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HI 1756-FC
User Manual
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Hardy HI 1756-FC User Manual

HI 1756 FC
Feeder Control Module
User’s Guide
Hardy Instruments Part Number: 0596-0318-01 Rev 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. We also have factory engineers who will travel to your facility anywhere in the world to help you solve challenging applications. We're ready to support you with:
Installation and start-up Routine maintenance and certification Plant audits and performance measurement Emergency troubleshooting and repair
To request Emergency Service and Troubleshooting, Start-up, Installation, Calibration, Verifica¬tion or to discuss a Maintenance 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 Instruments has built a network of support throughout the globe. For specific field service options available in your area please contact your local sales agent or our U.S. factory at +1 858-292-2710, Ext.
1757.

Contents

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CHAPTER 1 OVERVIEW..................................................................................... 1
About Hardy Manuals .................................................................................................................................1
HI 1756 FC Overview....................................................................................................................................1
Typical Applications...................................................................................................................................2
Features and Capabilities.............................................................................................................................2
CHAPTER 2 SPECIFICATIONS .......................................................................... 4
Basic Specifications.......................................................................................................................................4
General........................................................................................................................................................4
Power and Utility Requirements .................................................................................................................5
Environmental Requirements......................................................................................................................5
Pending Approvals ......................................................................................................................................6
Parameter Defaults......................................................................................................................................6
CHAPTER 3 INSTALLATION .............................................................................. 7
Unpacking......................................................................................................................................................7
Installing the HI 1756-FC.............................................................................................................................7
Allen-Bradley ControlLogix Pro cesso r o r R emote 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 1756 FC Feeder Control Module................................................................12
Configuration Output Table Overview.....................................................................................................13
First Word - 0: Command Number...........................................................................................................13
Command Return or Error Codes..............................................................................................................15
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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 .........................................................................................................................21 Refills
REC Parameters ........................................................................................................................................
23
Rate Calibration Parameters......................................................................................................................24
Input Table ..................................................................................................................................................25
States (Word 12 of input table).................................................................................................................26
Integrated Technician................................................................................................................................26
CIP Messages............................................................................................................................................27
CHAPTER 5 CALIBRATION.............................................................................. 29
Pre-Calibration Procedures........................................................................................................................29
Electrical Check Procedures ......................................................................................................................29
Load Cell/Point Input/Output Measurements............................................................................................29
Load Check ...............................................................................................................................................30
C2 Calibration.............................................................................................................................................30
C2 Calibration Using Ladder Logic ..........................................................................................................30
Hard Calibration.........................................................................................................................................31
Hard Calibration Ladder Logic Example ..................................................................................................31
CHAPTER 6 TROUBLESHOOTING............................................................... 32
Disassembly and Reassembly Notes, Warnings and Cautions ................................................................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 Millivolt Readings..................................................................................38
Testing an individual load cell signal output requires an IT Summing Junction box or millivolt meter...38
Use the load cell certificate to verify the millivolt per volt (mV/V) rating:..............................................38
G - Calibration Failed................................................................................................................................39
H - Mechanical Inspection ........................................................................................................................40
J - Electrical Inspection.............................................................................................................................41
K - Load Sharing and Load Sensor Checkout...........................................................................................42
Erratic Weight or Rate Control.................................................................................................................43
System and Load Cell Tests........................................................................................................................44
INTEGRATED TECHNICIAN (IT®)......................................................................................................45
Weight and Voltage Test...........................................................................................................................46
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Contents
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General Policies and Information..............................................................................................................46
Warranty....................................................................................................................................................46
For Further Information Contact ...............................................................................................................47
INDEX ................................................................................................................ 48
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Contents
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Chapter 1 Overview

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This manual provides users and service personnel wi t h speci fi cat i ons an d p rocedures for installing, configuring, operating, maintaining, and troub leshooting 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. If you find that the information in this manual does not provide the help you need, contact the HI Customer Service Department at:
Phone: (858) 278-2900 FAX: (858) 278-6700 Web Site: www.hardyinst.com Support e-mail address: support@hardyinst.com

About Hardy Manuals

An overview of each chapter’s contents is listed below:
Chapter One - Provides an overview of HI 1756 FC capabilities and features Chapter Two - Provides a overview of HI 1756 FC specific a t i ons Chapter Three - Describes the steps for installing both the standard and optional HI
1756 FC equipment and the HI 215IT series junction box
Chapter Four - Explains how to configure the HI 1756 FC Chapter Five - Provides calibration instructions 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 Allen­Bradley ControlLogix programmable controller and/or remote rack. The remote rack module is connected to the local chassis via a ControlNet link.
The analog-to-digital converter in the weigh module controller updates 100 times per second and is capable of 8,388,608 counts of resolution. This allows the instrument to tolerate large “dead” loads, over sizing of load cells/sensors, and still have sufficient resolution to provide accurate weight measurement and control.
The module supports both C2 electronic calibration and hard calibration (i.e., traditional calibration with weights).
The HI 1756 FC is a loss-in-weight controller that measures the flow rate from a feeding device located on a process weighing scale. The user enters the flow parameters, and an HI 1756 FC algorithm automatically calculates and adjusts the tuning parameters needed to maintain the desired rate. After comparing the desired flow rate to the actual flow rate (measured by calculating the loss of weight over short intervals), it computes the adjustments needed to achieve the desired rate and transmits signals to adjust the speed of the feeding device.
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Chapter 1
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NOTE
While the system rate calibration can fine tune the flow-rate parameters automatically, you can also make manual adjustments.

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, si n gle -feeder. It can be operated in batch, automatic, or manual mode.

Features and Capabilities

C2® Calibration
Traditional calibration uses certified test weights. C2® Electronic Calibration allows a scale to be calibrated without the need for test weights. A C2® weighing system consists of up to eight load cell sensors, a junction box, interconnect cable, and an instrument with C2® capabilities (e.g., the HI 1756 FC). Each Hardy Instruments C2-certified load sensor outputs digital information used for calculating the calibration. When the HI 1756 FC reads the signals from the load sensors, it calibrates the scale based on the load sensor’s output plus a user-supplied reference point value (from 0 to any known weight on the scale).
NOTE C2® is registered trademarks of Hardy Instruments Inc.
WAVERSAVER®
n measuring small weight changes, the affects of mechanical vibration and noise
Whe from the feeders and plant environment can introduce substantial interference. WAVERSAVER factors out vibration, noise, and other interference-related si gnals fr o m the load cell so the rate controller can better decipher the actual weight data.
While WAVERSAVER can factor out noise with frequencies as low as 0.25 Hz, five cut­off frequencies can be selected, with higher fre que nci e s pr oviding a faster response time. The default factory setting is 1 Hz vibration frequency immunity.
Alarms
o HI 1756 FC alarms flag deviations from your specified flow rate.
Tw The Rate Tolerance Alarm can alert you concerning flow-rate changes. It can be set to
trigger an alarm bit which, if sent to a PLC, can be used to respond (e.g., sound an alarm) when the flow rate is above or below the tolerance range you select for a time that exceeds a limit you set.
The Rate Exception Control (REC) Alarm is triggered by an out-of-tolerance flow rate
a guard band tolerance in conjunction with the Rate Tolerance Alarm. The REC sets
using statusword bits that can flag a low or high rate. These signals can be used to either send an alarm or shut down the feeder system. During an REC alarm state that has not resulted in shutdown, the controller will continue to maintain the flow rate while monitoring the loss in weight until the rate is within tolerance.
Integrated Technician™
e HI 1756 FC Integrated Technician™ (IT®), which requires an HI 215IT series
Th junction box, provides built-in system diagnostics that makes it possible to diagnose weighing system problems. IT allows the reading of individual load sensor voltages and weights and isolates individual system components for quick and easy troubleshooting.
Digital Volt Meter (DVM) - Option
DVM re
quires the HI 215IT Series Junction Box to monitor mV/V readings for each load
sensor and the total system. When the operator detects a problem, the DVM readings help
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Chapter 1
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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
is test is used to diagnose drifting or unstable weight reading problems. It requires the
Th HI 215IT Series Junction Box for full utilization. The ability to read the weight seen by the individual load sensors allows you to use this test for making cornering, lev eling and load sharing adjustments to the weighing system.
The Weighing System Test provides the following problem detection support:
1. Disconnects the controller and engages an internal reference signal to see if the problem is 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 Co ntrol Modes
omatic mode corrects for variations in desired flow rates automatically.
Aut
Continuous or Batch Modes
ser selectable operating modes provide support for continu ous or batch processing.
U
Automatic or Manual Refill
tomatic refill uses user-selectable refill points to start and stop the refill process
Au without interrupting the feed process. HI and LO alarms are used to detect a refill failure.
The Manual Refill option only allows for manual refill at any time.
Two and Five-Point Automatic Rate Calibration
e 5-point auto rate calibration creates a high feed accuracy for a wide range of feed
Th rates. It either provides the user with automatically calculated parameters, or it lets users manually enter their own derived values.
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Chapter 1
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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 in strument. All service personnel should be familiar with this section before installing or repairing the instrument.

Basic Specifications

General

Resolution
Internal:1:8,388,608
Input
Up to
eight 350-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
11
0dB at or below 60 Hz
Common-Mode Voltage Range
2.
5VDC maximum (with respect to earth ground)
Backplane Input Voltage/ Power Load
5 VDC
Backplane Current Load
<1
0.0125 Amps at 24 VDC (with 4-350 Ohm Load Cells)
Backplane Power Load
< 5W at < .3W at 24 VDC with 4-350 Ohm Load Cells
C2 Calibration Input
Isol
Cable lengths
1 250 feet maximum of C2 authorized cable (Maximum of 4 load sensors) with IT Junction
box.
and 24 VDC
Amp at 5 VDC
5 VDC
ation from digital section 1000 VDC minimum.
000 feet maximum of C2 authorized cable
C2® Maximum Cable Length
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Chapter 2
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000’ for C2, Non C2, or JB Card
1 250’ for IT
Load Cell Excitation
5 VDC
+/- 1.15 W maximum.
Isolation from digital section 100 0 VDC minimum
C2 Calibration Output
ation from digital section 1000 VDC minimum
Isol
Number of Channels
hannel
1 C
Update Rate
10
0 Updates per Second (10 ms)
Averages
1-255 Use
r-selectable in Single Increments
WAVERSAVER®
User Selectabl
e
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
63 Hz
47/
Power
10
Watts maximum with options

Environmental Requirements

Digital Voltmeter
Accuracy +/- 2% of full scale
Operating Temperature Range
0
to 60º C (32º F to 140º F)
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Chapter 2
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Temperature Coefficient
Less than 0.005% of full scale per degree C for Cal-LO and Cal-HI reference points
Storage Temperature Range
-4
0 to 85º C (-40 to 185º F)
Humidity Range
0
-90% (non-condensing)

Pending Approvals

UL, CUL, and CE

Parameter Defaults

Parameters Default Parameters Default
Chan Active 1 Total
Metric 0 Batch Total 0 span weight 100 Low Alarm Shut Down Rate 0 cal low weight 0 High Alarm Shut Down Rate 100
ROC time base 4 Alarm Delay 100 ROC time units 1 Rate Setpoint 0 Averages 1 REC P Limit 10
WAVERSAVER 3 PID_P 50 PID_I 20
batch amount 10 Preact 0 Mode 0 Prime Time 0
Pause Time 0 Feed time 40 Initial Refill on 0
Auto Refill On 0 Refill Start Weight 10 Refill End Weight 100
Refill Too High Weight 100000 Refill Shut Down Weight 0 Refill Op Adjust 0
Refill Op Adjust Percent 0 Wait Time 0 REC Level 20
REC Time 60 REC Shutdown Shutoff Low Percent
0.0
0.0
7 Rate Cal Rates 0 percent 1st percent 2nd percent 3rd percent 4th percent 5th percent 100 percent 7 Rate Cal Percentages 0 Percent 1st Percent 2nd Percent 3rd Percent 4th Percent 5th Percent 100 Percent ADC Average MANUALOP FAST_ROC Zerocount CalLowCount
0.0
None None None
None None None None
None None None
None None None
None None None
None None None
None
none
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Chapter 2
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Chapter 3 Installation

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Chapter 3 covers unpacking, cabling, interconnecting, configuring, and installing the Weigh Scale Module. User and service personnel should r ead 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. Write down the Model and Serial number of the module. Store this information
in a convenient location for reference when contacting The Custo mer Support
Department for parts or service. Step 4. Be sure to complete the warranty registration on the Hardy web site.

Installing the HI 1756-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 obse rve the foll owing 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.
Handle the module from the bezel in front away from the connector. Do not
touch the connector pins.
Do not install the module right next to an AC or high voltage DC module. Route all the load voltage cables away from high voltage cables.

A ControlLogix Chassis

Step 1. Make sure that the module is
oriented correctly for
installation. Step 2. Gently slide the module into the
Chassis. Step 3. Slide the digital board between
the PCB Guides on the top plate
and bottom plate of the chassis
to line up the module connector
with the backplane connector
Inserting the module
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Chapter 3
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Step 4. W
hen 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. Store in a safe, secure location in an anti-static bag or the original enclosure.

Installing the Module I/O Connector

The I/O connector at the front of the module connects the module to the Remote Terminal Assembly (-RTA), a load sensor, or the HI 215IT Series Junction Box, depending on how many load sensors are installed in the weighing system. (See 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. Install the cable and connector so it
allows the module door to be shut.
Step 3. With the plug oriented correctly
(See the pin-out diagram below), plug the I/O male connector into the I/O connector at the front of the module.
Note When the door is open, the button you see on the top right has no function.
HI 1756 FC with door open
Check to be sure that the connector is completely
Single Channel
Pin 1 Exc+
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Chapter 3
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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.

Load Cell Wiring Diagrams

The diagrams below show how Hardy Load Sensor with C2 wiring differs from standard Load Cell wiring.
n 2 Sense+
Pi Pin 3 Sig+ Pin 4 Sig­Pin 5 Sense­Pin 6 Exc­Pin 7 C2+ Pin 8 C2­Pin 9 Shield
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(es) or load sensor(s). The RTA comes with a standard 35 mm Din Rail Mounting and requires at least a 5” inch long DIN rail for mounting.
Remote terminal assembly
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Chapter 3
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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.

RTA Cable Assembly and Jumpers

x-foot cable connects to the HI 1756 FC module.
A si
RTA cable assembly - HI 1756WS

Hardy HI 215IT Junction Box

1756 FC
Load Cell Connector
J1
Jumpers
RTA with jumpers for load cells without
sense lines
RTA cable schematic
Hardy HI 215IT Junction Box Wiring Diagram
NOTE When connecting the Hardy HI 215IT Junction Box, you must remove the two fa ctory
installed jumpers 1&2 and 5&6 on the module and install sense lines.
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Chapter 3
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Chapter 4 Configuration

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Chapter 4 covers the settings used to prepare the controller for calibration and operation. The Setup procedures require Allen-Bradl ey’s RS Logix 5000, Allen-Bradley RSLi nx ™ 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.
Module LEDs

LEDS

Scale Data LEDs
Flashing Green Steady Green Running (Normal) Steady Red Error Read Failure or Error eeprom write. Contact HI
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
(Backplane Available) data or blank serial eeprom. Contact HI Customer Support. Steady Red Internal Hardware watchdog timer fault (e.g. bad Hardware
Flashing Red Communication Error.
Feeder is on
Customer Support
eeprom
or Firmware). ASIC is non-operational.
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Chapter 4
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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. 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 = 200
Step 5. Select DATA INT from the Comm Format
pull-down list.
Module Properties Dialog Showing General tab Step 6. Open the Connection Tab. Step 7. Set the RPI to 20 milliseconds or greater. Do not set this parameter lower than
20 milliseconds.
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Chapter 4
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Step 8. Click Finish.
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