HI 1756-WS & HI 1756-2WS WEIGH SCALE MODULE Series A OPERATION AND INSTALLATION MANUAL Corporate Headquarters 9440 Carroll Park Drive, Suite 150 San Diego, CA 92121 Phone: (858) 278-2900 FAX: (858) 278-6700 Web-Site: http://www.hardyinst.com Hardy Instruments Document Number: 0596-0247-01 Rev K Copyright November 2000 Hardy Instruments, Inc. All Rights Reserved. Printed in the U.S.A.
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Table of Contents Table of Contents OVERVIEW - - - - - - - - - - - - A Brief Description of Chapter 1 - - - About This Manual - - - - - - - - - Description - - - - - - - - - - - - - WAVERSAVER® - - - - - - - - - - C2® Calibration - - - - - - - - - - IT® - - - - - - - - - - - - - - - - - Excitation Monitor - - - - - - - Digital Volt Meter (DVM) - Optional Return to Zero Test - Optional - Weighing System Tests - Optional Auto Zero Tracking - - - - - - - - - - - - - - - - - - - CHAPTER 2 - SPECIFICA
HI 1756-WS WEIGH SCALE MODULE Optional Equipment- - - - - - - - - - - - - 1756 RTA (Remote Termination Assembly RTA Cable Assemblies - - - - - - - - - HI 215IT Series Junction Box - - - - - - Default Parameters - - - - - - - - - - - - - - - - - - - - - - - - -2-3 -2-3 -2-3 -2-3 -2-3 CHAPTER 3 - INSTALLATION - - - - - - - - - - - - - - - - - A Brief Description of Chapter 3 - - - - - - - - - - - - - - - - - Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing the HI 1756-WS
Table of Contents Cal Low Command (CALLOWCMD) - - - - - - - - - Cal High Command (CALHIGHCMD) - - - - - - - - - C2 Cal Command (C2CALCMD) - - - - - - - - - - - Read Weight Cal Command (READWEIGHTCAL) - - Perform Integrated Technician Tests (WEIGHSYSTEST) Structure (ITECHTEST)- - - - - - - - - - - - - - Search for C2 Load Sensors (C2SEARCH) - - - - - - Read C2 Sensor Serial Number (READC2SERIALNUM) Read Status of Module (GETSTATUS) - - - - - - - - Write Parameters (WRITEPARAM) - - - - - - - - - - Read Parame
HI 1756-WS WEIGH SCALE MODULE CHAPTER 7 - TROUBLESHOOTING - - - - - - - - - - A Brief Description of Chapter 7 - - - - - - - - - - - - - Scale LED stays off when Performing a C2 Calibration with The Button - - - - - - - - - - - - - - - - - - - - - - - Scale LED is Flashing Red - - - - - - - - - - - - - - - Return Codes- - - - - - - - - - - - - - - - - - - - Mechanical Inspection - - - - - - - - - - - - - - - - - Load Sharing and Load Sensor Checkout - - - - - - - - Guidelines for Instabilities on Formerly O
Table of Illustrations Table of Illustrations CHAPTER 3 - INSTALLATION - - - - - - - - - - - - - - POSITIONING THE MODULE FOR INSTALLATION - - - MODULE RELEASE(S) - - - - - - - - - - - - - - - - - - MODULE INSTALLED IN CHASSIS- - - - - - - - - - - - HI 1756-WS WITH DOOR OPEN - - - - - - - - - - - - - HI 1756-2WS WITH DOOR OPEN - - - - - - - - - - - - INDUSTRY STANDARD LOAD CELLS WIRING DIAGRAM HARDY LOAD SENSOR/C2 WIRING DIAGRAM - - - - - REMOTE TERMINAL ASSEMBLY - - - - - - - - - - - - RTA WITH JUMPERS FO
HI 1756-WS WEIGH SCALE MODULE GUIDELINES FOR INSTABILITIES ON FORMERLY OPERATING SYSTEMS - - - - - - - - - - - - - - - - - - - - - -7-7 GUIDELINES FOR INSTABILITIES ON FORMERLY OPERATING SYSTEMS - ELECTRICAL - - - - - - - - - - - - - -7-8 MECHANICAL STABILITY AND CONFIGURATION SETTINGS - - -7-9 II
Chapter 1 - Overview CHAPTER 1 - OVERVIEW A BRIEF DESCRIPTION OF CHAPTER 1 This manual is designed for use by installers, operators, and service personnel. It provides specifications and procedures for linking, configuring, operating, maintaining, and troubleshooting the Hardy Instruments HI 1756-WS and HI 1756-2WS ControlLogix® I/O Weigh Scale Modules. NOTE: Control/Logix® is a registered trademark of the Rockwell Corporation.
HI 1756-WS WEIGH SCALE MODULE Chapter 4 - Provides hardware configuration instructions, including dip switch and jumper settings. Chapter 5 - Provides firmware/software setup procedures needed to operate and calibrate the instrument. Chapter 6 - Provides calibration instructions. Chapter 7 - Provides operating procedures. Chapter 8 - Provides troubleshooting procedures.
Chapter 1 - Overview WAVERSAVER® During the measurement of small weight changes, the affects of mechanical vibration and noise from the operating environment can introduce substantial interference. WAVERSAVER factors out vibration, noise, and other interference-related signals from the load cell so the rate controller can better decipher the actual weight data. WAVERSAVER® can be configured to ignore noise with frequencies as low as 0.25 Hz.
HI 1756-WS WEIGH SCALE MODULE between the module, Remote Terminal Assembly (RTA) and the IT® Junction box. If the measured current deviates more than a ± 10% tolerance, an “Excitation Error” bit (Module Status Word bit 9) is set to 1. Digital Volt Meter (DVM) - Optional NOTE: 1-4 Requires the HI 215IT Series Junction Box to monitor both mV and mV/V readings for the system and per individual load sensor.
Chapter 1 - Overview The ability to read the weight seen by each individual load sensor allows use of this test to make cornering, leveling and load sharing adjustments to the weighing system. AUTO ZERO TRACKING Auto Zero Tracking automatically adjusts for zero weight. This capability allows the module to ignore material build-up in the weighing system within a preset auto zero tolerance.
HI 1756-WS WEIGH SCALE MODULE 1-6
Chapter 2 - Specifications CHAPTER 2 - SPECIFICATIONS A Brief Description of Chapter 2 Chapter 2 lists the specifications for the HI 1756-WS and HI 1756-2WS Weigh Scale Modules. Specifications are listed for the standard instrument and for optional equipment. The specifications listed are designed to assist in the installation, operation and troubleshooting of the instrument. All service personnel should be familiar with this section before attempting an installation or repair of this instrument.
HI 1756-WS WEIGH SCALE MODULE Common-Mode Voltage Range 2.5VDC maximum (with respect to earth ground) Backplane Input Voltage 5 VDC and 24 VDC Backplane Current Load <1 Amp at 5 VDC 0.0125 Amps at 24 VDC (with 4-350 Ohm Load Cells Backplane Power Load < 5W at 5 VDC < .3W at 24 VDC with 4-350 Ohm Load Cells C2 Calibration Input Isolation from digital section 1000 VDC minimum.
Chapter 2 - Specifications • mV/V 4 digits to the right of the decimal Optional Equipment 1756 RTA (Remote Termination Assembly Hardy Part # -RTA (HI-1756-XX-RTA if ordered separately) Remote Termination supports two (2) separate HI 1756-WS weigh scale modules or one (1) HI 1756-2WS weigh scale module. Unit includes DIN rail mounting for 35mm x 15mm DIN rail. RTA Cable Assemblies Hardy Part # -C6 (HI 1756-XX-C6) • Cable Length: 6 ft. (1.525 meters) from the single channel module to the RTA.
HI 1756-WS WEIGH SCALE MODULE Parameter Default Setting Metric lbs 0 WAVERSAVER® 1 Hz 3 SpanWeight 10,000.00 CalLowWeight lbs Num Averages 10 ZeroTrackEnable False ROCTimeBase 10 ZeroTolerance 10 AutoZeroTolerance 10.0 lbs MotionTolerance 5.0 lbs 0 0 Table 2-1: Default Parameters NOTE: 2-4 * The HI 1756 modules do not have a real time clock, so the year; month; day and calid must be set by the operator.
Chapter 3 - Installation CHAPTER 3 - INSTALLATION A Brief Description of Chapter 3 Chapter 3 provides the recommended procedures for unpacking, cabling, interconnecting, configuring and installing the Weigh Scale Module. Users and service personnel should be familiar with this information before installing or operating the Weigh Scale module. If you experience any problems installing this equipment, contact Hardy Instruments Inc., Customer Support for assistance. Unpacking Step 1.
HI 1756-WS WEIGH SCALE MODULE Installing the HI 1756WS (2WS) into the ControlL ogix Chassis Step 1. • Touch a grounded object or surface to rid yourself of any electrostatic discharged prior to handling the module. • Handle the module from the bezel in front away from the connector. Never touch the connector pins. • Do not install the module right next to an AC or high voltage DC module. • Route all the load voltage cables away from high voltage cables.
Chapter 3 - Installation Step 5. The installation is complete. FIG. 3-2 MODULE RELEASE(S) FIG. 3-3 MODULE INSTALLED IN CHASSIS Removing the Module from the Chassis Step 1. Press down on the top and bottom processor releases simultaneously and pull the module out of the chassis. (See Fig. 3-3) Step 2. Store the module in a safe, secure location in an anti-static bag or its original package.
HI 1756-WS WEIGH SCALE MODULE Installing the Module I/ O Connector About the Module I/O Connector The I/O Connector at the front of the module connects the module to the Remote Terminal Assembly (RTA), a load sensor, or the HI 215IT Series Junction Box, depending on how many load sensors are installed in the weighing system. See below for the pin-out diagram, which is also located on the inside of the module door. (See Fig.
Chapter 3 - Installation receiving information from the load cells or if the relays do not operate correctly. FIG. 3-4 HI 1756-WS WITH DOOR OPEN FIG.
HI 1756-WS WEIGH SCALE MODULE Load Cell Wiring Diagrams Industry Standard Load Cells FIG. 3-6 INDUSTRY STANDARD LOAD CELLS WIRING DIAGRAM Hardy Load Sensor with C2 FIG.
Chapter 3 - Installation HI 1756 Remote Terminal Assembly (HI 1756-XX-RT) The RTA provides connection points between the HI module’s cable assembly and the wires from the junction box(es) or load sensor(s). It comes with a standard 35 mm Din Rail Mounting and requires at least a 5” inch DIN rail for mounting. FIG.
HI 1756-WS WEIGH SCALE MODULE RTA Cable Assembly • Six (6) foot cable that connects to the HI 1756WS module. FIG. 3-10 RTA CABLE ASSEMBLY - HI 1756WS SINGLE CHANNEL FIG. 3-11 RTA CABLE SCHEMATIC - HI 1756WS SINGLE CHANNEL • Six (6) foot cable that connects to the HI 17562WS module FIG.
Chapter 3 - Installation FIG. 3-13 RTA CABLE SCHEMATIC - HI 17562WS DUAL CHANNEL Hardy HI 215IT Junction Box Load Cell Connector J1 FIG. 3-14 HARDY HI 215IT JUNCTION BOX WIRING DIAGRAM NOTE: When connecting the Hardy HI 215IT Junction Box you must remove the two factory installed jumpers 1&2 and 5&6 on the module install sense lines.
HI 1756-WS WEIGH SCALE MODULE 3-10
Chapter 4 - Setup CHAPTER 4 - SETUP A Brief Description of Chapter 4 Chapter 4 covers the firmware and software settings used to prepare the module controller for calibration and operation. The Setup procedures require AllenBradley’s RS Logix 5000, Allen-Bradley RSLinx™ or RSLinx™ Lite. Power Check Step 1. To make or change settings, there must be power to both the PLC and the module. Verify that the LED’s are lit for normal operation. (See Figs. 4-1 and 4-2) FIG. 4-1 MODULE LEDS SINGLE CHANNEL FIG.
HI 1756-WS WEIGH SCALE MODULE LEDS Scale Data LEDs Flashing Green Steady Green Steady Red Flashing Red LED is Off OK Module Status LED Brief Steady Flashing Green Steady Green Steady Red (Backplane Available) Steady Red Flashing Red Reset Module Message Message Type: CIP Generic Service Code 5 (Hex) Class Name: 1 Instance Name: 1 Follow these steps to set up communication between the ControlLogix PLC and the Weigh Scale Module. The steps require that you have a new or open RS Logix® 5000 project.
Chapter 4 - Setup Step 2. Select New Module to display a list of modules. Step 3. Scroll to and select the Generic 1756 module to open the Module Properties form. Step 4. Enter the following connection parameters in the appropriate fields: • • • • • • NOTE: Name of Module Description of Module (Optional) Slot ID Input Assembly Instance:101 Size = 11 Output Assembly Instance: 146 Size = 1 Configuration Assembly Instance:241 Size = 0 configuration table not used) or (with version 2.
HI 1756-WS WEIGH SCALE MODULE Configuration Parameters for the HI 1765-WS Module With version 2.3 software, the HI 1765-WS module can recieve 32 words of the configuration data from a PLC upon power-up. These data are used only if the value for Config_rev_num is set to 1 and the parameters are sent in the correct format and range. NOTE: DINT Parameters can be interpreted as floating point based on the value of a bit within the DecimalPoints parameter of the channel.
Chapter 4 - Setup Parameter Offset (In Words) Dual Channel Config_rev_num1 * 16 ChanEnabled1 17 DecimalPoints1 ** 18 Metric1 19 NumAverages1 20 Waversaver1 21 SpanWeight1 22 CalLowWeight1 23 ZeroTrackEnables1 24 AutoZeroTolerance1 25 MotionTolerance0 26 TareWeight0 27 EnableButton0 28 RocTimeBased0 29 ZeroTolerance0 30 Spare1_0 31 * Must be set to 1 for the other values to apply ** Converts integers to floating-point When the parameters are displayed, they do not appear in
HI 1756-WS WEIGH SCALE MODULE Input Data NOTE: STATUSWORD This is discrete input data which is a module-defined data type, LOCAL:X:I (where X is the slot number). The TimeStamp is a 64-bit integer giving the system time in microseconds. The module returns a binary statusword where each bit indicates a state or condition within the module. To interpret these states, note which bits are ON and use the chart below to match each bit location to the state it represents.
Chapter 4 - Setup FIG. 4-4 DISCRETE DATA STATUSWORD bit positions refer to these variables: Word Number Definition ERRORADCONVERT 0x0001 Millivolt return from the load cell system is out of range for the unit. ERRORADFAILURE 0x0002 A/D converter in the unit is no longer responding. STATUSENGLISH 0x0004 Unit calibrated in lbs. If the bit is off, calibrated in kgs. STATUSZTRACK 0x0008 Auto Zero Tracking is turned on. STATUSBUTTONENABLED 0x0010 Enabled/Disabled calibrate button.
HI 1756-WS WEIGH SCALE MODULE Word Number Definition STATUSCMDERROR 0x4000 Output Table Command Failed STATUSCHANENABLED 0x8000 Set if channel is enabled Parameters for the HI 1756-WS (-2WS) Module NOTE: The Glossary at the end of this manual provides additional information about the parameters and other common weigh process definitions. All parameters in Table 4-1 are either type DINT (4byte integer) or REAL (4-byte floating point).
Chapter 4 - Setup # Type Parameter Description 9 DINT Waversaver Legal Values are 0-4 0 = 7.5 Hz 1 = 3.5 Hz 2 = 1 Hz 3 = .5 Hz 4 = 0.25 Hz 10 REAL SpanWeight Calibration weight, high, in lbs or kgs 11 REAL CalLowWeight Calibration weight, low, in lbs or kgs 12 DINT NumAverages Legal Values: 1-255 13 DINT ZeroTrackEnable Enable for Zero Tracking Legal Values: 0 = Not Enabled 1 = Enabled 14 DINT ROCTimeBase Legal Values: 1-1800 seconds 15 REAL ZeroTolerance In lbs or kgs.
HI 1756-WS WEIGH SCALE MODULE FIG. 4-5 PARAMETERS DIALOG BOX FIG.
Chapter 4 - Setup Commands Commands are configured in the RSLOGIX 5000 as follows: • • • • • • Message Type: CIP Generic Service Code 4c (Hex) Class Name: 4 Instance Name: 254 Object Attribute: None, leave this field blank Message source: a tag defining the data sent to the HI 1756-WS (-2WS). • Number of elements: defined by the command used. • Message destination: a tag where the reply data will be written. FIG.
HI 1756-WS WEIGH SCALE MODULE Reply data contains 3 fields • Command (DINT): The command number • Channel (DINT): The channel number • Status (DINT): Status information NOTE: Zero Command (ZEROCMD) Some commands will produce longer replies. The Zero Command requests that the current gross weight be set to zero.
Chapter 4 - Setup Write Non-Volatile Command (WRITENONVOL ATILE) The Write Non-Volatile Command causes all parameters (including calibration constants) to be saved to the non-volatile memory. Command Number: 4 (Hexadecimal) Channel Number: 0 or 1 Number of Elements: 8 Error Return Values: None Reload NonVolatile (RELOADNONVOL ATILE) The Reload Non-Volatile Command causes the weigh module to re-read the values stored in its non-volatile memory.
HI 1756-WS WEIGH SCALE MODULE Channel Number: 0 or 1 Number of Elements: 8 Error Return Values: None Cal Low Command (CALLOWCMD) The Cal Low Command sets the “calLowCount” parameter to the current A/D average counts when doing a hard calibration. An Integrated Technician function gets called during low calibration.
Chapter 4 - Setup Error Return Values: Read Weight Cal Command (READWEIGHTCAL) • STATUSWORD - there was a conversion error, weight in motion or an A/D error or all three. • C2FAILNODEVS - detected no C2 load cells. • C2FAILCAPEQ - detected two load cells with different capacities. Weight data at calibration points are saved.
HI 1756-WS WEIGH SCALE MODULE Structure (ITECHTEST) Structure 4-16 Item Description DINT command* 0x66 DINT channel* 0 or 1 DINT status* N/A DINT nSensors* Number of load sensors.
Chapter 4 - Setup Structure REAL Item weight_4** NOTE: Search for C2 Load Sensors (C2SEARCH) Description Gross Weight, load cell 4 * Required Command Data * * Available only with the HI 215IT Junction Box. Searches for C2 Load Sensors Command Number: 0x6E (Hexadecimal) Channel Number: 0 or 1 Number of Elements: 8 Return Values: • COMMAND • CHANNEL • STATUS • C2ROM - The number of C2 sensors detected. • C2SWITCH - The number of JBOX switches detected. • CAPACITY - Combined sensitivity of C2 load cells.
HI 1756-WS WEIGH SCALE MODULE Return Data: • COMMAND • CHANNEL • STATUS • 9 DINT SERIAL NUMBER Error Return Values: • OUTOFTOLERANCE - No C2 Sensor found. Read Status of Module (GETSTATUS) NOTE: Reads the condition of the module. Command Number: 0x80 (Hexadecimal) Channel Number: 0 or 1 Number of Elements: 8 See the Timed Out Command section. Return Data: • COMMAND • CHANNEL • STATUS - Returns status of the last timed out command. Write Parameters (WRITEPARAM) Writes all the parameters.
Chapter 4 - Setup Read Parameters (READPARAM) Reads all the parameters. Command Number: 0x69 (Hexadecimal) Channel Number: 0 or 1 Number of Elements: 8 Return Data: • COMMAND • CHANNEL • STATUS • PARAMETERS (See Table 4-1) Read Live Weight (READLIVEWEIGHT) Reads gross weight in units set by the Metric Parameter, either lbs or kgs.
HI 1756-WS WEIGH SCALE MODULE Number (Hex) Command NOTE: TARECMD* 2 WRITENONVOLATILE* 4 RELOADNONVOLATILE* 0x10 GETSTATUS 0x80 ENABLEBUTTONCMD** 0x20 DISABLEBUTTONCMD** 0x40 SETDEFAULTPARAMS 0x94 CALLOWCMD* 0x64 CALHIGHCMD* 0x65 C2CALCMD* 0x66 WRITEPARAM 0x68 READPARAM 0x69 WEIGHSYSTEST 0x6D C2SEARCH 0x6E READC2SERIALNUM 0x70 READLIVEWEIGHT 0x6B * These commands can be sent through the output table.
Chapter 4 - Setup The least significant 16 bits are a command for Channel 0, the next 16 bits are a command for Channel 1. Commands are “1 shot”, occurring upon a 0-1 transition. Bit 0x2000 in the STATUSWORD will be set upon completion of the output table comand. Bit 0x4000 will also be set if the command failed. Setting the command word to zero will clear these status bits.
HI 1756-WS WEIGH SCALE MODULE Calibration Setup Procedures Setting the Unit of Measure The Unit of measure can be set to either kilograms or pounds. Any weight value input to the module (e.g. CALLOWWEIGHT, SPANWEIGHT) are in the currently selected units. The unit of measure can be set at any time, not just at calibration. Setting the unit of measure before calibrating reminds the user what unit of measure is being displayed.
Chapter 4 - Setup Setting the Span Weight Value The Span Weight is a reference point derived from an actual measured weight. This should not be confused with the Scale Capacity. If you have a 100 pound weight and you place it on the scale, the Span Weight would be 100 pounds. Setting the WAVERSAVER® Value There are 5 selectable levels. 0 provides the least vibration immunity with the fastest response time. 4 provides the most vibration immunity with the slowest response time. Default setting is 2.
HI 1756-WS WEIGH SCALE MODULE 4-24
Chapter 5 - Calibration CHAPTER 5 - CALIBRATION A Brief Description of Chapter 5 Chapter 5 provides the recommended calibration procedures for the HI 1756 (WS or 2WS) Weigh Scale Module. For the module to work properly, it must be calibrated prior to operation, and it should be re-calibrated periodically or when not in use for extended periods of time. Be sure to follow all the procedures completely to insure that the weights read by the module are accurate.
HI 1756-WS WEIGH SCALE MODULE FIG. 5-1 PROPERLY INSTALLED LOAD CELL W/NO BINDING Electrical Check Procedures Load Cell/Point Input/Output Measurements Step 4. Typical Load Cell/Point Input/Output Measurements (EXC & SIG Outputs) a. The Weigh Module is designed to supply 5 VDC excitation to as many as eight 350 Ohm load cells/points. b. The expected output from each load cell/point depends on the mV/V rating of the load cell/point and the weight.
Chapter 5 - Calibration c. A zero reference point will vary from system to system depending on the “Dead Load” of the vessel. “Dead Load” is the weight of the vessel and appurtenances only, with no product loaded. In our example we will assume the dead load to be 500 pounds. (See Fig. 5-2) FIG. 5-2 MILLIVOLTS/WEIGHT SCALE Based on the example, the operating range for this scale is 5-10 mVDC with a 500 pound weight range.
HI 1756-WS WEIGH SCALE MODULE Step 2. • For example: If the ladder logic display reads 100 pounds and a 20 pound weight is placed on the vessel or scale, the ladder logic display should read 120 or some value over 100. • If the ladder logic display reads 100 pounds and a 20 pound load is placed on the vessel or scale and the reading is 80 pounds, the reading is going in the wrong direction and indicates some problem with the system.
Chapter 5 - Calibration FIG. 5-3 “THE BUTTON” C2 CALIBRATION HI 1756-WS FIG. 5-4 “THE BUTTON” C2 CALIBRATION HI 1756-2WS NOTE: If the module is being calibrated for the first time and you are not sure what parameters to set, use the default parameters which are set by the module at power up. Once the calibration is successful, feel free to change the parameters to meet the requirements of your weighing process.
HI 1756-WS WEIGH SCALE MODULE Step 4. NOTE: C2 Calibration Using Ladder Logic Press “The Button” again to perform the C2 Calibration. Once the calibration is completed the Scale LED returns to a steady green. If you do not press the Button again within 20 seconds, the calibration process times out. Step 1. Step 2. Check to be sure that the parameters have been setup for your weighing process. (See Chapter 4, Setup) We have provided a Ladder Logic example explaining how to perform the C2 Calibration.
Chapter 5 - Calibration • Step 3. Step 4. Step 5. If you used a weight remove it from the scale. Place the high (Span) calibration weight on the scale. Send a Cal High Command (CALHIGHCMD). • The Cal High Command - Sets the Span Weight parameter to the current A/D average counts when doing Hard CAL. • Command Number: 0x65 (Hexadecimal) Channel Number: 0 or 1 Number of Elements: 8 For more information on the Cal High Command go to Chapter 4, Setup, page 4-12. • • • Step 6. Step 7.
HI 1756-WS WEIGH SCALE MODULE meant to provide a ladder logic model only. Your application may vary and the example may or may not meet your requirements. The Hard Calibration Ladder Logic Example is located at the Hardy Instruments Inc. Web Site. If you have access to the Internet: Step 3. a. Type the following URL: http://www.hardyinst.com b. c. d. e. Step 4. 5-8 Click on the Support button. Click on Sample Programs. Click on the pull down menu for the product you are calibrating.
Chapter 6 - Operating Procedures CHAPTER 6 - OPERATING PROCEDURES A Brief Description of Chapter 6 Chapter 6 covers the operation of the HI 1756 (-WS and -2WS) Weigh Scale Modules. The Operating Procedures include Reading data transferred to the PLC from the weigh scale module. (See Fig. 6-1) FIG. 6-1 COMMUNICATION CONFIGURATION DIALOG BOX Input Data NOTE: This is the discrete input data which is in module defined data type, LOCAL:X:I (where X is the slot number). (See Fig.
HI 1756-WS WEIGH SCALE MODULE FIG.
CHAPTER 7 - Troubleshooting CHAPTER 7 - TROUBLESHOOTING A Brief Description of Chapter 7 Chapter 7 covers troubleshooting and problem resolution. Maintenance personnel and users should be familiar with Chapter 7 before attempting to repair the HI 1756-WS or HI 1756-2WS. Scale LED stays off when Performing a C2 Calibration with The Button If the scale LED does relight when running C2 Calibration (pressing the button), there is probably a hardware problem. Contact Hardy Customer Support for assistance.
HI 1756-WS MANUAL Cmd Passed Run Cmd Is Cmd a Write Parameter? Status 0 Yes Yes No No Status = 0? Yes Cmd passed Index of return values for Write Parameter No Is Status Positive? Yes A1 No Is Status Negative? Yes A2 1. CALACTIVE 2. CALYEAR 3. CALMONTH 4. CALDAY 5. CALID 6. CALIB TYPE 7. TAREWEIGHT 8. METRIC 9. WAVERSAVER 10. SPAN WEIGHT 11. CAL LOW WEIGHT 12. NUMBER AVERAGES 13. ZERO TRACK ENABLE 14. ROC TIME BASE 15. ZERO TOLERANCE 16. AUTO ZERO TOLERANCE 17.MOTION TOLERANCE FIG.
CHAPTER 7 - Troubleshooting A2 A1 Definition Action Definition Action. Status = 1 Yes B1 Yes C1 Status = -3 Yes B5 Yes Status = 2 Yes B2 Yes C2 Status = -5 Yes B6 Yes C6 Status = 64 Yes B3 Yes C3 Status = -6 Yes B7 Yes C7 Status = 256 Yes B4 Yes C4 Status = -7 Yes B8 Yes C8 Status = -8 Yes B9 Yes C9 C5 . FIG. 7-2 COMMAND DEFINITIONS AND ACTIONS Name / Code # Definition Action erroradconvert 1 B1: Load cell input out of range (i.e.
HI 1756-WS MANUAL Name / Code # Definition Action erroreepromwrite 256 B4: Module cannot write (save settings) to non-volatile memory. EEPROM is probably bad. C4: Contact Customer Support to return module for repair. success - 0 Command passed. No errors None outoftolerance -3 B5: 1. Occurs with the Zero cmd when zeroing the current weight exceeds the tolerance limit. C5: 1.
CHAPTER 7 - Troubleshooting Mechanical Inspection See Fig. 7-1 1) 2) 3) 4) 5) 6) 7) 8) All pipes and conduits flexible? Mechanically isolated from ladders and connecting structures? 1) 2) 3) Keep flexures on the horizontal Vertical flexures should be avoided Do not use flexures to correct for misaligned piping Do not use hose flexures to make right angle bends Non-flexed piping should have an unsupported horizontal run using a ratio of 36 times it's diameter.
HI 1756-WS MANUAL Load Sharing and Load Sensor Checkout See Figure 7-4 1) 2) Does the mV signal increase in a positive direction. If you receive a negative results, check if load cell is mounted correctly. a) The arrow goes with the direction of force. b) If there isn't an arrow, you must manually verify the correct direction. A negative reading indicates the load cell is upside down. c) Load cells in tension will not reflect a negative reading if install upside down.
CHAPTER 7 - Troubleshooting Guidelines for Instabilities on Formerly Operating Systems See Figure 7-5 Check for Electrical Stability OK ? No B1 No B2 No B3 Yes Check for Mechanical Stability OK ? Yes Check Configuration settings for Stability OK ? Yes Contact Hardy Instruments Customer Support FIG.
HI 1756-WS MANUAL Electrical See Figure 7-6 B1 Electrical B1.1 Physical Grounding All common equipment share a common ground point. Keep the ground cable length to earth ground as short as possible. Install a new ground rod if the cable length is excessive. B1.2 Cable Cuts or breaks in the loadcell cable insulation allow moisture to wick into the cable and loadpoints. This can setup stray capacitance charges and allow ground current to exist. This could create a highly intermittent situation. B1.
CHAPTER 7 - Troubleshooting Mechanical Stability and Configuration Settings See Figure 7-7 Mechanical Stability Vessel When inspecting a vessel keep in mind, the Center of Gravity (COG) should be low and centered equally over all the load cells. Insure the load is directly over or under the load point to avoid side-loading. Insure there isn't any side loading from piping or external forces. Install flexures on all piping to insure a free floating vessel.
HI 1756-WS MANUAL 7-10
Index Index Symbols “dead” loads 1-2 “The Button” 1-2 “THE BUTTON” C2 Calibration 5-4 Numerics 1756 RTA (Remote Termination Assembly 2-3 350 Ohm load cells/points 5-2 5 VDC excitation 5-2 A A Brief Description of Chapter 2 2-1 A Brief Description of Chapter 3 3-1 A Brief Description of Chapter 4 4-1 A Brief Description of Chapter 5 5-1 A Brief Description of Chapter 6 6-1 A Brief Description of Chapter 7 7-1, 7-8 A/D average counts 4-14, 5-7 abnormal mechanical forces 1-4 About C2 Calibration 5-4 About Har
HI 1756-WS MANUAL Backplane Input Voltage 2-2 Backplane Power Load 2-2 Before signing 3-1 Binding 5-1 C C2 Cal Command (C2CALCMD) 4-14, 4-15 C2 Calibration 5-4 C2 Calibration Input 2-2 C2 Calibration Output 2-2 C2 Calibration Using Ladder Logic 5-6 C2 load sensors 5-4 C2® Calibration 1-3 C2FAILCAPEQ 4-21 C2FAILNODEVS 4-21 C2ROM 4-17 C2SEARCH 4-21 C2SWITCH 4-17 Cable lengths 2-2 Cal High Command 5-7 Cal High Command (CALHIGHCMD) 4-14 Cal Low Command 5-6 Cal Low Command (CALLOWCMD 4-13 Calibration Setup Proc
Index ControlLogix I/O 1-2 Conversion Rate 2-1 Customer Support Department 1-1 D damaged load sensors 1-4 Dead Load 5-3 Default Parameters 2-3 Description 1-2 Digital Volt Meter 1-4 Digital Voltmeter 2-2 DINT 4-8 discrete input data 6-1 dual channel 1-2 DVM 1-4 DVM readings 1-4 E Electrical 7-8 Electrical Check Procedures 5-2 electrostatic discharge 3-1 Environmental Requirements 2-2 Error Code List 4-21 Error Return Value 4-12 Error Return Values 4-12 EXC & SIG Outputs 5-2 Excitation Monitor 1-3, 2-1 exci
HI 1756-WS MANUAL H HARCALFAILCOUNTS 4-21, 7-4 Hard CAL 4-14, 5-7 Hard Calibration 5-6 Hard Calibration Ladder Logic Example 5-7 HARDCALFAILCOUNTS 4-14 Hardy HI 215IT Junction Box 3-9 Hardy Instruments C2 certified load sensors 1-3 Hardy Load Sensor with C2 3-6 HI 1756 Remote Terminal Assembly 3-7 HI 215IT Junction Box 1-4 HI 215IT Series Junction Box 1-4, 2-3, 3-4 high voltage cables 3-2 http //www.hardyinst.
Index LEDS 4-2 Load Cell Excitation 2-2 Load Cell Wiring Diagrams 3-6 Load Cell/Point Input/Output Measurements 5-2 Load Check 5-3 Load Sharing and Load Sensor Checkout 7-6 loose connections 3-4 M Mechanical Inspection 7-5 Mechanical Stability and Configuration Settings 7-9 Message Type 4-2, 4-11 Model and Serial number 3-1 Module Properties 4-3 mV 1-4 mV/V rating 5-2 mV/V readings 1-4 N NEVER touch the connector pins 3-2 Non-Linearity 2-1 NOSUCHCMD 4-21, 7-4 NOTALLOWED 4-21 Number of Elements 4-12 O OK Mo
HI 1756-WS MANUAL Perform Integrated Technician Tests (WEIGHSYSTEST) 4-15 pin-out diagram 3-4 Pre-Calibration Procedures 5-1 Processor Releases 3-2 R Read C2 Sensor Serial Number (READC2SERIALNUM) 4-17 Read Live Weight (READLIVEWEIGHT) 4-19 Read Parameters (READPARAM) 4-18 Read Status of Module (GETSTATUS) 4-18 Reading data 6-1 REAL 4-8 Reload Non-Volatile (RELOADNONVOLATILE) 4-13 Remote Rack 1-2 Remote Terminal Assembly 3-4 Remote Termination Assembly 1-1 Removing the Module from the Chassis 3-3 Report an
Index Setting the Unit of Measure 4-21 Setting the WAVERSAVER Value 4-22 Setting the Zero Tolerance Value 4-22 Setting Up Communications Between the PLC and the HI 1756-WS (2WS) 4-2 Setup 1-2 Span Weight 4-22 Span Weight paramete 4-14, 5-7 SPANWEIGHT 4-21 Specifications 1-1 Specifications for a Standard HI 1756-WS 2-1 STATUSWORD 4-12, 4-14 Storage Temperature Range 2-2 Structure (ITECHTEST) 4-15 SUCCESS 4-21 T Tare Command (TARECMD) 4-12 Temperature Coefficient 2-2 Timed Out Commands 4-21 U Unpacking 3-1 U
HI 1756-WS MANUAL Write Parameters (WRITEPARAM) 4-18 Z Zero Command (ZEROCMD) 4-12
Glossary of Terms GLOSSARY OF TERMS ACCURACY Closeness of a reading to the actual value of the quantity being measured. ALARM Indication of a tolerance deviation. APPURTENANCE Any added equipment other than the weigh vessel, platform scale or feeder. Pipes, Valves etc. AUTO ZERO TOLERANCES Automatic version of Zero Tolerance which is the limit for enabling the module to zero off the weight automatically. This is not used unless you have the Zero Track Enable bit set to on.
HI 1756-WS MANUAL CHANNEL ACTIVE A parameter that turns the channel off/on. If channel is set to 0 it is off or inactive. If channel is set to 1 it is on or active. COMMAND A request made by the host computer (PLC) to perform an Action. This consists of either number or letter command designators. CAPACITY The maximum weight that can be placed on a scale or balance. CHECK WEIGHING Comparing a weight against limits to determine if the weight is within preset limits.
Glossary of Terms E-MAIL Short for electronic mail, the transmission of messages over communications networks. ENTER KEY This key is used to accept user input into the memory. EPROM Electrically Programmable Read-only Memory. ERROR A message that indicates an unacceptable input has been entered. EVEN A parity configuration. EXCITATION DC voltage supplied to the load cell for power. FILLER Filling is a Gain-in-Weight process.
HI 1756-WS MANUAL LED Light Emitting Diode. these are used as status indicators. LOAD CELL A device which produces output signal proportional to the applied weight or force. Also called a strain gauge. MENU A set of prompts used to configure the instruments. MENU DRIVEN Operational prompts suppled in common language via the system display to guide an operator through a procedure. METRIC Unit of measure selection for weight readings, either lbs or kgs. Set 0 for lbs, 1 for kgs.
Glossary of Terms equipment against spalshing water, seepage of water, falling or hose-directed water and severe external condensation. NEMA 4X An enclosure that is water tight, dust tight and usable both in doors and outdoors. Will protect the enclosed equipment against splashing water, seepage of water, falling or hose directed water and severe external condensation. Corrosion Resistant. NODE A node is an active device connected to the network, such as an HI 3000 Instrument, computer or a printer.
HI 1756-WS MANUAL PREACT The number of units above or below the set point value of which the relay will trip. Use as an “in flight” compensation value. PREVIOUS KEY A key used to step back through menus. PROMPTS Instructions or options presented in a menu by the instrument. PROTOCOL Network protocols are standards that allow computers to communicate.
Glossary of Terms SECURE MEMORY MODULE (SMM) The Secure Memory Module stores and protects vital information from corruption. The SMM also allows the transference of data from one instrument to another with no re-calibration ore re-configuration necessary. SET POINT Ordered weight of a particular ingredient. Weight reading at which a relay will be actuated. SPAN WEIGHT the total amount of test weights used (placed on the scale) for the high point when performing a “Traditional Calibration”.
HI 1756-WS MANUAL TRANSMITTER ZERO Value the transmitter puts out with the minimum weight on the load cell. TTL Transistor-Transistor Logic TXD Transmit Data UPDATE RATE Number of times per second a new weight reading is taken. WAVERSAVER® Setting to remove the effects of ambient vibration from interfering with a weight reading. The range of settings is to eliminate vibration at various frequencies. ZERO Weight reading once the dead load has been offset.
