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39 

 

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Chapter 6 

 

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.

•  When weight is applied there is a positive increase 
   in the signal millivolt readings 

•  The compression load cell has not been installed 

    upside down. Refer to the load cell installation guide 
    for installation instructions.

•  No mechanical binding is restricting the vessel 

   movement during the load

•  The load cell wiring is correct

•  Each load cell signal changes under load.  A single 
   load cell installed upside down or wired backwards 
   can change the total signal output.

SPAN WEIGHT TOO SMALL
  
•  1000 counts out of 985,000 is very small

•  A 100,000 lb scale would require a minimum of 101 lbs

ERROR

  PROCEED 
       WITH 
CALIBRATION

  Contact Hardy
    Instruments 
Customer Service 
  (800) 321-5831 
       Ext. 1757

Yes

No

 

 

Содержание HI 1756-FC

Страница 1: ...e User s Guide Hardy Process Solutions Part Number 0596 0318 01 Rev C Corporate Headquarters 10075 Mesa Rim Road San Diego CA 92121 5201 Phone 1 858 292 2710 Phone 1 800 821 5831 FAX 858 278 6700 Web site http www hardysolutions com ...

Страница 2: ...its and performance measurement Emergency troubleshooting and repair To request Emergency Service and Troubleshooting Start up Installation Calibration Verification or to discuss a Maintenance Agreement please call 800 821 5831 Option 4 or Emergency Service after hours Standard Hours 6 00 AM to 5 30 PM Pacific Standard Time and weekends Option 4 Outside the U S Hardy Process Solutions has built a ...

Страница 3: ...7 Installing the HI 1756 FC 7 Allen Bradley ControlLogix Processor or Remote Rack 7 A ControlLogix Chassis 7 Removing the Module from the Chassis 8 Installing the Module I O Connector 8 Load Cell Wiring Diagrams 9 HI 1756 Remote Terminal Assembly HI 1756 XX RT 9 Hardy HI 215IT Junction Box 10 CHAPTER 4 CONFIGURATION 11 Power Check 11 LEDS 11 Setting Up Communications 12 Linking the PLC with the HI...

Страница 4: ...ns 32 Weight and Voltage Testing 32 IT Test 33 General Troubleshooting Flow Chart Index 33 A1 Guidelines for Instabilities on Formerly Operating System 34 B Guidelines for Instabilities on Formerly Operating Systems Cont d 35 B1 Guidelines for Instabilities on Formerly Operating Systems Cont d 36 B1 Guidelines for Instabilities on Formerly Operating Systems Cont d 37 F Verify Individual Load Cell ...

Страница 5: ...iii Contents General Policies and Information 46 Warranty 46 For Further Information Contact 47 INDEX 48 ...

Страница 6: ...Chapter Six Provides troubleshooting procedures for repair of the HI 1756 FC HI 1756 FC Overview The HI 1756 FC module is a self contained microprocessor based ControlLogix I O module Its control inputs and outputs will easily plug into the backplane of an Allen Bradley ControlLogix programmable controller and or remote rack The remote rack module is connected to the local chassis via a ControlNet...

Страница 7: ...can better decipher the actual weight data While WAVERSAVER can factor out noise with frequencies as low as 0 25 Hz five cut off frequencies can be selected with higher frequencies providing a faster response time The default factory setting is 1 Hz vibration frequency immunity Alarms Two HI 1756 FC alarms flag deviations from your specified flow rate The Rate Tolerance Alarm can alert you concern...

Страница 8: ...inside of the instrument 2 Disconnects the load sensors and engages an internal in the junction box reference signal to see if the cable between the instrument and the Junction Box is causing the problem 3 Reads the weight of each load sensor to see if the load sensor might be causing the problem Automatic or Manual Control Modes Automatic mode corrects for variations in desired flow rates automat...

Страница 9: ...0 ohm Full Wheatstone Bridge Strain Gauge Load Sensor Cells 5 volt excitation on one vessel Non Linearity 0 0015 of Full Scale Common Mode Rejection 110dB at or below 60 Hz Common Mode Voltage Range 2 5VDC maximum with respect to earth ground Backplane Input Voltage Power Load 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 Loa...

Страница 10: ... of Channels 1 Channel Update Rate 110 Updates per Second 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 25 Hz Digital Voltmeter IT Accuracy 2 of full scale Power and Utility Requirements Voltage 24 VDC Standard 100 240 VAC Universal Optional Frequency 47 63 Hz Power 10 Watts maximum with options Environmental Requiremen...

Страница 11: ...ges 1 REC P Limit 10 WAVERSAVER 3 7 Rate Cal Rates None PID_P 50 0 percent None PID_I 20 1st percent None batch amount 10 2nd percent None Preact 0 3rd percent None Mode 0 4th percent None Prime Time 0 5th percent None Pause Time 0 100 percent None Feed time 40 7 Rate Cal Percentages None Initial Refill on 0 0 Percent None Auto Refill On 0 1st Percent None Refill Start Weight 10 2nd Percent None R...

Страница 12: ... FC Allen Bradley ControlLogix Processor or Remote Rack WARNING Electrostatic discharge may damage semiconductor components in the module DO NOT TOUCH THE CONNECTOR PINS and observe the following handling precautions Wear an approved wrist strap grounding device when handling the module Touch a grounded object or surface to rid yourself of any electrostatic discharged prior to handling the module ...

Страница 13: ... 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 the pin out diagram below A pin out diagram is also located on the inside of the module door Step 1 Open the module door to access to the I O connector Step 2 Ins...

Страница 14: ...d Load Cell Wiring Diagrams The diagrams below show how Hardy Load Sensor with C2 wiring differs from standard Load Cell wiring Industry standard load cells wiring Hardy load sensor c2 wiring HI 1756 Remote Terminal Assembly HI 1756 XX RT The Remote Terminal Assembly RTA provides connection points between the cable assembly from the HI 1756 FC module and the individual wires from the junction box ...

Страница 15: ... 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 RTA cable assembly HI 1756WS RTA cable schematic Hardy HI 215IT Junction Box Load Cell Connector J1 1756 FC Hardy HI 215IT Junction Box Wiring Diagram NOTE When connecting the Hardy HI 215IT Junction ...

Страница 16: ... is on Steady Green Running Normal Steady Red Error Read Failure or Error eeprom write Contact HI Customer Support Flashing Red Read Convert Error LED is Off Channel is Inactive OK Module Status LED Brief Steady During power up the LED lights Red for about one second Flashing Green In Program mode Normal Steady Green In Run Mode Normal Steady Red Config Fault The eeprom checksum failed bad serial ...

Страница 17: ...lder which will open a menu Step 2 Select New Module to display a list of modules Step 3 Select the Generic 1756 module to open the Module Properties form Step 4 Enter the following connection parameters in the appropriate fields Name of Module Description of Module Optional Slot ID Input Assembly Instance 101 Size 32 Output Assembly Instance 100 Size 32 Configuration Assembly Instance 102 Size 20...

Страница 18: ... Command Hex Description NOCMD 0 No command STARTCMD 1 START STOPCMD 2 STOP REFILLCMD 3 REFILL WRITENONVOLATILE 4 Saves all parameters including calibration constants to the non volatile memory Error Return Values None MANUALCMD 5 Enters manual mode ABORTCMD 6 Stop go straight to IDLE mode CLEARALARMS 0x7 Clear all alarms from the rate status word RELOADNONVOLATILE 0x10 Causes the weigh module to ...

Страница 19: ...erage counts when doing Hard CAL Error Return Values STATUSWORD There was a conversion error or A D conversion failure HARDCALFAILCOUNTS There are less than 1000 counts between the zero and the span weights C2CALCMD 0x66 Performs a C2 Calibration Uses CalLowWeight as the reference point Error Return Values STATUSWORD There was a conversion error or A D conversion failure C2FAILNODEVS Detected no C...

Страница 20: ...23 means TOTAL decimal places is 1 WEIGHT decimal places is 2 RATE decimal places is 3 For example writing the value 0x0123 in the format word sets the total decimal place value which is used for the TOTAL and BATCH TOTAL values to 1 It sets the weight decimal place which is used for the gross weight to 2 and it sets the rate decimal place which is used for the rate of change ROC values to 3 Total...

Страница 21: ... in the chart below Parameters hex sub Brief Description Note Expanded descriptions are listed below the chart by hexadecimal number Chan Active 1 0 1 flag determines if a channel is alive Metric 2 0 1 Report Weight In Units of measure listed below span weight 3 Calibration weight high Must be 0 Weight DP cal low weight 4 Calibration weight low Must be or 0 Weight DP ROC time base 5 In seconds 0 d...

Страница 22: ... 0x2032 is the next stepped rate 3rd rate 3032 0x3032 is the next stepped rate 4th rate 4032 0x4032 is the next stepped rate 5th rate 5032 0x5032 is the next stepped rate 100 rate 6032 0x6032 is the MAX RATE 7 Rate Cal Percentages xx33 7 rate calibration percents Uses 2 decimal places 0 00 100 00 0 Percent 0033 0x0033 is the minimum 1st Percent 1033 0x1033 is the next stepped 2nd Percent 2033 0x20...

Страница 23: ... actual measured weight used at cal low or C2 cal Normally you would remove all live load weight from the scale to obtain a CalLow Weight of 0 0 The location of the decimal point in this value is based on the Weight decimal point parameter Range Must be or 0 Parameter 5 ROC time base The Time Base is the length of time in seconds between two weight readings that are subtracted to determine the ini...

Страница 24: ...f 20 averages the instrument reads the 20 most current input signals totals the signals divides by 20 drops the oldest one reads one new signal along with 19 old readings totals the signals divides by 20 drops the oldest one etc Range 1 255 default 1 See also WAVERSAVER for information on filtering unstable weight readings Parameter 8 WAVERSAVER Chapter One provides a detailed description of WAVER...

Страница 25: ...ops completely The decimal point is positioned based on the Weight Decimal parameter for preact No limits Range 0 0 default 0 0 No limits Parameter D Mode You can operate either in continuous or batch mode depending on the process Range 0 continuous or 1 batch Parameter E Prime Time The time in seconds it takes to get the system up to full flow for the first calibration point on the first test OP ...

Страница 26: ...Auto Refill Parameter 13 14 Refill Start Weight and End Weight The Start Weight which is set in mass units actual gross weight triggers a signal to begin the refill process You need to determine when you want the refill to automatically begin or an alarm to trigger so an operator can refill the feeder The Start Weight value must be higher than the Lo Shutoff value End Weight signals when the hoppe...

Страница 27: ...etpoint beyond the alarm delay time the Lo Shutoff alarm can be configured to signal an alarm condition that can either shut the process down or lower the output to a set percentage See Shutoff Out below The decimal point is positioned based on the Rate DP parameter NOTE The Lo Shutoff alarm value must be equal to or less than the lowest set point value Range No limits Parameter 21 High Alarm Shut...

Страница 28: ...cent A shutdown signal can trigger a fixed OP response if Shutoff Percent is greater than 0 0 This allows for processes that should not be halted completely even if an error occurs to continue at a slower rate Range 0 decimal places 0 100 Parameter 1E Total The controller records the total amount dispensed The Total number displays the amount of material that has been processed from the start of t...

Страница 29: ...nnot do an Auto RateCal and you know the flow rate for all seven output percentage selections If user set calibration is selected you must manually enter the PI settings and the output and rate for all calibration pairs The entered flow rates can come from experience with the material often through trial and error We recommend that you select output percentage points where your expected control se...

Страница 30: ... word is replaced with a command status that indicates whether a command succeeded or failed The next words are the OP rate of change the gross weight rate setpoint state version and the module status word There is also a counter which continuously increments Command Offset Description CMD 0 Command echo the command from the input CMD_STATUS 1 Status of command PARAM_VALUE 2 Parameter value LSW PA...

Страница 31: ...OST 0x0020 5 Controller communication failure ERROR_SHUTDOWN 0x0040 6 Shutdown ERROR_RANGE 0x0080 7 Out of range value ERROR_REC 0x0100 8 REC value over high limit ERROR_RECMINUS 0x0200 9 REC value below low limit ERROR_REFILL_OVER 0x0400 10 Exceed refill limit STATUS_REFILL 0x0800 11 Refill process active STATUS_BATCH_COMPLETE 0x1000 12 Batch process completed ERROREEPROMWRITE 0x4000 14 EEPROM Ha...

Страница 32: ...ist of commands below Channel 0 or 1 Rate Decimal points 0 7 7 pairs of rate calibration values Each pair has an operating percentage OP with two decimal places and an associated rate shown with the number of decimal places specified by the Rate Decimal points parameter CalZeroCounts CalLowCounts CalibK Return Value Hex Description PARAMID_ITECH 0x0036 INSTANCE_VSENSE 0036 Sense voltage 2 decimal ...

Страница 33: ...s The two commands below read and write configuration data Each returns 52 DINT values which are the command the channel and the format word followed by 49 parameter values which are listed in the order of the parameter IDs 5 Command 0x0F Read configuration data 6 Command 0x8F Write configuration data The format word is like the one in the configuration data table but in the least significant word...

Страница 34: ...w the load cell free vertical movement and may prevent the instrument from returning to the original zero reference point A load cell must be mounted so that 100 of the load Vessel w Contents passes vertically through the load cell Verify that nothing is binding the load cell This means that nothing is draped across the scale vessel or the load cell such as a hose electrical cord tubes or other ob...

Страница 35: ...e If the input table 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 With the input table display reading 100 pounds if 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 If the input table ...

Страница 36: ...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 Process Solutions Inc web site explains how to set the weigh process parameters Depending on your application this Lad...

Страница 37: ...ing stress lack of piping flexures cables draped over pipes etc can make a load cell seem to be the problem If you are in doubt as to how to resolve a problem or if you need assistance look for Hardy Process Solutions Web tech at http www hardysolutions com Web tech is updated often and is available 365 days a year 24 7 It contains several frequently asked questions to aid you in troubleshooting a...

Страница 38: ...illivolts volts To convert to mV multiply the mV V times the sense voltage IT Test If your system has an Integrated Technician Summing Junction box the IT test can help identify individual load cell problems up to a maximum of four load cell selections Sensor Number Indicates which sensor is under test Select the target sensor to be tested Warning Do not install your HI 215IT summing board in area...

Страница 39: ... and shields except AC Power Monitor the reading for stability STABLE Reconnect signal cables one at a time A1 If installing any cable causes unstable readings REVIEW TROUBLESHOOTING SECTION B B1 1 B1 7 Go to B Yes No Monitor the display for stability Problem could be in the instrument Contact Hardy Customer Support PH 800 821 5831 ...

Страница 40: ...ines for Instabilities on Formerly Operating Systems Cont d Check for Electrical Stability OK Check for Mechanical Stability B Yes No B1 OK Check Configuration settings for stability Yes No B2 OK Yes No B3 Go To A Stability ...

Страница 41: ...provide a direct discharge path to ground around the load points B1 5 Cable Routing Separate high voltage sources and cables form low voltage signal cables Stay a minimum of 14 inches from magnetic fields and VFD controls Avoid parallel high voltage and signal cable runs B1 6 Cable Shielding Ground low voltage cable shields only at the controller end Grounding both cable ends produce ground curren...

Страница 42: ...ying pressure to the vessel when energized Use check stay rods to minimize vessel movement Make sure the check rods are loose and not interacting with the vessel Power down all vibration vacuum and pressurization equipment during the test process Configuration Settings Incorrect WAVERSAVER settings can cause unstable weight readings Adjust to the lowest WS setting that gives you a stable reading H...

Страница 43: ...5mV F Select IT TEST MV V IT TEST Checks individual load sensor output mV V readings Press ENTER to check load sensor Record load sensor mV V output level for comparison Repeat for all load sensors MV V readings acceptable Zero mV V reading 1 No dead load Apply load and re test 2 Wiring error Verify color code using the load cell certificate 3 Open bridge circuit Disconnect power and verify load p...

Страница 44: ...t is applied there is a positive increase in the signal millivolt readings The compression load cell has not been installed upside down Refer to the load cell installation guide for installation instructions No mechanical binding is restricting the vessel movement during the load The load cell wiring is correct Each load cell signal changes under load A single load cell installed upside down or wi...

Страница 45: ...forklifts and adjacent processing equipment H3 Are the load cells properly mounted 1 Level solid mounting base 2 The load cell is mounted right side up 3 All load cell bolts installed using anti seize compounds 4 Mechanically aligned to compensate for expansion and contraction H4 Are check rods installed to dampen vessel movement 1 Protects the load cells from overload and impact forces 2 Limits t...

Страница 46: ...e correct if a calibration procedure was not performed J3 Does the scale reflect a weight change 1 Read the NET weight 2 Send a TARE command to ZERO the NET weight 3 Apply weight to the vessel DO NOT POWER UP THE CONTROLLER UNTIL INPUT VOLTAGES CAN BE VERIFIED a Does the weight increase and decrease in the correct direction with the weight b Does the weight return to ZERO NET c The weight value wi...

Страница 47: ...42 Chapter 6 K Load Sharing and Load Sensor Checkout ...

Страница 48: ...stable rate should be If the rate displayed on the monitor continuously falls and rises and you never get a stable rate or symmetrical weight loss pattern The rate may be too slow for the load call capacity The material may be bridging or liquefying and basically inconsistent The feeder motor may be feeding too fast mechanisms may be damaged or working conditions may not be right ROC calculation T...

Страница 49: ...rection factor P determines the amount of action or reaction that is made in response to an out of range rate indication I the speed of that action reaction This value normally requires only a small adjustment 0 2 increments If the rate is always high reduce the I If it is always low increase I The feeder fails to stop in HOLD STOP or IDLE Determine whether the motor speed control OP analog card m...

Страница 50: ...stics utility that enables the operator to rapidly troubleshoot the individual load cells in a weighing system An HI 215IT Summing junction box is required to read data for individual load points It provides separate inputs for each load cell If you have more than one load cell without the IT junction box there is no easy way to isolate the load cell signals If you have more than one load cell wit...

Страница 51: ... load sensor is malfunctioning or its cable to the junction box is loose or incorrectly wired General Policies and Information Hardy Process Solutions provides world wide support for its products The following paragraphs describe Hardy s customer support services and equipment warranty When returning a product call the Technical Service Department listed below for a Return Authorization Number You...

Страница 52: ...asic load cell theory or as complete as troubleshooting techniques which allow you to service your equipment For Further Information Contact Hardy Technical Services Hardy Process Solutions 10075 Mesa Rim Road San Diego CA 92121 Telephone 1 858 292 2710 Option 4 FAX 1 858 278 6700 Web Site http www hardysolutions com E Mail hardysupport hardysolutions com ...

Страница 53: ... Rejection 4 Common Mode Voltage 4 configuration output table 13 Connecting PLC to the HI 1756 FC 12 Continuous Mode 3 ControlLogix I O module 1 COUNTER 26 D Deinstalling the Module 8 Digital Volt Meter 2 Din Rail Mounting 9 DVM Digital Volt Meter 2 E End Weight 21 Error Codes 15 ERROR status words 26 Excitation 5 F Feed Time 20 Feeder Control Module 12 Five point rate calibration 3 Five point rat...

Страница 54: ...ate Calibration PID P 19 Rate Decimal Point 15 Rate Exception Control REC 43 Rate of Change ROC calculation 43 Rate Setpoint 22 RATE_CAL parameters table 13 RateCal Percents 24 RATESETPOINT 25 READPARAM 13 14 REC Parameter 23 Refill auto manual initial 21 Refill OP Adjust wgt 22 Refill shutdown too high weight 21 Refill Start Weight and End Weight 21 REFILLCMD 13 RELOADNONVOLATILE 13 Remote Termin...

Страница 55: ...tage 5 Voltage Testing 32 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 ...

Страница 56: ...ll Rights Reserved Printed in the U S A All information within is subject to change without notice Visit our website for latest specifications WAVERSAVER C2 IT ADVANTAGE and ANY WEIGH are registered trademarks of Hardy Process Solutions Inc Allen Bradley CompactLogix MicroLogix and Encompass are trademarks of Rockwell Automation Inc All other trademarks or registered trademarks are the property of...

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