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Chapter 3 - Setup

3-1

CHAPTER 3 - SETUP

Remote I/O Setup

Bargraph LEDS
Secondary
Functions (HI 2151/
20WC only)

While the RIO menu is displayed, the Bargraph LEDs have the follow-
ing secondary functions.

A. The Zero Track LED displays the status of the “Green LED” on the

RIO.

•

On = Run

•

Off = Off Line

•

Flashing indicates either program mode or frequent
retries.

B. The Motion LED indicates Self-Test. Self-Test is executed when

the instrument powers up. The Motion LED flashes continuously if
the Self-Test fails.

C. The Ctr Zero LED illuminates if communications fail. This failure

can be caused by improper cabling, incorrect selection or improper
use of termination resistors.

D. The Total LED is used for factory testing and illuminates when the

status byte is set to 7.

FIG. 3-1 FRONT PANEL/HI 2151/20WC

NOTE:

The bargraph LED Secondary functions above are for the HI 2151/20 only. The setup
procedures in the remainder of this chapter are for both the HI 2151/20 and the HI
2151/30.

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Summary of Contents for HI 2151 Series

Page 1: ...rate Headquarters 9440 Carroll Park Drive San Diego CA 92121 Phone 858 278 2900 FAX 858 278 6700 Web Site http www hardysolutions com Hardy Process Solutions Document Number 0596 0173 01 Rev L Copyright September 2011 Hardy Process Solutions Inc All Rights Reserved Printed in the U S A 941028 ...

Page 2: ...ts and performance measurement Emergency troubleshooting and repair To request Emergency Service and Troubleshooting Start up Installation Calibration Verification or to discuss a Mainte nance Agreement please call 800 821 5831 Ext 1757 or Emergency Service after hours Standard Hours 6 00 AM to 6 00 PM Pacific Standard Time and weekends Ext 1111 Outside the U S Hardy Process Solutions has built a ...

Page 3: ...2 Blind Unit Operation Setup 3 2 About Blind Units 3 3 Blind Unit Configuration 3 3 CHAPTER 4 DISCRETE TRANSFERS 4 1 Discrete Writes 4 1 Structure of the Two Words in the PLC Output Image Table 4 1 Bit Shift 4 1 Weight Parameter 4 1 Status Byte 4 2 Example 4 2 Discrete Reads 4 2 0 Relay Status Byte 4 2 1 Remote Function Status Byte 4 3 2 Indicator Group 2 Status Byte 4 3 3 Indicator Group 1 Status...

Page 4: ...point Description Bytes 5 17 Block Write Command Number 53 Send Tare Value 5 18 Block Write Command Number 54 Scale Calibration Action 5 19 Block Write Command Number 55 Calibration Parameters 5 20 Block Write Command Number 56 Configuration of Rate of Change 5 21 Block Write Command Number 57 BCD Output Configuration 5 22 Block Write Command Number 58 Configuration of Analog Output 5 22 Block Wri...

Page 5: ... 1 FIG 2 1 REMOTE I O S1 DIP SWITCH SETTINGS DEFAULT 2 1 CHAPTER 3 SETUP 3 1 FIG 3 1 FRONT PANEL HI 2151 20WC 3 1 CHAPTER 5 BLOCK TRANSFERS 5 1 FIG 5 1 BLOCK TRANSFER READ EXAMPLE 5 14 FIG 5 2 BLOCK TRANSFER WRITE EXAMPLE 5 27 FIG 5 3 INTEGER TO FLOATING POINT ROUTINE 5 29 ...

Page 6: ... 9 CONFIGURATION OF STANDARD RS232 PORT 5 11 TABLE 5 13 BLOCK READ COMMAND NUMBER 10 STICKER VALUE 5 11 TABLE 5 14 BLOCK READ COMMAND NUMBER 11 AUTO ZERO TOLERANCE 5 12 TABLE 5 15 BLOCK READ COMMAND NUMBER 12 INTEGRATED TECHNICIAN 5 13 TABLE 5 16 BLOCK WRITE COMMAND NUMBER 51 ACTIVATE SCALE FUNCTIONS 5 15 TABLE 5 17 BLOCK WRITE COMMAND NUMBER 52 DOWNLOADING SETPOINT RELAY PARAMETERS 5 17 TABLE 5 1...

Page 7: ...HI 2151 SERIES WEIGHT CONTROLLERS REMOTE I O OPTION b TABLE 6 2 RELAY STATUS 6 1 TABLE 6 3 BINARY TO DECIMAL CHART 6 2 TABLE 6 4 BLOCK WRITE EXAMPLE 6 2 ...

Page 8: ...ting weighing parameters to and from an HI 2151WC controller Each Hardy HI 2151WC represents a quarter 1 4 rack of discrete I O 32 bits in the PLC Output and Input image files to the scanning PLC and supports both discrete and block transfers The PLC continually exchanges 32 bits of its PLC Input Image Table and 32 bits of its Out put Image Table with each 1 4 rack device In a 1771 I O Rack these ...

Page 9: ...ch Weighing Control Monitoring Rate of Flow Evaluating Totalized Weight Check Weighing Weight Level Alarming NOTE There are two standard and six optional setpoint relays which provide control of ingredient weighments and weight level alarming Monitoring Weighing Parameters The HI 2151WC series weight controllers are capable of calculating five types of weight data including the standard Gross and ...

Page 10: ...verview 1 3 or can be entered as a numeric value via the keypad on the front panel of the HI 2151WC This new tare value is the reference point for Net Weight TV G N TV Tare Value weight G Gross Weight N Net Weight ...

Page 11: ...other devices on the daisy chain both dip switches should be set to OFF See Fig 2 NOTE Refer to your Allen Bradley PLC 2 PLC 3 PLC 5 and SLC 500 manuals for the maximum number of nodes available Setting the Cable Termination Dip Switches Step 1 For all RIO board options except for the last device make sure the dip switches are set to the OFF position See Fig 2 1 FIG 2 1 REMOTE I O S1 DIP SWITCH SE...

Page 12: ...ing down align the RIO Option Board over the connector on the A D board In either option slot Step 2 Gently slide the pins into the connector until it stops Step 3 Attach the board to the standoffs by installing the four screws to the standoffs Step 4 Connect the cable to the 6 pin connector on the RIO board The 6 pin connector on the RIO option board is used for all Remote I O connections Pin def...

Page 13: ...st Self Test is executed when the instrument powers up The Motion LED flashes continuously if the Self Test fails C The Ctr Zero LED illuminates if communications fail This failure can be caused by improper cabling incorrect selection or improper use of termination resistors D The Total LED is used for factory testing and illuminates when the status byte is set to 7 FIG 3 1 FRONT PANEL HI 2151 20W...

Page 14: ... a change is necessary press the Test Clr button Step 11 Use the numeric buttons and enter the PLC quarter number maximum 3 NOTE The quarter rack number in the PLC is displayed in decimal Qtr 0 PLC Group 0 Qtr 1 PLC Group 2 Qtr 2 PLC Group 4 Qtr 3 PLC Group 6 Step 12 Press the Enter button Step 13 Press the Enter button to view last quarter status Step 14 Use the up or down arrow buttons to select...

Page 15: ...uto configuration of the PLC Blind Unit Configuration Step 1 Disconnect the power cord from the instrument Step 2 Set the Interior Dip Switches See Table 3 1 ON 1 OFF 0 NOTE Remember to select the appropriate jumper positions on the Remote I O Option Board INTERIOR DIP SWITCHES Switch Position S2 which is located on the Power Relay board 1 n u 2 n u 3 n u 4 n u 5 last quarter in rack ON Yes OFF No...

Page 16: ... 3 EXTERIOR DIP SWITCHES NOTE B0 through B5 represent a binary value for rack from 1 to 63 TABLE 3 4 BINARY QUARTER NUMBER ON 1 OFF 0 EXTERIOR DIP SWITCHES Switch Position S3 which is located on the Rear Panel 1 B5 32 2 B4 16 3 B3 8 4 B2 4 5 B1 2 6 B0 1 7 C1 8 C0 BINARY QUARTER C1 C0 Quarter 0 0 0 0 1 1 1 0 2 1 1 3 ...

Page 17: ...ied by the fac tor shown below to yield the actual weight value 0 No shift the lowest 16 bits are transferred 1 Shift one digit multiply by 2 to achieve actual weight value 2 Shift two digits multiply by 4 to achieve actual weight value 3 Shift three digits multiply by 8 to achieve actual weight value 4 Shift four digits multiply by 16 to achieve actual weight value Weight Parameter Select either ...

Page 18: ...ause the HI 2151WC to place the least significant sixteen bits of the internal 20 bit net weight value and Indicator Groups 1 and 2 Status Bytes in the PLC Input Image Table Discrete Reads the HI 2151WC places the weight and status information specified in the last discrete write command in the PLC Input Image Table The data is arranged as shown in Table 3 2 NOTE Negative values are sent in two s ...

Page 19: ...ht currently displayed bit 4 Totalized weight currently displayed bit 5 Reserved bit 6 Excitation Monitor Error bit 7 Reserved 4 Dipswitch Settings exterior Status Byte bit 0 RE calibrate toggle bit 1 Option menu keypad lockout bit 2 Setpoint menu keypad lockout bit 3 Lb Kg Net Gr Tare Zero keypad lockout bit 4 Zero tracking enable bit 5 Reserved for future use bit 6 RS232 command lockout bit 7 Mu...

Page 20: ...intout NOTE The addresses begin with the letter I not the number I ADDRESS 17 0 ADDRESS 17 0 I 000 0000 0000 0000 0000 I 020 0100 0010 0011 1001 I 001 0000 0000 0000 0000 I 021 0000 0110 0000 0110 I 002 0000 0000 0000 0000 I 022 0000 0000 0000 0000 I 003 0000 0000 0000 0000 I 023 0000 0000 0000 0000 I 004 0000 0000 0000 0000 I 024 0000 0000 0000 0000 I 005 0000 0000 0000 0000 I 025 0000 0000 0000 ...

Page 21: ...lock I O transfer NOTE Negative values are sent in two s complement form NOTE The maximum block size is 51 words NOTE Block writes cannot be performed while the instrument is in the calibration mode The calibration must be sealed by pressing enter at Endcal Totalized weight uses all 32 bits available in the two words to represent unsigned data the block transfer commands and formats are listed in ...

Page 22: ...lized weight currently displayed bit 13 Reserved for future use bit 14 Reserved for future use bit 15 Reserved for future use 1 0 Indicator Group 2 Status bit 0 Weight currently displayed in pounds units bit 1 Zero Track feature enabled bit 2 Reserved for future use bit 3 Current gross weight 0 bit 4 Weight in motion i e changing bit 5 Gross weight currently displayed bit 6 Net weight currently di...

Page 23: ...al bit 10 Hold value on display bit 11 Hold option card updates bit 12 Force display to Net weight mode bit 13 Toggle lbs kg bit 14 Acquire Tare bit 15 Print request RS232 and BCD ports Note When the HI 2151WC is configured as a blind unit the status of the dipswitches are not visible See section on blind operation for more information 1 2 Rate of Change Peak force of weight Total weight in accumu...

Page 24: ...atus on off bit 1 Relay 7 status on off bit 2 Relay 6 status on off bit 3 Relay 5 status on off bit 4 Relay 4 status on off bit 5 Relay 3 status on off bit 6 Relay 1 status on off bit 7 Relay 2 status on off bit 8 15 Setpoint description byte A See Table 5 4 5 5 1 1 bits 0 7 Setpoint description byte B See Table 5 4 5 5 bits 8 15 Setpoint description byte C See Table 5 4 5 5 1 2 Deadband value for...

Page 25: ... E5 hex Relay 3 Rate of Change Word 2 bits 8 15 0000 0110 06 hex Relay 4 Peak Relay 5 Totalizer Relay 6 Gross Relay 7 Gross Relay 8 Gross Setpoint value for setpoint 1 Setpoint value for setpoint 2 Setpoint value for setpoint 3 Setpoint value for setpoint 4 Setpoint value for setpoint 5 Setpoint value for setpoint 6 Setpoint value for setpoint 7 Setpoint value for setpoint 8 2 2 2 2 2 2 2 2 35 37 ...

Page 26: ...ion and Diagnostics START WORD DEFINITIONS WORDS WORD Command number A value of 3 decimal bit 0 1 bit 1 1 bit 2 0 bit 3 0 bit 4 0 bit 5 0 bit 6 0 bit 7 0 Instrument type by model number bit 8 A value of 1 if set for the HI 2151 bit 9 15 Reserved for future use 1 0 Firmware revision level ASCII format i e 65 A 1 1 Zero calibration analog to digital converter raw counts 2 2 Span calibration analog t...

Page 27: ...WORDS 3 BLOCK READ COMMAND NUMBER 5 Calibration Parameters START WORD DEFINITIONS WORDS WORD Command number A value of 5 decimal bit 0 1 bit 1 0 bit 2 1 bit 3 0 bit 4 0 bit 5 0 bit 6 0 bit 7 0 bits 8 15 Reserved for future use 1 0 Units of Measure bits 0 7 A value of 0 for pounds or 1 for kilograms Decimal point position places to the right of the decimal bits 8 15 A value from 0 to 5 1 1 Totalize...

Page 28: ...oint value 2 7 Scale Capacity Full limit of scale A 20 bit number in proper integer format 2 9 Mid point Linearity Calibration Value A 20 bit number in proper integer format 2 11 TOTAL NUMBER OF WORDS 13 BLOCK READ COMMAND NUMBER 5 Calibration Parameters START WORD DEFINITIONS WORDS WORD BLOCK READ COMMAND NUMBER 6 Configuration of Rate of Change START WORD DEFINITIONS WORDS WORD Command number A ...

Page 29: ...nt button or remote function is activated bit 9 Reserved for future use bit 10 If set will output weight data currently displayed bit 11 If set will output tare value bit 12 If set will output net weight bit 13 If set will output gross weight bit 14 15 Reserved for future use 1 0 Reserved for future use 1 1 TOTAL NUMBER OF WORDS 2 BLOCK READ COMMAND NUMBER 8 Configuration of Analog Output START WO...

Page 30: ...5 0 bit 6 0 bit 7 0 bits 8 15 Reserved for future use 1 0 Format of Communication bit 0 Print initiation If configured as printer 1 print button 0 continuous If configured as bi directional 0 print button 1 altered print bit 1 Setpoint Deadbands and Preact values transmitted bit 2 Rate of Change transmitted bit 3 Tare weight transmitted bit 4 Net weight transmitted bit 5 Gross weight transmitted b...

Page 31: ...1 Software Note Parameters are not used in the HI 2151 30WC 1 4 Echo bits 0 7 A value of 0 or 1 0 Off 1 On Device Address bits 8 15 A value from 0 to 99 1 5 TOTAL NUMBER OF WORDS 6 BLOCK READ COMMAND NUMBER 9 Configuration of Standard RS232 Port START WORD DEFINITIONS WORDS WORD BLOCK READ COMMAND NUMBER 10 Sticker Value HI 2151 20SC Only START WORD DEFINITIONS WORDS WORD Command number A value of...

Page 32: ...ted Technician HI 2151 30WC Only NOTE Integrated Technician is not used with the HI 2151 20WC BLOCK READ COMMAND NUMBER 11 Auto Zero Tolerance START WORD DEFINITIONS WORDS WORD Command number A value of 11 decimal bit 0 1 bit 1 1 bit 2 0 bit 3 1 bit 4 0 bit 5 0 bit 6 0 bit 7 0 bits 8 15 Reserved for future use 1 0 Auto Zero Tolerance A 16 bit number in proper integer format 1 1 TOTAL NUMBER OF WOR...

Page 33: ...h needs to be changed to use other block transfer read types This routine will continually read the HI 2151WC as long as it is running N21 0 will have a 2 to request a block transfer read 2 BLOCK READ COMMAND NUMBER 12 Integrated Technician START WORD DEFINITIONS WORDS WORD Command number A value of 12 decimal bit 0 0 bit 1 0 bit 2 1 bit 3 1 bit 4 0 bit 5 0 bit 6 0 bit 7 0 bit 8 Reserved for futur...

Page 34: ...151 to verify that the data was received and implemented The response word will either show a successful processing of the block or will indicate the first error encountered in processing of the data NOTE Setpoints deadbands and preacts can all accept negative values To enter negative values use the twos complement method NOTE Block Writes cannot be performed while the instrument is in calibration...

Page 35: ...1 bit 5 1 bit 6 0 bit 7 0 Remote Functions Byte bit 8 Acquire TARE Set tare value current gross weight bit 9 Initiates print on standard RS232 or optional BCD port bit 10 Add current Net weight to Total bit 11 Clear Peak Hold register bit 12 Clear Totalizer Accumulation bit 13 Zero the instrument bit 14 Enable Zero Tracking Blind Unit Only bit 15 Reserved for future use Note The bit must be toggle...

Page 36: ...ht setpoint enable bit must be 0 bit 2 Turn relay 6 on regardless of weight setpoint enable bit must be 0 bit 3 Turn relay 5 on regardless of weight setpoint enable bit must be 0 bit 4 Turn relay 4 on regardless of weight setpoint enable bit must be 0 bit 5 Turn relay 3 on regardless of weight setpoint enable bit must be 0 bit 6 Turn relay 1 on regardless of weight setpoint enable bit must be 0 bi...

Page 37: ... Preact value for setpoint 3 Preact value for setpoint 4 Preact value for setpoint 5 Preact value for setpoint 6 Preact value for setpoint 7 Preact value for setpoint 8 2 2 2 2 2 2 2 2 19 21 23 25 27 29 31 33 Setpoint value for setpoint 1 Setpoint value for setpoint 2 Setpoint value for setpoint 3 Setpoint value for setpoint 4 Setpoint value for setpoint 5 Setpoint value for setpoint 6 Setpoint va...

Page 38: ... 6 Gross Relay 7 Gross Relay 8 Gross Block Write Command Number 53 Send Tare Value TABLE 5 20 BLOCK WRITE COMMAND NUMBER 53 SEND TARE VALUE BLOCK WRITE COMMAND NUMBER 53 Send Tare Value START WORD DEFINITIONS WORDS WORD Command number A value of 53 decimal bit 0 1 bit 1 0 bit 2 1 bit 3 0 bit 4 1 bit 5 1 bit 6 0 bit 7 0 bit 8 15 Reserved for future use 1 0 Tare Value 2 1 TOTAL NUMBER OF WORDS 3 ...

Page 39: ...rument that current weight is an empty scale bit 9 Setting then clearing this bit tells the instrument that current weight is span weight bit 10 Setting then clearing this bit stores critical data in the Secure Memory Module bit 11 Setting then clearing this bit restores critical data from the Secure Memory Module bit 12 Setting then clearing this bit tells the instrument that current weight is Mi...

Page 40: ...bration bits 8 15 Load Cell Count set to zero for Hard Cal 1 2 Display Graduation Size count by A value of 1 2 5 10 20 50 100 200 or 500 1 3 Motion Tolerance A sixteen bit value representing the lower 16 bits of the 20 bit internal weighing range 1 4 Zero Tolerance A sixteen bit value representing the lower 16 bits of the 20 bit inter nal weighing range 1 5 Number of readings averaged A value from...

Page 41: ...mal bit 0 0 bit 1 0 bit 2 0 bit 3 1 bit 4 1 bit 5 1 bit 6 0 bit 7 0 bit 8 15 Reserved for future use 1 0 Displayed Rate of Change time units A value of 0 to 2 0 sec 1 min 2 hr 1 1 Rate of Change timebase evaluation period A value of 0 to 15 from list below 0 1 second 4 5 seconds 8 15 seconds 12 240 seconds 1 2 seconds 5 6 seconds 9 30 seconds 13 450 seconds 2 3 seconds 6 10 seconds 10 60 seconds 1...

Page 42: ...print button or remote function is activated bit 9 Reserved for future use bit 10 If set will output weight data currently displayed bit 11 If set will output Tare Value bit 12 If set will output Net Weight bit 13 If set will output Gross Weight bit 14 15 Reserved for future use 1 0 TOTAL NUMBER OF WORDS 1 TABLE 5 24 BLOC WRITE COMMAND NUMBER 57 BCD OUTPUT CONFIGURATION BLOCK WRITE COMMAND NUMBER ...

Page 43: ...0 Format of Communication bit 0 Print Initiation 1 altered print bit 6 must 0 bit 1 Setpoint Deadbands and Preact values transmitted bit 2 Rate of Change Transmitted bit 3 Tare Weight Transmitted bit 4 Net Weight Transmitted bit 5 Gross Weight Transmitted bit 6 Print initiation 0 continuous 1 print button bit 0 must 0 bit 7 15 Reserved for future use 1 1 Port Configuration bits 0 7 A value of 0 or...

Page 44: ...of 0 or 1 0 OFF 1 ON Device Address bits 8 15 A value of 0 to 99 1 5 TOTAL NUMBER OF WORDS 6 BLOCK WRITE COMMAND NUMBER 59 Configuration of Standard RS232 Port START WORD DEFINITIONS WORDS WORD BLOCK WRITE COMMAND NUMBER 60 Sticker Value START WORD DEFINITIONS WORDS WORD Command number A value of 60 decimal bit 0 0 bit 1 0 bit 2 1 bit 3 1 bit 4 1 bit 5 1 bit 6 0 bit 7 0 bits 8 15 Reserved for futu...

Page 45: ...it 0 1 bit 1 0 bit 2 1 bit 3 1 bit 4 1 bit 5 1 bit 6 0 bit 7 0 bits 8 15 Reserved for future use 1 0 Auto Zero Tolerance A 16 bit number in proper integer format 1 1 TOTAL NUMBER OF WORDS 2 BLOCK WRITE COMMAND NUMBER 62 Waversaver Excitation Monitor START WORD DEFINITIONS WORDS WORD Command number A value of 62 decimal bit 0 0 bit 1 1 bit 2 1 bit 3 1 bit 4 1 bit 5 1 bit 6 0 bit 7 0 Waversaver bits...

Page 46: ... ured to do a BTW 52 of the relay setpoint data The block length is the only value which needs to be changed to use other block transfer write types Once called the routine will write the block until a return code of 06 BTW OK is sent A value of 70 is at N 11 60 B 3 0 will enable routine and is cleared when completed Valid BTW Data starts at N 11 0 ...

Page 47: ...ansfers 5 27 FIG 5 2 BLOCK TRANSFER WRITE EXAMPLE Integer to Floating Point Routine This example assumes the two words representing the desired weight value have been read with a block transfer read They must also reside ...

Page 48: ...PTION 5 28 as MSW in memory location N10 9 and as LSW in memory location N10 10 This routine works for all values except the totalizer NOTE All negative numbers are sent from the weight controller to the programmable con troller in twos complements ...

Page 49: ...erforms a block write it should then perform the response code block read This block read will return two bytes The first byte is the command number of the last block write performed The second byte will be the response or error code returned If the error code is a NACK 21 then the returned command number will be a 99 ...

Page 50: ...8 Zero tolerance value must be greater than 0 and positive 57 39 Acceptable number of averages is between 1 and 200 58 3A Span weight value during calibration must be positive 59 3B Scale capacity value must be positive 60 3C Midpoint linearity value must be positive 61 3D Rate of Change time units selection must be 0 1 or 2 62 3E Rate of Change time base out of range 63 3F BCD option not installe...

Page 51: ...cho request must be a 0 or 1 Error Code for Block Write Command 53 76 4C Tare greater than span Error Code for Block Write Command 51 77 4D Blind unit option only Error Code for Block Write Command 55 96 60 Load cell count error 97 61 No C2 load cells found 98 62 Load cell capacity sensitivity error 99 63 Load cell checksum error 100 64 Too many significant digits after the decimal to be displayed...

Page 52: ...y two four bit nibbles 0110 and 1001 Looking at the table we see this is equal to a Hex value of 69 Bit 3 Bit 2 Bit 1 Bit 0 Hex Value Bit 7 Bit 6 Bit 5 Bit 4 0 0 0 0 0 0 0 0 1 1 0 0 1 0 2 0 0 1 1 3 0 1 0 0 4 0 1 0 1 5 0 1 1 0 6 0 1 1 1 7 1 0 0 0 8 1 0 0 1 9 1 0 1 0 A 1 0 1 1 B 1 1 0 0 C 1 1 0 1 D 1 1 1 0 E 1 1 1 1 F TABLE 6 1 HEX CHART Bit Bit Status Hex Description Bit 0 1 On 9 Relay 8 status on ...

Page 53: ...nteger To convert from integer to floating point your ladder logic program would follow these steps Step 1 Convert the lower sixteen bits into a floating point number Step 2 Test the seventeenth bit bit 16 and if set add 65 536 to the floating point number Step 3 Test each subsequent bit and add the appropriate numeric value to the floating point number Bit 4 0 Off 6 Relay 4 status on off Bit 5 1 ...

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