Filler/Dispenser/IBC HI-3010 USER GUIDE
i Table of Contents Table of Contents Table of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -i Table of Illustrations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -I Chapter 1 Overview - - - - - - - - - - - - - - - - - - - - - - - - - - General Introduction to the Hardy Filler/Dispenser/IBC HI 3010 User Guide - - - - - - - - - - - - - - - - - - - - Description - - - - - - - - - - - - - - - - - - - - - - - - - Typical Applications - - - - - -
HI 3010 Filler/Dispenser/IBC User Guide Chapter 4 Clear Button - - - - - - - - - - - - - - Ingr./1 Button - - - - - - - - - - - - - 2/ABC Button - - - - - - - - - - - - - Setup/3/DEF Button - - - - - - - - - - Amount/4/GHI - - - - - - - - - - - - - Units/5/JKL Button - - - - - - - - - - - 6/MNO Button - - - - - - - - - - - - - Cycle/7/PQRS Button - - - - - - - - - 8/TUV Button - - - - - - - - - - - - - Test/9/WXYZ Button - - - - - - - - - - User/./_/@ Button - - - - - - - - - - - 0/Char.
iii Table of Contents About Help - - - - - - - - - - - - - - Operating the Dispenser from the Front Panel Front Panel Display - - - - - - - - - - Button Functions - - - - - - - - - - - Start Button - - - - - - - - - - - - Stop Button - - - - - - - - - - - - Help Button - - - - - - - - - - - - Manual Button - - - - - - - - - - - Print Button - - - - - - - - - - - - Up/Down - Left/Right Buttons - - - Enter Button - - - - - - - - - - - - Exit Button - - - - - - - - - - - - Clear Button - - - - - - - - - - -
HI 3010 Filler/Dispenser/IBC User Guide Chapter 5 Discharge On Alarm - - - - - - - - - - - - - - Operating the Dispenser from the Ethernet (Web Site) Getting Started - - - - - - - - - - - - - - - - - - Monitoring the HI 3010 - - - - - - - - - - - - - View and Clear Totalized Weight - - - - - - - - Operating in Manual Mode from the Front Panel - - Operating in Manual Mode from the Web Browser - - - - - - - - - - - 48 - 48 - 48 - 49 - 49 - 50 - 51 Operating Procedures/IBC Dispenser - - - - Dispens
v Table of Contents No Slow Feed Alarm - - - - - - - - - - - - - - - - - - Slow Feed On Alarm - - - - - - - - - - - - - - - - - - Under dispense/Over dispense Alarms - - - - - - - - - Dispense Timeout Alarm - - - - - - - - - - - - - - - - Jog Alarms - - - - - - - - - - - - - - - - - - - - - - - - Did Not Jog Alarm - - - - - - - - - - - - - - - - - - - Jog Stuck On Alarm - - - - - - - - - - - - - - - - - - Jog Count Alarm - - - - - - - - - - - - - - - - - - - - Discharge Alarms - - - - - - - - - - - - - -
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I Table of Illustrations Table of Illustrations Chapter 1 Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - FIG. 1-1 FILLING A VESSEL USING A FEEDER - - - - - - - - - FIG. 1-2 FILLING INTO A VESSEL FROM ANOTHER VESSEL - FIG. 1-3 DISPENSING INTO A VESSEL FROM A FEEDER - - - FIG. 1-4 DISPENSING (LOSS-IN-WEIGHT) FROM A VESSEL TO A ANOTHER VESSEL - - - - - - - - - - - - - - - - - - - - - - - - - - 1 2 2 2 Chapter 2 Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - FIG.
HI 3010 Filler/Dispenser/IBC User Guide Chapter 4 FIG. 3-36 PAUSING THE ACTUATE FUNCTION - - - - - - - - FIG. 3-37 FILL DISPLAY FAST FILL ON - - - - - - - - - - - - - FIG. 3-38 SLOW FILL DISPLAY - - - - - - - - - - - - - - - - - FIG. 3-39 FILL DISPLAY FAST FILL ON - - - - - - - - - - - - - FIG. 3-40 SLOW FILL DISPLAY - - - - - - - - - - - - - - - - - FIG. 3-41 FAST FILL HOLD - - - - - - - - - - - - - - - - - - - FIG. 3-42 SLOW FILL HOLD - - - - - - - - - - - - - - - - - - FIG.
III Table of Illustrations FIG. 4-7 SELECTION ALERT DISPLAY - - - - - - - - - - - - - - FIG. 4-8 STANDBY DISPLAY - - - - - - - - - - - - - - - - - - - FIG. 4-9 USER MENU - - - - - - - - - - - - - - - - - - - - - - - FIG. 4-10 USER NAME/JOE - - - - - - - - - - - - - - - - - - - - FIG. 4-11 INGREDIENT MENU - - - - - - - - - - - - - - - - - - - FIG. 4-12 NEW INGREDIENT NUMBER/4 - - - - - - - - - - - - - - FIG. 4-13 STANDBY MENU/SELECTED INGREDIENT - BERRIES - FIG.
HI 3010 Filler/Dispenser/IBC User Guide FIG. 4-64 WAIT DISPLAY - - - - - - - - - - - - - - - - - - - - FIG. 4-65 UNDERDISPENSE ALARM - - - - - - - - - - - - - - FIG. 4-66 OVERDISPENSE ALARM - - - - - - - - - - - - - - - FIG. 4-67 ACCEPT DISPENSE DISPLAY - - - - - - - - - - - - FIG. 4-68 TIMEOUT ALARM - - - - - - - - - - - - - - - - - - FIG. 4-69 RESUME DISPENSE FAST DISPLAY - - - - - - - - - FIG. 4-70 RESUME DISPENSE SLOW DISPLAY - - - - - - - - FIG.
V Table of Illustrations FIG. 5-27 PAUSING THE AUXILIARY FUNCTION - - - - - - - - - - FIG. 5-28 FAST DISPENSE/WITH AUXILIARY ON - - - - - - - - - FIG. 5-29 IBC DISPENSE WAIT TIMER DISPLAY - - - - - - - - - - FIG. 5-30 BEGINNING DISPENSE CYCLE #2 - - - - - - - - - - - - FIG. 5-31 LAST DISPENSE CYCLE - - - - - - - - - - - - - - - - - FIG. 5-32 STANDBY MENU - - - - - - - - - - - - - - - - - - - - - FIG. 5-33 JOG ON DISPLAY - - - - - - - - - - - - - - - - - - - - FIG.
HI 3010 Filler/Dispenser/IBC User Guide FIG. 5-53 CLEAR TOTALIZER LIST/SELECTING INGREDIENT TO CLEAR - - - - - - - - - - - - - - - - - - - - - - - - - - - FIG. 5-54 MANUAL MODE DISPLAY/SELECTING TARE SCALE FIG. 5-85 TARE MODE DISPLAY - - - - - - - - - - - - - - - - FIG. 5-86 DISCHARGE MODE DISPLAY/STARTING DISCHARGE FIG. 5-87 LINK TO DOWNLOAD PAGE - - - - - - - - - - - - - FIG.
1 CHAPTER 1 Overview CHAPTER 1: OVERVIEW General Introduction to the Hardy Filler/ Dispenser/IBC HI 3010 User Guide This User Guide provides the User with a complete description of the operating procedures for the HI 3010 Filler/Dispenser/IBC. To get the maximum service life from this product, operators should use this instrument in accordance with recommended practices either implied or expressed in this manual.
HI 3010 Filler/Dispenser/IBC User Guide ters” over Ethernet/IP and Devicenet communications while optional interfaces for Allen-Bradley Remote I/O, Profibus provides communication to PLC® and DCS systems. Hard copy records can be printed via a standard 232 simplex printer port to an external printer. NOTE: PLC® is a registered trademark of the AllenBradley Corporation.
3 CHAPTER 1 Overview Load Point Load Point Dispense Gate WAVERSAVER® technology which eliminates the effects of vibratory forces present in all industrial weight control and measurement applications. By eliminating the factor of vibratory forces the controller is capable of identifying the actual weight data. WAVERSAVER® can be configured from the front panel to ignore noise with frequencies as low as 0.25 Hz.
HI 3010 Filler/Dispenser/IBC User Guide Set Point Relays The HI 3010 is fitted with four (4) standard internal selectable and Form A mechanical (SPST) relays. The relays can be used to open or close valves or gates, turn on/off motor, mixers, vibration equipment, heaters or coolers to name a few. Serial Port One standard RS 232 serial port which can be configured to receive commands and transmit weight data to a serial printer. Baud rates are user selectable at 600, 1200, 2400, 4800, 9600 or 19,200.
5 CHAPTER 1 Overview PLC Controller and supports both discrete and block transfers of data. It can support up to 230.4 Kbaud transfer rates. Profibus Allows bi-directional communications to Profibus (Process Fieldbus) products including those made by Siemens, GE Fanuc and Texas Instruments. This interface supports PROFIBUS-DP (Decentralized Periphery) and processes both Selectable Predetermined and Block transfer commands. It supports up to 12 Mbaud transfer rates.
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7 CHAPTER 2 Calibration CHAPTER 2: CALIBRATION Getting Started The Hardy Filler/Dispenser can be calibrated two ways. The first is with the Hardy C2® Second Generation calibration which requires no test weights. C2® Calibration is one of Hardy’s Core Technologies. We will describe the C2 Calibration process in this chapter. The second calibration technique is called traditional calibration which requires certified test weights.
HI 3010 Filler/Dispenser/IBC User Guide FIG. 2-6 C2 CALIBRATION FIG. 2-3 CALIBRATION MENU/C2 CAL Step 4. Press the Enter button. C2 CAL Sub-menu appears. (See Fig. 2-4) Step 11. A “function OK” momentarily appears on the screen indicating the calibration was successful • • FIG. 2-4 C2 CALIBRATION SUB-MENU Step 5. The Load Sensor number is a read only field. It tells you how many load sensors are connected to the instrument. Step 6.
9 CHAPTER 2 Calibration Step 7. Click on the Do C2 Calibration button. Step 8. A page telling you that the C2 Calibration completed OK appears. (See Fig. 2-18) FIG. 2-10 CAL COMPLETED OK FIG. 2-8 CONFIGURATION PAGE Step 2. Click on Calibration. The Calibration Sub-menu appears. (See Fig. 2-17) FIG. 2-9 CALIBRATION SUB-MENU Step 3. The Load Sensor number is a read only field. It tells you how many load sensors are connected to the instrument. Step 4.
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11 CHAPTER 3 Filler CHAPTER 3: OPERATING PROCEDURES/FILLER About Chapter 3 Chapter 3 contains step-by-step instructions for operating the Hardy Process Solutions, HI 3010 Filler/Dispenser. The procedures include complete instructions for operating the Filler from the Front Panel, DeviceNet, and the Web Browser. We highly recommend reading the procedures before operating the Filler/Dispenser. Being familiar with the operating procedures insures that the Filler/Dispenser will provide trouble free service.
HI 3010 Filler/Dispenser/IBC User Guide • • • • 12 Current Fill/Dispense Current Cycle Totals Setup Data Press the Print button, the following screen appears: > Pr int cur r ent Fil l Pr int cur r ent cycl e Tot al s Set up Dat a FIG. 3-2 FILLER/PRINT SCREEN DEFAULT FIG. 3-4 LIST SELECTION/ENTER BUTTON For example, when selecting units from a pick list, use the left and right arrows to move the cursor in front of the unit you want and press the Enter button.
13 CHAPTER 3 Filler left arrow button to erase the current entry and enter another. Setup/3/DEF Button This enables you to access the configuration and setup menus. Also enters the number 3 and the letters D, E, F. Amount/4/GHI Enables you to change the amount of the ingredient while in the standby mode. Also enters the number 4 and the letters C, H, I.
HI 3010 Filler/Dispenser/IBC User Guide FIG. 3-9 USER MENU FIG. 3-7 SELECTION ALERT DISPLAY Filling Procedures About Filling 14 Step 2. Press the Clear button to erase the current entry. Step 3. Use the Alphanumeric buttons to enter your user ID. A user ID is three (3) characters long and can consist of Alphanumeric characters. The Filling Operation is a Gain-in-Weight process. The Filler controller measures the weight gain into a vessel until the pre-set, weight set point has been reached.
15 CHAPTER 3 Filler 2. are not saved when the instrument is powered down. The ingredient parameters that are configured in setup are the only parameters that are saved. If you want to permanently change the parameters for this ingredient you must go through the configuration process. For configuration information see the HI 3010 Installation and Service Manual for instructions. Press the Clear button to remove the current ingredient number.
HI 3010 Filler/Dispenser/IBC User Guide 16 meric keypad to enter the new target weight. (See Figs. 3-19 & 3-20) FIG. 3-16 TARGET WT/NEW VALUE • Press the Enter button. The Standby Menu appears with the new Amount Required. In our example we used 225 lbs. (See Fig. 317) FIG. 3-17 STANDBY MENU/NEW AMOUNT REQUIRED FIG. 3-19 FILLS MENU/ERASED VALUES NOTE: You can enter values from 1 - 9999. FIG. 3-20 FILLS MENU/NEW FILLS NUMBER • Step 5. If the number of fills is the number you want, go to Step 7.
17 CHAPTER 3 Filler refill can occur at any time during the filling process. (See Fig. 3-22) FIG. 3-24 FILL DISPLAY FAST FILL ON FIG. 3-22 REFILL DISPLAY NOTE: NOTE: The Autozero function is selectable and can be turned ON or OFF. If Autozero is turned OFF during setup, than the instrument checks for motion and autotares the scale before filling. The “Fast Fill” appears for both Single or Dual Speed Filling. • • • • Ingredient = flour Current filled amount = 9 lbs out of 225 lbs.
HI 3010 Filler/Dispenser/IBC User Guide ingredient being filled and becomes part of the Ingredient Parameter. It is highly recommended that you turn the Auto Pre-Act function ON. (For configuration information see the HI 3010 Service Manual for instructions) NOTE: 18 To prevent excessive Jogging make sure you have turned the Auto Pre-Act ON. FIG. 3-29 JOG ON DISPLAY • The Filler/Dispenser goes through one JOG sequence that was previously set up for this ingredient. (See Figs.
19 CHAPTER 3 Filler Pausing the Jog Function • You can pause the JOG cycle by pushing the Stop button once at any time during the JOG cycle. 1. If you pause the Jog On cycle the JOG Hold display appears. (See Fig. 3-32) FIG. 3-34 AWAITING COMMAND TO DISCHARGE DISPLAY Step 2. If the OK to Discharge is ON, the instrument checks to see if it is OK to discharge. The instrument also checks to see if the discharge gate is open. FIG. 3-32 PAUSING JOG IN THE JOG ON CYCLE 2.
HI 3010 Filler/Dispenser/IBC User Guide NOTE: • If you want to Stop the auxiliary function press the Stop button two times. Filling - Dual Speed 20 The slow fill continues until the gain in weight reaches the Target Window. (See Fig. 3-38) Dual Speed Sequential About Dual Speed Filling • Dual speed filling involves two fill rates, Fast and Slow Sequential and Fast and Slow Simultaneous.
21 CHAPTER 3 Filler • Pausing Slow Fill To pause the Slow Fill, press the Stop button once. (See Fig. 3-42) Lost OK to Fill Alarm - - - - - ALARM CONDITION - - - - During the filling process, conditions may develop that cause the Filler/Dispenser to lose the OK to FILL during Fast Fill or Slow Fill. When this occurs an alarm appears that says LOST OK TO FILL. (See Figs. 3-44 & 3-45) FIG. 3-42 SLOW FILL HOLD • To resume Slow fill press the Start button. List of Fill Alarms FIG.
HI 3010 Filler/Dispenser/IBC User Guide 22 Feed On Alarm - - - - - ALARM CONDITION - - - - • If the Fast Fill Gate valve or feeder does not close or stop at the end of a fill, the FEED ON alarm appears on the display. (See Fig. 3-50) FIG. 3-47 RESUME FILLING SLOW No Fast Feed Alarm - - - - - ALARM CONDITION - - - - • If the Fast Fill Gate valve or feeder is not open or on at the time you want to fill, the NO FAST FEED alarm appears on the display. (See Fig. 3-48) FIG. 3-50 FAST FEED ON ALARM 1. 2. 3.
23 CHAPTER 3 Filler 3. If the fill weight is NOT within the target window and the Jog Function is not turned on, the fill is not accepted and an UNDER FILL or OVER FILL ALARM appears depending on the weight filled. Fill Timeout Alarm FIG. 3-52 RESUME FILLING SLOW 3. NOTE: Press the Start button to resume slow filling. • If the Fill Timeout function is turned on it times the fill cycle between the ON and WAIT modes. If this time is exceeded the TIMOUT ALARM displays. (See Fig.
HI 3010 Filler/Dispenser/IBC User Guide 4. If the Stop button is pressed the instrument will go to Standby mode and does not complete any more requested cycles. • UNDERFILL ALARM, press the Clear button to clear the alarm, the Accept the Fill display appears. At this time you can: 1. Underfill /Overfill Alarm 2. - - - - - ALARM CONDITION - - - - - 3. FIG. 3-58 UNDERFILL ALARM • • OVERFILL ALARM, press the Clear button to clear the alarm. The Accept the Fill display appears. (See Fig.
25 CHAPTER 3 Filler you that you have used up the JOGs for this sequence. (See Fig. 3-64) FIG. 3-62 TO JOG AGAIN PRESS START DISPLAY 2. The Jog sequence resumes from where the Jog left off when it was paused. FIG. 3-64 JOG COUNT ALARM 1. Jog Stuck On Alarm 2. - - - - - ALARM CONDITION - - - - • After each jog the instrument goes to a pause state (Jog OFF) for a pre-determined period of time if the jog stops. In this state it checks the weight to see if it is within the target window.
HI 3010 Filler/Dispenser/IBC User Guide 1. 2. 3. Check to see what is causing the Not OK to discharge alarm to appear. Correct the problem. Press the Clear button to clear the alarm. If Auto Discharge is On, the instrument looks for an OK to Discharge signal. If Auto Discharge is Off the Awaiting Command to Discharge display appears. (See Fig. 367) 26 FIG. 3-69 AWAITING COMMAND TO DISCHARGE Discharge Clogged Alarm - - - - - ALARM CONDITION - - - - • FIG.
27 CHAPTER 3 Filler FIG. 3-71 DISCHARGE ON ALARM 1. 2. 3. 4. Check to see what is causing the problem. Correct the problem. Press the Clear button to clear the alarm. The CLOSE DISCHARE MANUALLY display appears. After you manually close the discharge, press the Start button. (See Fig. 3-72) FIG. 3-73 FILLER/DISPENSER HOME PAGE/ SELECTING OPERATIONS Step 4. Click on “Operations”.
HI 3010 Filler/Dispenser/IBC User Guide 28 FIG. 3-75 OPERATION PAGE Diagnostics - See The HI 3010 Technical Service Manual, Chapter 7 - System Integrity Check and Fault Determination From the Web Browser Monitoring the HI 3010 The monitoring page displays the Standby and run Displays. This information is automatically updated every 3 seconds. To update it more often press on the Refresh button in your browser. Step 1. Click on “Back” to return to the Operation page.
29 CHAPTER 3 Filler NOTE: The ability to operate the instrument from a Web Page will be available in future iterations of the Web Site. Step 6. Press the Enter button. The Discharge Mode display appears. (See Fig. 3-104) Operating in Manual Mode from the Front Panel The HI 3010 allows the user to perform some of the operations in manual mode. The following Filling Functions can operate Manually: • • • • • • Step 1. Tare Scale Discharge Refill Auxiliary Device (Output Relay) Fast Fill Slow Fill FIG.
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31 CHAPTER 4 Operating Procedures/Dispenser CHAPTER 4: OPERATING PROCEDURES/DISPENSER Dispensing Procedures About Dispensing The Dispenser is a Loss-in-Weight instrument. The Dispenser controller measures the weight loss out of a vessel, until the pre-set, Target Weight has been reached. The Dispenser controller then stops dispensing and automatically goes to a wait condition, waiting for the next container to be positioned.
HI 3010 Filler/Dispenser/IBC User Guide • • • • • 32 Current Dispense Current Cycle Totals Setup Data Self Test Press the Print button, the following screen appears: PRINT KEY MENU > Pr int cur r ent Disp Pr int Cur r ent Cycl e Pr int Tot al s FIG. 4-2 PRINT SCREEN DEFAULT FOR DISPENSER Note that the cursor is in front of the Print Current Dispense menu. That is the default setting. The print button will only print the menu with a cursor in front of it.
33 CHAPTER 4 Operating Procedures/Dispenser This enables you to access the configuration and setup menus. Also enters the number 3 and the letters D, E, F. Amount/4/GHI Step 1. The First display you will see on a product right from the factory or when changing from a Filler to a Dispenser, is the “How Will I Be Used?” Display asking you what you how to use the Filler/Dispenser. (See Fig. 4-5) Enables you to change the amount of the ingredient while in the standby mode.
HI 3010 Filler/Dispenser/IBC User Guide FIG. 4-10 USER NAME/JOE FIG. 4-7 SELECTION ALERT DISPLAY Predispense Procedures Step 1. Check to be sure that the first container you are going to dispense into is in the correct position. Step 2. Check to see if the Dispenser is configured for your specific dispensing application. If it is not you will have to configure the instrument. For configuration procedures please refer to the HI 3000 Service/ Installation Manual for instructions. Step 3.
35 CHAPTER 4 Operating Procedures/Dispenser FIG. 4-14 TARGET WEIGHT FIG. 4-12 NEW INGREDIENT NUMBER/4 NOTE: • The ingredient number listed usually will have an ingredient name, which is created during the Dispenser setup process. • Press the Clear button to erase the values displayed. (See Fig. 4-15) Press the Enter button. The Standby Menu appears with the chosen ingredient name, cycle number, amount required and user name. In our example Ingredient 4 is Berries. (See Fig. 4-13) FIG.
HI 3010 Filler/Dispenser/IBC User Guide 36 Step 5. If the number of dispenses is the number you want, go to Step 7. Step 6. If you want to change the number of dispenses, do the following: NOTE: 1Dispense = 1 Cycle. Dispenses and Cycles are used interchangeably. • Press the Cycle/7 button. The Choose Dispense Menu appears. (See Fig. 4-18) FIG. 4-20 DISPENSE MENU/NEW DISPENSES NUMBER • Press the Enter button. The Standby Menu appears with the new cycles value. (See Fig. 4-21) FIG.
37 CHAPTER 4 Operating Procedures/Dispenser Dispense instruction sent from a PLC or DCS and so on. Auto Refill ON - The configuration is the same with a Refill High set point and Refill Low set point. The Refill Low set point is based on the required dispense weight. However the Dispenser checks the Refill level before each cycle and if there is not enough material it refills to the Refill High set point for the ingredient selected.
HI 3010 Filler/Dispenser/IBC User Guide • 38 If the Dispense (loss in weight) is below the Target Window the Jog Function Automatically starts. (See Jog Function) Step 11. The Dispenser Continues going through the dispense cycles until all the dispense cycles are completed. (See Fig. 4-26) FIG. 4-26 LAST DISPENSE CYCLE Step 12. After completion of all the cycles, the Filler/Dispenser goes back to the Standby Menu. (See Fig. 427) FIG.
39 CHAPTER 4 Operating Procedures/Dispenser FIG. 4-30 DISCHARGING ON FIG. 4-33 JOG OFF DISPLAY Step 4. When the discharge is complete, the instrument closes the discharge gate and returns to the Dispense On display or the Standby Display depending on the dispensing cycle. Step 3. The instrument goes to the Jog Off state where it checks to see if the loss in weight is within the target window. A timer is displayed counting down the time the instrument is in the Jog Off state.
HI 3010 Filler/Dispenser/IBC User Guide 40 insuring that “UNDERDISPENSE” and “OVERDISPENSE” conditions do not occur. The new Pre Act value is saved for the ingredient being dispensed and becomes part of the Ingredient Parameter. It is highly recommended that you turn the Auto Pre-Act function ON. (For configuration information see the HI 3010 Service Manual for instructions) FIG. 4-38 SLOW DISPENSE ON DISPLAY Pause Slow Dispense • To pause the Slow Dispense, press the Stop button once. (See Fig.
41 CHAPTER 4 Operating Procedures/Dispenser Dispense Alarms Over Refill Alarm - - - - - ALARM CONDITION - - - - - FIG. 4-41 SLOW DISPENSE DISPLAY 3. 4. If the dispense is within the target window and you do not have the Discharge Function turned ON (See Discharge Function above), the instrument returns to the Waiting On Display, repeats the motion check, autotares and/or checks the OK to Dispense processes and begins dispense cycle number 2, then 3, 4 and so on. (See Fig.
HI 3010 Filler/Dispenser/IBC User Guide Refill Off Alarm NOTE: 42 If the dispenser returns to the standby display you must press start again. - - - - - ALARM CONDITION - - - - Not OK to Dispense Alarm • If the Refill gate, valve or feeder does not open or start within a preset time period when the refill is detected the REFILL OFF ALARM appears. (See Fig. 4-46) - - - - - ALARM CONDITION - - - - • If the function is turned on and it is NOT OK TO DISPENSE, an alarm appears in the display. (See Fig.
43 CHAPTER 4 Operating Procedures/Dispenser FIG. 4-49 LOST OK TO DISPENSE ALARM/FAST DISPENSE FIG. 4-52 RESUME DISPENSE SLOW No Fast Feed Alarm - - - - - ALARM CONDITION - - - - • If the Fast Dispense Gate valve or feeder is not open or on at the time you want to dispense, the NO FAST FEED alarm appears on the display. (See Fig. 4-53) FIG. 4-50 LOST OK TO DISPENSE ALARM/SLOW DISPENSE 1. 2. 3.
HI 3010 Filler/Dispenser/IBC User Guide FIG. 4-55 FAST DISPENSE ON FIG. 4-58 UNDERDISPENSE ALARM FIG. 4-56 RESUME FILLING SLOW DISPLAY FIG. 4-59 OVERDISPENSE ALARM 44 Fast Feed On Alarm No Slow Feed Alarm - - - - - ALARM CONDITION - - - - - - - - - ALARM CONDITION - - - - • If the Fast Dispense Gate valve or feeder does not open close or turn off at the end of a cycle, the FAST FEED ON alarm appears on the display. (See Fig.
45 CHAPTER 4 Operating Procedures/Dispenser Under Dispense/Over Dispense Alarms - - - - - ALARM CONDITION - - - - • FIG. 4-61 RESUME DISPENSE SLOW DISPLAY If the target weight is NOT within the target window and you do not have the JOG function turned ON, the dispense is not accepted and an UNDERDISPENSE or OVERDISPENSE alarm appears depending on the weight dispensed. (See Fig.
HI 3010 Filler/Dispenser/IBC User Guide FIG. 4-66 ACCEPT DISPENSE DISPLAY • FIG. 4-68 RESUME DISPENSE FAST DISPLAY UNDERDISPENSE ALARM, press the Clear button to clear the alarm, the Accept the Dispense display appears. At this time you can: 1. 2. 3. Accept the dispense by pressing the START button. If your system allows, physically add some of the material until it meets the target window requirements and then press the START button.
47 CHAPTER 4 Operating Procedures/Dispenser you that you have used up the JOGs for this sequence of cycles. (See Fig. 4-73) FIG. 4-71 TO JOG AGAIN PRESS START DISPLAY 2. The Jog sequence resumes from where the Jog left off when it was paused. FIG. 4-73 JOG COUNT ALARM 1. Jog Stuck On Alarm 2. - - - - - ALARM CONDITION - - - - • After each Jog the instrument goes to a pause state (Jog Off) for a pre-determined period of time if the Jog stops.
HI 3010 Filler/Dispenser/IBC User Guide 1. 2. 3. 48 Check to see what is causing the Not OK to discharge alarm to appear. Correct the problem. Press the Clear button to clear the alarm. If auto discharge is on the dispenser looks for an OK to Discharge signal. If the OK to Discharge is Off the awaiting Command to Discharge display appears. (See Fig. 4-76) FIG. 4-78 DISCHARGE ON ALARM 1. 2. 3. 4. FIG. 4-76 AWAITING COMMAND TO DISCHARGE No Discharge Alarm 5.
49 CHAPTER 4 Operating Procedures/Dispenser Step 4. Click on “Operations”. When entering Operations for the first time after cycling the power off/ on, an Alert asking for a User Name and Password appears. (See Fig. 4-104) Step 1. Click on “Monitor”. The Monitor Page Appears. (See Fig. 4-106) FIG. 4-82 MONITORING THE INSTRUMENT Step 2. FIG. 4-80 ENTERING USER NAME AND PASSWORD Step 5. Enter the User Name and Password and click OK. The Operation Page appears. (See Fig.
HI 3010 Filler/Dispenser/IBC User Guide 50 FIG. 3-85 MANUAL MODE DISPLAY/SELECTING TARE SCALE Step 2. Press the Enter button. The Tare Mode display appears. (See Fig. 3-110) FIG. 4-84 CLEAR TOTALIZER LIST/SELECTING INGREDIENT TO CLEAR Step 3. Step 4. Click on the Ingredient # you want to clear. Click on the Clear Totalizer button to clear the totalized weight for the selected ingredient. CAUTION: PRESSING THE CLEAR TOTALIZER BUTTON WILL SET THE SELECTED TOTALIZER TO ZERO. Step 5.
51 CHAPTER 4 Operating Procedures/Dispenser FIG. 3-88 DISCHARGE MODE DISPLAY/STOPPING DISCHARGE Step 8. Step 9. Step 10. To select another function, press the up or down button to move the cursor in front of the function that you want to perform. Press Exit to return to the Manual Mode display. Press Exit to return to the Standby display. Operating in Manual Mode from the Web Browser You currently cannot operate the instrument from the Web Browser.
HI 3010 Filler/Dispenser/IBC User Guide 52
53 CHAPTER 5 Operating Procedures/IBC Dispenser CHAPTER 5: OPERATING PROCEDURES/IBC DISPENSER Dispensing Procedures About Dispensing The IBC (Intermediate Bulk Container) Dispensing Operation is a Loss-in-Weight instrument. The IBC Dispenser controller measures the weight loss out of Super Bags, Drums, Totes or Gaylord Bulk Bins, until the pre-set, Target Weight has been reached.
HI 3010 Filler/Dispenser/IBC User Guide 54 Print Button Enter Button The Print Button when pressed brings up a series of screens and allows the user to Print the following: The Enter button enters the Alpha/Numeric value entered for a menu item in the display. The Enter button also enters the selections from a pick list. (See Fig. 5-4) • • • • • • Current IBC Dispense Current Cycle Totals Setup Data Self Test Error Log Press the Print button, the following screen appears: FIG.
55 CHAPTER 5 Operating Procedures/IBC Dispenser the next alphanumeric entry. This is true for all the Alphanumeric buttons. If this occurs use the left arrow button to erase the current entry and enter another Setup/3/DEF Button This enables you to access the configuration and setup menus. Also enters the number 3 and the letters D, E, F.
HI 3010 Filler/Dispenser/IBC User Guide 56 FIG. 5-10 USER NAME/JOE FIG. 5-7 SELECTION ALERT DISPLAY Some examples: Predispense Procedures Step 1. Step 2. Step 3. Check to be sure that the first bulk container you are going to dispense into is in the correct position. Check to see if the IBC Dispenser is configured for your specific dispensing application. If it is not you will have to configure the instrument. For configuration procedures please refer to the HI 3010 Service Manual for instructions.
57 CHAPTER 5 Operating Procedures/IBC Dispenser through the configuration process. For configuration information see the HI 3010 Service Manual for instructions. • Press on the Amount/4 button once. The Target WT. Menu appears. (See Fig. 5-15 FIG. 5-12 PRESS THE CLEAR BUTTON TO CLEAR INGREDIENT NUMBER FIG. 5-15 TARGET WEIGHT • FIG. 5-13 NEW INGREDIENT NUMBER NOTE: 1. The ingredient number listed usually will have an ingredient name, which is created during the IBC Dispenser setup process.
HI 3010 Filler/Dispenser/IBC User Guide • 58 Press the Enter button. The Standby Menu appears with the new Amount Required. In our example we used 1000.00 lbs. (See Fig. 5-18) FIG. 5-21 IBC DISPENSE MENU/NEW DISPENSES NUMBER • FIG. 5-18 STANDBY MENU/NEW AMOUNT REQUIRED Step 5. Step 6. NOTE: Press the Enter button. The Standby Menu appears with the new cycles value. (See Fig. 5-22) If the number of dispenses is the number you want, go to Step 7.
59 CHAPTER 5 Operating Procedures/IBC Dispenser • Step 10. If it is NOT OK to Dispense, an alarm appears in the display. If the Fast Dispense Display appears showing a steady weight (no loss-in-weight) and there is no indication of motion. If you have enabled the Auto Auxiliary function the instrument turns on the auxiliary timer at the same time. (See Fig. 526) FIG. 5-24 IBC DISPENSE DISPLAY/WAITING ON NOTE: Step 9.
HI 3010 Filler/Dispenser/IBC User Guide Step 11. 60 When the Net weight on the scale is equal to or greater than the target weight minus its preact value the Filler/Dispenser/IBC goes into a wait sequence to allow things to settle before checking to see if the dispensed (loss-in-weight) material is correct. (See Fig. 5-29) FIG. 5-31 LAST DISPENSE CYCLE Step 14. After completion of all the cycles, the Filler/Dispenser/IBC goes back to the Standby Menu. (See Fig. 5-32) FIG.
61 CHAPTER 5 Operating Procedures/IBC Dispenser DISPENSE” conditions do not occur. The new Pre Act value is saved for the ingredient being dispensed and becomes part of the Ingredient Parameter. It is highly recommended that you turn the Auto Pre-Act function ON. (For configuration information see the HI 3010 Service Manual for instructions) FIG. 5-34 JOG 1 DISPLAY Step 3. The instrument goes to the Jog Off State where it checks to see if the loss in weight is within the target window.
HI 3010 Filler/Dispenser/IBC User Guide 62 IBC/Dispensing - Dual Speed About Dual Speed IBC Dispensing About Dual Speed Dispensing FIG. 5-38 AWAITING COMMAND TO DISCHARGE DISPLAY Step 2. Step 3. Step 4. If the OK to Discharge is ON, the instrument checks to see if it is OK to discharge. The instrument also checks to see if the discharge gate is open. The system discharges the current dispensed material from the receiving container. (See Fig.
63 CHAPTER 5 Operating Procedures/IBC Dispenser 4. FIG. 5-43 SLOW DISPENSE HOLD • autotares and/or checks the OK to Dispense processes and begins dispense cycle number 2, then 3, 4 and so on. If the dispense is within the target window and it is the last dispense cycle (See Fig. 4-46) of a dispense sequence, the instrument goes to Standby and the Standby Display appears. (See Fig. 4-47) To resume Slow dispense press the Start button.
HI 3010 Filler/Dispenser/IBC User Guide 2. 2. Once the problem has been fixed, push the Clear button to clear the Alarm. The Filler/Dispenser/IBC returns to the Standby mode waiting a Start Command. 3. NOTE: The OK to DISPENSE Timer has a preset time to determine if it is OK to Dispense. If the OK to Dispense times out, it means that the preset time maybe too short for the process and the NOT OK to DISPENSE Alarm appears with no real alarm condition.
65 CHAPTER 5 Operating Procedures/IBC Dispenser 1. 2. 3. NOTE: alarm. The RESUME DISPENSE SLOW appears. (See Fig. 5-57) Press the Clear button to clear the alarm then manually inspect the IBC to determine if it is empty. If it is empty replace the IBC with a full one. When the full IBC is in place, press the Start button. The IBC dispenser completes the dispense from where it left off before the bag change. If the IBC is not empty, fix the problem and press the Start button once.
HI 3010 Filler/Dispenser/IBC User Guide 66 No Slow Feed Alarm - - - - - ALARM CONDITION - - - - • If the Slow Dispense Gate valve or feeder is not open or on at the time you want to slow dispense, the NO SLOW FEED alarm appears on the display. (See Fig. 559) FIG. 5-61 SLOW FEED ON ALARM 1. 2. Determine why the Slow Feed is On and correct the problem. Press the Clear button to clear the alarm. The wait timer display appears. (See Fig. 5-62) FIG. 5-59 NO SLOW FEED ALARM 1. 2.
67 CHAPTER 5 Operating Procedures/IBC Dispenser • OVERDISPENSE ALARM, press the Clear button to clear the alarm. The Accept the Dispense display appears. (See Fig. 5-65) At this time you can: 1. 2. 3. NOTE: Accept the dispense by pressing the START button. If your system allows, physically remove some of the material until it meets the target window requirements and then press the START button.
HI 3010 Filler/Dispenser/IBC User Guide Filler/Dispenser/IBC is placed in a hold state. (See Fig. 5-69) 68 Jog Count Alarm - - - - - ALARM CONDITION - - - - • If the pre-programmed number of JOG sequences are completed and an UNDERDISPENSE condition still exists, a JOG count alarm appears telling you that you have used up the JOGs for this sequence of cycles. (See Fig. 5-71) FIG. 5-69 DID NOT JOG ALARM 1. 2. Check to see why there was no Jog. Correct the problem.
69 CHAPTER 5 Operating Procedures/IBC Dispenser Discharge On Alarm - - - - - ALARM CONDITION - - - - • If the Discharge gate valve or feeder does not close or turn off, a DISCHARGE ON ALARM appears. (See Fig. 5-76) FIG. 4-73 NOT OK TO DISCHARGE ALARM 1. 2. 3. Check to see what is causing the Not OK to discharge alarm to appear. Correct the problem. Press the Clear button to clear the alarm. If auto discharge is on the dispenser looks for an OK to Discharge signal.
HI 3010 Filler/Dispenser/IBC User Guide 70 FIG. 5-79 OPERATION PAGE FIG. 5-77 FILLER/DISPENSER HOME PAGE/ SELECTING OPERATIONS Step 4. Click on “Operations”. When entering Operations for the first time after cycling the power off/ on, an Alert asking for a User Name and Password appears. (See Fig.
71 CHAPTER 5 Operating Procedures/IBC Dispenser NOTE: The ability to operate the instrument from a Web Page will be available in future iterations of the Web Site. Operating in Manual Mode from the Front Panel The HI 3010 allows the user to perform some of the operations in manual mode. The following Dispensing Functions can operate Manually: • • • • • • Step 1. FIG. 5-81 OPERATION - TOTALIZERS PAGE Step 2.
HI 3010 Filler/Dispenser/IBC User Guide Step 6. 72 Press the Enter button. The Discharge Mode display appears. (See Fig. 3-109) FIG. 5-85 DISCHARGE MODE DISPLAY/STARTING DISCHARGE Step 7. Press the Start button. To stop the discharge you will have to manually press the stop button. (See Fig. 3-110) FIG. 5-87 LINK TO DOWNLOAD PAGE Step 2. Select the link: Downloads for current HI 3010 weight controller users. FIG. 5-86 DISCHARGE MODE DISPLAY/STOPPING DISCHARGE Step 8. Step 9. Step 10.
73 CHAPTER 5 Operating Procedures/IBC Dispenser Step 7. Click Browse to find and select the file you downloaded.. Step 8. With both the IP address and file selected, click Update. When asked for a User Name, enter hardy, and for Password use updatepass (all lowercase ) and click OK. A percent complete bar will show the progress of the upgrade followed by a screen indicating the programming is complete.
HI 3010 Filler/Dispenser/IBC User Guide 74
Index INDEX Numerics 0/Char.
HI 3010 Filler/Dispenser/IBC User Guide F IP Address Fanuc 5 Fast Dispense 37, 40, 59, 63 Fast Dispense 62 Fast Dispense Display 59 Fast Fill Display 20 Fast Fill Gat 22 Fast Fill Set Point 20 Fast Gate Did Not Open Alarm 22, 43 Fill Standby Display 19 Filler/Dispenser Home Page 8, 9, 27, 69 Filler/Dispenser/IBC 1, 53 Filling - Single Speed 14 Filling Operation is a Gain-in-Weight Process Form A mechanical (SPST) Relays 4 Front Panel 11, 53 Front Panel Display 31, 53 J 14 -JB 4 Jog Alarms 24, 46 Jog C
Index Operating the Dispenser from the PDA 48 Operating the Filler from the Ethernet (Web Site) 27 Operating the IBC Dispenser from the Ethernet (Web Site) 69 Operating the IBC/Dispenser from the PDA 69 Operation Page 49 Options 4 Output Alarms 1 Over Refill Alarm 41 Overdispense Alarm 45 Overfill Alarm 24 P Pausing the Discharge 39 Pausing the Discharge Cycle 62 Pausing the Jog Cycle 61 -PB 4 Performance Diagnostics 1 PLC® 2 Predispense Procedures 56 Print Button 11, 31, 54 Print Current Dispense Menu 32
HI 3010 Filler/Dispenser/IBC User Guide V View and Clear Totalized Weight 28 VPN 1 W Wait Sequence 17 Wait Timer Display 44 WAP Enabled Devices 3 WAVERSAVER® 1, 3 WAVERSAVER® Technology Web Browser 11 3
9440 Carroll Park Drive, San Diego, CA 92121 Telephone: 1-800-821-5831 FAX: (858) 278-6700 Web Address: http://www.hardysolutions.com Hardy Process Solutions Document Number: 0596-0259-01 REV E Copyright 2011, Hardy Process Solutions All Rights Reserved. Printed in the U.S.A.
