this zone are inadequate (Nominal weight - 2 x TNE**) than 376g

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Retail Code of Practice System
Product build-up Configurable
1 sensor
4 lamp indicator
4
2 Reject confirmation
5 Bin door 2
sensors status sensor

Error reset/ Bin full

3 sensor test
6 sensor 3
1

Highlights of features
• Reject Confirmation System
• Lockable Reject / Bin full System
• Air Pressure System 6
• Metal Detector Failure
• Build Back Sensor / Reject Check Sensor
• Automatic Reject System 5
• Tunnel Guard / Windshield
• Pack Tracking
• Fail Safe Sensors
• Functional testing can be achieved
• Error Reset Switch
• Beacon Lamp Indicator

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Retail Code of Practice
Reject Confirmation - Reject Confirmation -
Retail Channel Marks & Spencer Tesco Sainsbury's Morrisons
DACS-W-N DACS-G
Automatic Reject System
Lockable
Bin Full Status
Tunnel Guard (Fixed)
Locked Hatch
Interlocked Hatch (optional) (optional)
Reject Confirmation
Photogating Sensor
Metal Detector Fault
Reject Failure (Metal) Low Air
Product Build Back
Bin Lock/ Open Status
Reject Check Sensor
Audible/ Visual Confirmation
of successful reject

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Options
and optional extras
Working with data
• The checkweigher will gather data, which can be used in various ways
• We need to know how the checkweigher will integrate into the
packaging line/network as this affects both the hardware connections
we provide and the software we pre-load

Hardware connections: connecting to other machines

The checkweigher can either have a Serial or Ethernet connection.

Barcode readers
• In some applications there is a
requirement for the checkweigher to
weigh packs or multipacks coming
from different lines.

A barcode reader can be used to read

the product barcode and automatically
Serial connection. Can be used to Ethernet connection (recommended). select the associated checkweigher
communicate data with cable lengths The most robust data transfer preset with the appropriate reference
of up to 30 meters. protocol, cable lengths of up to weight. This mode of operation cannot
100m can be used. be used in MID applications.

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Checking your options match
• Host interface: sends data via Ishida’s custom protocol. A custom interface and
application needs to be written. You can read and write machine data and access
statistics, batch reports and preset information.

• Preset communication: used to keep compatible machines (like a CCW)

synchronised to the DACS by changing both presets when only one is adjusted.
This is particularly useful when machines are not in the same part of the building.

• Weigh data output: sends a special command string which contains the weigh
result. This is useful when you just want simple information about the weight.

• External print: displays the same data that is going to the printer, in real time.
• Modbus: sends data over Ethernet. Custom software needs to be developed
and can give access to all the data on the checkweigher, including start and stop,
error message and batch reports.

Not all hardware and protocols work together. Use this table to check that it all makes sense.

Host Preset Weigh data External

Modbus
interface communication output Print

Serial
Ethernet
Needs custom software

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Working with data
Reference weight renewal Feedback control
This is used for counting items in a bag or pack, for products where the • The checkweigher can control other • Can be linked to one or two machines
weight of a batch can vary, but the number of items in a bag needs to remain devices via pulse relays in the line
constant. If the batch is heavier or lighter than normal, the reference weight is • Most common with filling machines like
automatically adjusted so that the count remains correct. • Sends messages to packing machines to coffee
adjust amount of product going into a pack

Proper count software

This is used to the count the number of proper
packs. When the set amount is reached it will give Our system may not be compatible with all fillers, therefore always send technical details on
an output to indicate the count is reached or perform how our system works with the quote
an action. This could include sounding an alarm, or
moving a diverting arm.

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What is IDCS?
The Ishida Data Capture System (IDCSII) is a Management Information System that constantly
monitors line performance through interrogation of the Checkweigher to identify and record many
parameters including individual pack weight (every pack), number of packs passing down the line and
availability of the machine.

Ishida Data Capture System (IDCSII)

This recorded data can then be presented to factory management staff (or indeed line operators) such
that line effectiveness can be reported in real time. The IDCS system incorporates a level of reporting
flexibility within the software so that customers can selectively configure the system to meet their
individual reporting requirements. Additionally the Overall Equipment Effectiveness (OEE) can be
calculated and reported against predefined user limits.

To enable a Checkweigher to be fully compatible with the IDCS system an interface module needs to
be installed on the machine. This interface modules collects and records the data from the machine
before transmission to the hosting server where the various reports are configured and the encrypted
pack data stored.

A key feature of this interface module is the fact that it acts as a data buffer between the machine and
the server, if for any reason the server goes down or is unavailable the pack data is stored within the
interface module until such time as communication with the server is re-established and data can be
transferred, this buffer ensures data integrity (i.e. removes the opportunity for any pack data to be lost).

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Ishida Data Capture System
(IDCS)
Custom-built software

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ISHIDA EUROPE LIMITED ISHIDA CZECH REPUBLIC ISHIDA FRANCE ISHIDA GERMANY ISHIDA MIDDLE EAST ISHIDA NETHERLANDS
Kettles Wood Drive Tel: +420 317 844 059 Tel: +33 (0)1 48 63 83 83 Tel: +49 (0)791 945 160 Tel: +971 (0)4 299 1933 Tel: +31 (0)499 39 3675
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Birmingham [email protected] [email protected] [email protected] [email protected] [email protected]
B32 3DB
United Kingdom ISHIDA ROMANIA ISHIDA RUSSIA AND CIS ISHIDA SOUTH AFRICA ISHIDA SWITZERLAND
Tel: +44 (0)121 607 7700 Tel: +40 (0)21 589 73 52 Tel: +7 499 272 05 36 Tel: +27 (0)11 976 2010 Tel: +41 (0)41 799 7999
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[email protected] [email protected] [email protected] [email protected] [email protected]

(E) DACS GUIDE 02.16

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