HI 1756 FC Feeder Control Module User’s Guide Hardy Instruments Part Number: 0596-0318-01 Rev A
3860 Calle Fortunada, San Diego, CA 92123-1825 Telephone: 1-800-821-5831 FAX: (858) 278-6700 Web Address: http://www.hardyinstruments.com Hardy Instruments Part Number: 0596-0318-01 REV A Copyright February 2010, Dynamic Instruments, All Rights Reserved. Printed in the U.S.A. Local Field Service Hardy has over 200 field technicians in the U.S., and more positioned throughout the world to assist you in your support needs.
Contents ●●●●● CHAPTER 1 OVERVIEW ..................................................................................... 1 About Hardy Manuals .................................................................................................................................1 HI 1756 FC Overview....................................................................................................................................1 Typical Applications ................................................................
Second Word - 1: Format Word ................................................................................................................15 Format Word Decimal Point Parameters...................................................................................................15 Third / Fifth Words - 2, 3, 4: Parameter Number and Value..................................................................16 Parameter 13-18 Refills ................................................................................
General Policies and Information ..............................................................................................................46 Warranty....................................................................................................................................................46 For Further Information Contact ...............................................................................................................47 INDEX ......................................................
Chapter 1 Overview ●●●●● This manual provides users and service personnel with specifications and procedures for installing, configuring, operating, maintaining, and troubleshooting the Hardy Instruments HI 1756 FC Rate Controller with WAVERSAVER.® NOTE WAVERSAVER is a registered trademark of Hardy Instruments, Inc. To ensure good performance and maximum service life, follow all guidelines described in this manual. Be sure you understand all cautions, warnings, and safety procedures.
While the system rate calibration can fine tune the flow-rate parameters automatically, you can also make manual adjustments. NOTE Typical Applications Closed-loop rate control can be used in a variety of material-flow applications, such as auger, belt, and vibration-based feeders, converting them from volumetric to gravimetric. The Feeder Controller controls a single-ingredient, single-feeder. It can be operated in batch, automatic, or manual mode.
to isolate the faulty component. Further, the DVM readings can be used to level a system and to make corner adjustments to platform scales. Accuracy is +/- 2% or better of full scale. NOTE If you do not have the HI 215IT Junction Box connected to the module, the mV/V reading is the total for all load cells on the system. Weighing System Tests - Optional This test is used to diagnose drifting or unstable weight reading problems. It requires the HI 215IT Series Junction Box for full utilization.
Chapter 2 Specifications ●●●●● Chapter 2 provides specifications for the HI 1756 FC feeder controller and other equipment that may come with the package. 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 installing or repairing the instrument.
00’ for C2, Non C2, or JB Card 250’ for IT Load Cell Excitation 5 VDC +/- 1.15 W maximum. Isolation from digital section 1000 VDC minimum C2 Calibration Output Isolation from digital section 1000 VDC minimum Number of Channels 1 Channel Update Rate 100 Updates per Second (10 ms) Averages 1-255 User-selectable in Single Increments WAVERSAVER® User Selectable OFF 7.50 Hz 3.50 Hz 1.00 Hz (Default) 0.50 Hz 0.
Less than 0.
Chapter 3 Installation ●●●●● Chapter 3 covers unpacking, cabling, interconnecting, configuring, and installing the Weigh Scale Module. User and service personnel should read this chapter before installing or operating the Weigh Scale module. Unpacking Step 1. Before signing the packing slip, inspect the packing and contents for damage of any kind. Report any damage to the carrier company immediately. Step 2. Verify that everything in the package matches the bill of lading. Step 3.
Step 4. When the module connector is touching the backplane connector, firmly but carefully push toward the chassis until the pins are plugged in and the top and bottom module releases are snapped into place. Module release(s) Module installed in chassis Removing the Module from the Chassis Step 1. Press down on the top and bottom module releases simultaneously until the module can be pulled away from the chassis. (See Figure above.) Step 2. Pull the module out of the chassis. Step 3.
plugged in before operating the module. NOTE Most module-related problems are due to loose connections. Be sure to check the I/O connection first in the event you have a problem receiving information from the load cells or if the relays do not operate correctly. Pin 2 Sense+ Pin 3 Sig+ Pin 4 SigPin 5 SensePin 6 ExcPin 7 C2+ Pin 8 C2Pin 9 Shield Load Cell Wiring Diagrams The diagrams below show how Hardy Load Sensor with C2 wiring differs from standard Load Cell wiring.
You must have sense jumpers or sense lines installed to properly reference the excitation voltage. To properly reference a C2 calibration, run sense lines and remove the sense jumper. NOTE When using load cells that do not have sense lines, you will need to jumper the Sense (-) to the Excitation (-) and the Sense (+) to the Excitation (+) for one or both channels. Jumpers RTA with jumpers for load cells without sense lines RTA Cable Assembly and Jumpers A six-foot cable connects to the HI 1756 FC module.
Chapter 4 Configuration ●●●●● Chapter 4 covers the settings used to prepare the controller for calibration and operation. The Setup procedures require Allen-Bradley’s RS Logix 5000, Allen-Bradley RSLinx™ or RSLinx™ Lite. Power Check To make or change settings, there must be power to both the PLC and the module. Verify that the LEDs are lit for normal operation.
Setting Up Communications Linking the PLC with the HI 1756 FC Feeder Control Module To set parameters for the weigh scale module, you must establish communications with a ControlLogix PLC. Follow the steps below to set up the communication link. You will need a new or open RS Logix® 5000 project. For instructions, see your RS LOGIX 5000 manual. Step 1. Look for a list of folders on the left side of the screen. Scroll to and select the I/O Config folder, which will open a menu. Step 2.
Configuration Output Table Overview To configure the module, you send commands via the PLC output table. The 1756 module uses 32 16-bit INT words in and out. Only 5 words of the output table are normally used.
RATE_CAL_5POINT_CMD 0x60 RATE_CAL_2POINT_CMD 0x61 14 ● ● ● ● ● Chapter 4 CALLOWCMD 0x64 CALHIGHCMD 0x65 C2CALCMD 0x66 WRITEPARAM 0x67 READPARAM 0x69 SETDEFAULTPARAMS 0x94 a 5-point rate calibration. The other points are filled with data based on these 2 points. Runs the 5-point rate calibration at whatever points have previously been defined. Runs the 2-point rate calibration at whatever points have previously been defined.
Command Return or Error Codes Commands always return the command word and command status.
Third / Fifth Words - 2, 3, 4: Parameter Number and Value The third and fourth words in the output table, Parameter Value, are used by the WRITEPARAM command. The fifth word is the parameter ID, used by the WRITEPARAM and READPARAM commands. Parameter values are written with the least significant word first and one 32-bit integer per parameter. For details see the Parameter Table below. Expanded descriptions are listed below the table by hex number. All parameters are DINT.
1A 1 decimal place. Must be > or = 0. REC Level REC Time 1B Seconds, 0 decimal places. Must be > or = 0 REC Shutdown 1C 0=no, 1=yes Shutoff Percent 1D 0 decimal places. 0-100 Total 1E Total DP Batch Total 1F Total DP. Must be > or = 0 Low Alarm Shut Down Rate 20 Rate DP. No limits High Alarm Shut Down Rate 21 Rate DP. No limits Alarm Delay 22 Seconds, 0 decimal places. Must be > or = 0. Rate Setpoint 23 Rate DP. Must be > or = 0, < MAX RATE.
Bit 12 MANUALOP 37 FAST_ROC zerocount calLowCount 38 0x0A00 0x0A01 Initial Refill Mode Two decimal places. This it the output percent when in MANUAL mode. Lightly averaged rate of change, read only, RATE decimal places.
Thus: TIME BASE = 0.088/0.05 TIME BASE = 1.76 (rounded to 2) MINIMUM TIME BASE = 2 seconds Range: In seconds, 0 decimal places. 1-1800 seconds. Parameter 6 ROC time units The units of time (seconds, minutes or hours) you want for the Rate of Change. The ROC display on the summary display will read in these units.
You must calibrate the scale prior to rate calibration. NOTE The PI controller calculates an output percentage based on the parameters P (proportional) and I (integral). The rate calibration process can set the values for P and I automatically. The output percent is determined by the formula: P*((Setpoint - ActualRate)/MaxRate + I * (integral of the proportional term)). P and I Must be > or = 0 Parameter A Rate Calibration Configuration PID I The I parameter for Rate Calibration.
Parameter 13-18 Refills Automatic Refill uses user-selectable refill points to signal a start or stop of the refill process without interrupting the feed process. HI and LO alarms can be used to flag a refill failure. Manual Refill allows for manual refill at any time. The Manual Refill stops at the Refill High point. Initial Refill Initial Refill ensures that the feeder contains enough material to safely begin operation. It can help to decrease the number of refills during a run.
ON-FIXED: With Auto Refill, you can use ON-FIXED to either lock in an effective learned value or enter a noted value that has worked well on previous applications. Range: 0, 1 or 2 Parameter 18 OP Adjust %/wgt during refill Refill OP Adjust %/wgt This is the OP (Output Percentage) Adjust % per unit of wgt. Rate calibration determines this parameter, so you may not want to set it. It would be difficult to know what to enter. The weight of an ingredient in a hopper can affect the rate of feed.
REC Parameters Parameter 1A REC Level % The REC Level % (RECPERCENT or REC LEVEL% parameter) is a percentage of Max Rate. It is the level of error above or below the Setpoint Rate that you can accept before the instrument goes into REC mode. For example: If the rate calibration Max Rate is 5.0 lb/min, and the REC level % is 20%, the allowable deviation is 1.0 lb/min from the Rate Setpoint before a Rate Exception error occurs. Range: 0-100.0 (default 20%. This allows for a very large error.
Rate Calibration Parameters Three types of calibrations determine the flow rate per output percentage: 1. Two-point rate calibration: Used for Auto RateCal. If a two-point Auto Rate Calibration is selected, two flow rate points (points two and four) are used for calculating other rate point values. The unit will go to the high rate output percent for a period of feed time plus prime time (See parameters E and 10 above).
1. For the 2 pt Cal Type (Pt2 and Pt4), the two flow rates for the percentages you selected are the actual flow rates. The instrument calculates the remaining three flow rates. 2. For the 5 pt Cal Type, you provide the five RateCal percents between the Low and High output percentages. 3. For the User-set cal Type, you provide known flow rates for output percentage setpoints (Pt2 and Pt4) and the output percentages. This only establishes the rate lookup table for startup rates. Input Table .
13 14 15 VERSION STATUS COUNTER Firmware version Statusword (See Statusword below) Statusword At word 14, 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. For Example: If the statusword is 69 with a binary value of 0000 0000 0100 0101, bits 0, 2, and 6 are on.
JBOX, the instrument can also read the weights and voltages of the individual sensors attached to the IT JBOX. To initiate an IT test, do a WRITEPARAM command, with parameter number 0x0036, and a parameter value equal to the number of sensors, which should be 1-4 if you have an IT JBOX. If you do not have an IT JBOX, the parameter value does not matter. To read back the results, do a READPARAM command, with parameter numbers 0x0036, 0x1036, 0xB036. The return values are listed below.
1. Command 1: Read calibration values. Use this command to read the rate and weight calibration values. 2. Command 0x81: Write rate calibration values. Use this command to set the 7 rate calibration pairs. 3. Command 0x82: Write weight calibration. Use this command to set the 3 weight calibration values: zero counts, low counts, and CalibK (weight per A/D count). 4. Command 0x83: Write both weight and rate calibration values. The two commands below read and write configuration data.
Chapter 5 Calibration ●●●●● The Feeder Controller Module should be calibrated before use. We also recommend that you verify the calibration periodically or when not in use for extended periods of time. Users and service personnel should be familiar with the procedures in this chapter before installing or operating the Feeder Controller Module. NOTE Do not perform a calibration while the application is in operation. Pre-Calibration Procedures Verify that the load cells have been properly installed.
capacity is rated at 1000 pounds, the load cell/point will be 10 mVDC at 1000 pounds, 7.5 mVDC at 750 pounds, 5 mVDC at 500 pounds and so on. 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. The operating range for the scale in this example is 5-10 mVDC with a 500 pound weight range.
Hard Calibration Hard Calibration is the traditional method of calibration using test weights. Hardy recommends that the test weights total 80 to 100% of the load capacity. Hard Calibration Ladder Logic Example Verify that the parameters have been setup for your weighing process in accordance with the setup information provided in Chapter 4. A Ladder Logic example on the Hardy Instruments Inc. web site explains how to set the weigh process parameters.
Chapter 6 Troubleshooting ●●●●● Chapter 6 provides procedures for troubleshooting the electrical, mechanical and firmware elements of the HI 1756 FC and for using Hardy’s Integrated Technician (IT®) software utility to isolate problems. Flow charts provide troubleshooting s for the rate controller, load cells, and cabling.
mV/V DC voltage signals are between 0-15 millivolts. Overloads and negative millivolt readings are not shown as actual readings but 15.3 for over voltage and 0.0 for negative voltage. You will need to use a multimeter with a 200 or 300 mVDC range to view the out-of-range voltages. Millivolt/volt equals the output from a load cell per each volt of excitation. The HI 1756 FC reads the load cell output in mV/V, which provides higher resolution (4 decimal places) than an mV reading.
A1 - Guidelines for Instabilities on Formerly Operating System A1 UNSTABLE RATE CONTROLLER Disconnect external signal cables and shields, except AC Power Monitor the reading for stability Yes Reconnect signal cables one at a time STABLE? No Problem could be in the instrument. Contact Hardy Customer Support PH: 800-821-5831 Monitor the display for stability If installing any cable causes unstable readings REVIEW TROUBLESHOOTING SECTION B: B1.1-B1.
B - Guidelines for Instabilities on Formerly Operating Systems (Cont’d) B 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 Go To A Stability 35 ● ● ● ● ● Chapter 6
B1 - Guidelines for Instabilities on Formerly Operating Systems (Cont’d) B1 B1.1 B1.2 Chapter 6 Cable Cuts or breaks in the load cell insulation allow moisture to wick into the cable and load points. This can setup stray capacitance charges and allow ground currents to exist. This could create a highly intermittent situation. Vessel, Fill and discharge piping Ground all to a common point to eliminate electrical differences in potential and static build-up. B1.
B1 - Guidelines for Instabilities on Formerly Operating Systems (Cont’d) B1 B2 OK? No Yes B3 OK? Yes No Vessel When inspecting a vessel, 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 and that there isn’t any side loading from piping or external forces. Install flexures on all piping to insure a free floating vessel.
F - Verify Individual Load Cell Millivolt Readings Testing an individual load cell signal output requires an IT Summing Junction box or millivolt meter. Use the load cell certificate to verify the millivolt per volt (mV/V) rating: Example: 3mV/V load cells produce approximately 15mV at full load. That is 5 volts excitation x 3 mV/V. At a scale capacity of 1,000 lbs. with 100 lbs. of deadload when empty, the load point mV reading should measure 1.5mV.
G - Calibration Failed: Not Enough Counts Between ZERO and SPAN This error only occurs at the SPAN parameter. You may ZERO out chains and temporary calibration equipment to hold or hoist test weights. Zeroing the temporary weight does not effect the calibration. G The difference between zero and span is less than 1000 counts Using a millivolt meter, verify that: • The signal millivolt reading is positive and within the acceptable range of 0 to 15 mV.
H - Mechanical Inspection H H2 Mechanically isolated from ladders and connecting structures? H3 Are the load cells properly mounted? 1) 2) 3) 4) H4 Are check rods installed to dampen vessel movement? 1) Protects the load cells from overload and impact forces 2) Limits the movement of the vessel 3) Rods must be loose and not interact with the vessel H5 Are cables routed properly? Housekeeping J Chapter 6 (a) You weigh the output valve, not the input valve (b) Does the weight scale see all the p
J - Electrical Inspection J DO NOT POWER UP THE CONTROLLER UNTIL INPUT VOLTAGES CAN BE VERIFIED 1) 2) 3) 4) J1 Verify the proper voltage level has been supplied J2 Apply power to the controller only if supply voltage is correct J3 Does the scale reflect a weight change? J4 Cabling To Verify Proper Load Cell Operations Go to K 41 ● ● ● ● ● Chapter 6 Verify the proper input power, AC or DC, is properly installed Use a meter to verify neutral, ground and hot are correct Isolated from SCR and mot
K - Load Sharing and Load Sensor Checkout 42 ● ● ● ● ● Chapter 6
Erratic Weight or Rate Control This section explains how to resolve problems relating to rate and Rate of Change (ROC) calculation, Rate Exception Control (REC), motor speed control, and weight calibration. Rate calculations 1. Rate calculations are no better than the scale’s calibration accuracy. Verify the scale calibration using test weights. 2. Follow the weight troubleshooting flow charts and correct any equipment binding, rubbing, and piping problems. 3.
If the output is properly wired back to the motor speed controller, verify that the PLC analog card parameters for that analog out are set correctly and that the HI 1756 FC analog signal is programmed for the corrected controller terminals. Hardy Instruments Inc. does not provide motor speed control converters or analog out PLC modules. Consult the motor speed controller manufacturer’s manual for troubleshooting and settings. NOTE REC +/- settings 1.
UNIVERSAL JOINT OR HOSE USE SYMMETRIC BEAM LOADED THROUGH SHEAR CENTER TO AVOID TWIST WITH LOAD JUNCTION BOX HI 4060 Rate Controller INTERMEDIATE SUPPORT FRAME FULLY CONSTRAINED LATERALLY WITH STAY RODS BIN ACTIVATOR NON METALLIC EXPANSION ASSEMBLY OR HOSE The load cell/point takes as an input the 5 volts DC excitation voltage generated by the HI 1756 FC.
To determine if an instrument or cabling problem exists, verify the basic operation of the system by performing the following system checks. Weight and Voltage Test The Weight and Voltage tests are used to diagnose a weighing system and, if certain types of problems are indicated, determine their source. It provides the total scale input to the instrument, such as mV/V and Weight in the units selected (i.e. lbs, kg, oz, g).
On-site training: A Hardy Support Representative can be scheduled to train your operations and maintenance personnel. This can be as simple as basic load cell theory or as complete as troubleshooting techniques which allow you to service your equipment. For Further Information Contact Technical Service Manager Hardy Instruments, Inc. 3860 Calle Fortunada, San Diego, CA 92123-1825 Telephone: +1 (858) 278-2900 FAX: +1 (858) 278-6700 Web Site: http://www.hardyinstruments.com E-Mail: hardysupport@hardyinst.
Index A ABORTCMD, 13 Alarm Delay, 23 Alarm LEDs, 11 Alarms, 2 Applications, 2 Approvals, 6 Automatic mode, 3 Automatic refill, 3 Automatic Refill, 21 Averages, 5, 19 D Deinstalling the Module, 8 Digital Volt Meter, 3 Din Rail Mounting, 9 DVM - Digital Volt Meter, 3 E End Weight, 21 Error Codes, 15 ERROR status words, 26 Excitation, 5 B Backplane Input Voltage / Current Load / Power Load, 4 Batch amount, 20 Batch Mode, 3 Batch Total, 24 C C2 calibration, 2, 30 C2 Calibration Input, 4 C2 Calibration Outpu
L LEDs, 11 Linking PLC to the HI 1756 FC, 12 Load Cell, 29 Load Cell Excitation, 5 Load Cell Tests, 44 Load Cell Wiring, 9 Loss of weight, 1 Low Alarm Shut Down Rate, 22 M Manual Mode, 3 Manual Refill, 3, 21 MANUALCMD, 13 Metric, 18 Mode, 20 Mode (state) Table, 27 Mode Rejection, 4 Mode Voltage, 4 Motor speed control, 43 mV/V readings, 3 N NOCMD, 13 Non-Linearity, 4 Number of Channels, 5 O ON-FIXED, 22 ON-LEARN, 22 OP, 26 OP Adjust, 22 OP Adjust %/wgt, 22 Operating Temperature, 5 Output commands, 13 Outp
U UL, 6 Update Rate, 5 V VERSION, 26 Voltage, 5 Voltage Testing, 32 50 ● ● ● ● ● Index W Wait Time, 22 WAVERSAVER, 2, 5, 19 Weighing System Tests, 3 Weight and Voltage Testing, 32 Weight and Voltage tests, 46 weight calibration, 43 Weight Decimal Point, 15 Wiring Diagrams, 9 WRITENONVOLATILE, 13, 16 WRITEPARAM, 13, 14, 27
3860 Calle Fortunada, San Diego, CA 92123-1825 Telephone:1-800-821-5831 FAX: (858) 278-6700 Web Address: http://www.hardyinstruments.com Hardy Instruments Document Number: 0596-0318-01 Rev A Copyright January 2010, Hardy Instruments, All Rights Reserved. Printed in the U.S.A.
