Hardy HI 1769-FC User Manual
HI 1769-FC
Feeder Control Module
User’s Guide
Corporate Headquarters
9440 Carroll Park Drive, Suite 150
San Diego, CA 92121-5201
Phone: 1-800- 821-5831
FAX: (858) 278-6700
Web-site: http://www.hardysolutions.com
Hardy Process Solutions Document Number: 0596-0321-01 Rev E
Copyright 2011-2013 Hardy Process Solutions, All Rights Reserved.
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, Verification or to discuss a
Maintenance Agreement please call 800-821-5831 Optio n 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 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 +1 858-2922710, Option 4
Contents
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CONTENTS ........................................................................................................... I
CHAPTER 1 OVERVIEW ..................................................................................... 1
About Hardy Manuals ................................................................................................................................. 1
HI 1769-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
Approvals .................................................................................................................................................... 5
CHAPTER 3 INSTALLATION .............................................................................. 6
Unpacking ...................................................................................................................................................... 6
Installing the HI 1769-FC ............................................................................................................................. 6
Installing the Hi 1769-FC onto the CompactlLogix and MicroLogix 1500 Bank ....................................... 7
Installing the I/O Connector Diagrams ....................................................................................................... 8
About the Module I/O Connector ................................................................................................................ 8
Installing the HI 1769-FC on a DIN rail .................................................................................................... 11
Load Cell Wiring Diagrams ....................................................................................................................... 12
HI 1769 Remote Terminal Assembly (HI 1769-XX-RT) .......................................................................... 12
Hardy HI 215IT Junction Box ................................................................................................................... 15
CHAPTER 4 CONFIGURATION ........................................................................ 16
Power Check ................................................................................................................................................ 16
LEDS ......................................................................................................................................................... 16
Setting Up Communications ....................................................................................................................... 17
Linking the MicroLogix 1500 processor with the HI 1769-FC Feeder Control Module ........................... 17
Alternate Setup procedures ........................................................................................................................ 18
Linking the MicroLogix 1500 processor with the HI 1769-FC Feeder Control Module ........................... 18
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Configuring the HI 1769-FC Feeder Control Module in the RSLogix 5000 for CompactLogix with the HI
1769-FC Feeder Control Module .............................................................................................................. 19
Output Table Overview .............................................................................................................................. 29
First Word - 0: Command Number ........................................................................................................... 29
Command Return or Error Codes .............................................................................................................. 31
Second Word - 1: Format Word ................................................................................................................ 31
Format Word Decimal Point Parameters ................................................................................................... 31
Third / Fifth Words - 2, 3, 4: Parameter Number and Default Value .................................................... 32
Parameter 13-18 Refills ......................................................................................................................... 37
REC Parameters ........................................................................................................................................ 40
Rate Calibration Parameters ...................................................................................................................... 41
Input Table .................................................................................................................................................. 42
States (Word 12 of input table) ................................................................................................................. 43
Integrated Technician ................................................................................................................................ 44
CHAPTER 5 CALIBRATION .............................................................................. 45
Pre-Calibration Procedures ........................................................................................................................ 45
Electrical Check Procedures ...................................................................................................................... 45
Load Cell/Point Input/Output Measurements ............................................................................................ 45
Load Check ............................................................................................................................................... 46
Calibration Procedures ............................................................................................................................... 46
C2 Calibration ........................................................................................................................................... 46
C2 Calibration Procedures ......................................................................................................................... 47
Traditional Calibration .............................................................................................................................. 47
Rate Calibration ......................................................................................................................................... 48
To perform the rate calibration: ................................................................................................................. 49
CHAPTER 6 OPERATING PROCEDURES .................................................... 50
Input Data .................................................................................................................................................... 50
CHAPTER 7 TROUBLESHOOTING ............................................................... 52
Disassembly and Reassembly Notes, Warnings and Cautions ................................................................ 52
Weight and Voltage Testing ....................................................................................................................... 52
IT Test ....................................................................................................................................................... 53
General Troubleshooting Flow Chart Index ............................................................................................. 53
A - Guidelines for Instabilities on Formerly Operating System ................................................................ 54
B - Guidelines for Instabilities on Formerly Operating Systems (Cont’d) ................................................ 55
B1 - Guidelines for Instabilities on Formerly Operating Systems (Cont’d) .............................................. 56
B1 - Guidelines for Instabilities on Formerly Operating Systems (Cont’d) .............................................. 57
F - Verify Individual Load Cell Millivolt Readings .................................................................................. 58
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Testing an individual load cell signal output requires an IT Summing Junction box or millivolt meter. .. 58
Use the load cell certificate to verify the millivolt per volt (mV/V) rating: .............................................. 58
G - Calibration Failed ................................................................................................................................ 59
H - Mechanical Inspection ........................................................................................................................ 59
J - Electrical Inspection ............................................................................................................................. 61
K - Load Sharing and Load Sensor Checkout ........................................................................................... 62
Erratic Weight or Rate Control ................................................................................................................. 63
System and Load Cell Tests ........................................................................................................................ 64
INTEGRATED TECHNICIAN (IT®) ...................................................................................................... 65
Weight and Voltage Test ........................................................................................................................... 66
General Policies and Information .............................................................................................................. 66
Warranty .................................................................................................................................................... 66
For Further Information Contact ............................................................................................................... 67
INDEX ................................................................................................................ 68
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Contents
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Chapter 1 Overview
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This manual provides users and service personnel with specificatio ns and procedures for
installing, configuring, operating, maintaining, and troubleshoo ting the Hardy HI 1769FC Rate Controller with WAVERSAVER®, C2®, and INTEGRATED TECHNICIAN
(IT®) diagnostics.
The module is configurable via ladder logic. The HI 1769-FC module lock with other
modules by means of a tongue and groove design and have integrated communication bus
that is connected from module to module by a movable bus connector.
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 Hardy Customer Service Department at:
Phone: (858) 278-2900
FAX: (858) 278-6700
Web Site: www.hardysolutions.com
Support e-mail address: support@hardysolutions.com
About Hardy Manuals
An overview of each chapter’s contents is listed below:
Chapter One - Provides an overview of HI 1769-FC capabilities and features
Chapter Two - Provides an overview of HI 1769-FC specifications
Chapter Three - Describes the steps for installing both the standard and optional HI
1769-FC equipment and the HI 215IT series junction box
Chapter Four - Explains how to configure the HI 1769-FC
Chapter Five - Provides calibration instructions
Chapter Six – Provides troubleshooting procedu res f or repair of the HI 1769-FC
Hardy hopes that this manual meets your needs for information and operation. All
corrections or suggestions for improvements of this manual are welcome and can be sent
to the Technical Publications Department or Customer Support Department at Hardy
Process Solutions, Inc.
HI 1769-FC Overview
The HI 1769-FC module is a self-contained, microprocessor-based CompactLogix® and
MicroLogix® 1500 I/O module . Its control inputs and outputs will easily plug into the
backplane of an Allen-Bradley CompactLogix and MicroLogix 1500 programmable
controller.
The HI 1769-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 1769-FC algorithm automatically calculates and adju sts the tuning parameters need ed
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
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Chapter 1
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the feeding device.
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).
Typical Applications
Closed-loop rate control can be used in a variety of material-flow applications, such as
auger, belt, and vibration-based feeders, converting them from volumetric to gravimetric.
The Feeder Controller controls a single-ingredient, single-feeder. It can be operated in
batch, automatic, or manual mode.
Features and Capabilities
C2® Calibration
Traditional calibration uses certified test weights. C2 Electronic Calibration allows a
scale to be calibrated without the need for heavy 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 1769-FC). Each Hardy Process Solutions
C2-certified load sensor outputs digital information used for calculating the calibration.
When the HI 1769-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).
WAVERSAVER
When measuring small weight changes, the effects of mechanical vibration and noise
from the feeders and plant environment can introduce substantial interference.
WAVERSAVER factors out vibration, noise, and other interference-related signals from
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 frequencies providing a faster response time.
The default factory setting is 1 Hz vibration frequency immunity.
Alarms
Two HI 1769-FC alarms flag deviations from your specified flow rate.
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.
The Rate Exception Control (REC) Alarm is triggered by an out-of-tolerance flow rate
using
a guard band tolerance in conjunction with the Rate Tolerance Alarm. The REC sets
status word 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
The HI 1769-FC Integrated Technician (IT
®
), which requires an HI 215IT series 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.
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Digital Volt Meter (DVM) - Option
DVM requires 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
to isolate the faulty component. Further, the DVM readings can be used to level a system
and to make corner adjustments to platform scales. Accuracy is +/- 2% or better of full
scale.
NOTE If you do not have the HI 215IT Junction Box connected to the module, the mV/V reading
is the total for all load cells on the system.
Weighing System Tests - Optional
This test is used to diagnose drifting or unstable weight reading problems. It requires the
HI 215IT Series Junction Box for full utilization. The ability to read the weight seen by
the individual load sensors allows you to use this test for making cornering, leveling 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 Control Modes
Automatic mode corrects for variations in desired flow rates automatically.
Continuous or Batch Modes
User selectable operating modes provide support for continuous or batch processing.
Automatic or Manual Refill
Automatic refill uses user-selectable refill points to start and stop the refill process
without interrupting the feed process. HI and LO alarms are used to detect a refill failure.
The Manual Refill option allows refill at any time.
Two and Five-Point Automatic Rate Calibration
The 5-point auto rate calibration creates a high feed accuracy for a wide range of feed
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
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Chapter 2 provides specifications for the HI 1769-FC feeder controller and other
equipment that may come with the package. The specifications listed are designed to
assist in the installation, operation and troubleshooting of the instrument. All service
personnel should be familiar with this section before installing or repairing the
instrument.
Basic Specifications
General
Conversion Rate
100 updates per second (10 mS)
Resolution n
Internal:1:8,388,608
Input
Up to four 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
120dB from 59 to 61 Hz
Common-Mode Voltage Range
2.5VDC maximum (with respect to earth ground)
Bus Input Voltage
5 VDC
Bus Current Load
<0.5 Amp at 5 VDC
Bus Power Load Power Load
< 5W at 5 VDC
C2 Calibration Input
Isolation from digital section 100 0 VDC m i ni mum.
Cable lengths
500 feet maximum of C2 authorized cable
250 feet maximum of C2 authorized cable (Maximum of 4 load sensors) with IT Junction
box.
Load Cell Excitation
5 VDC
C2 Calibration Output
Isolation from digital section 100 0 VDC m i ni mum
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Chapter 2
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Number of Channels
1 Channel
Averages
1-255 User-selectable in Single Increments
WAVERSAVER®
User Selectable
0 = OFF
1 = 7.50 Hz
2 = 3.50 Hz
3 = 1.00 Hz (Default)
4 = 0.50 Hz
5 = 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
Environmental Requirements
Operating Temperature Range
0 to 60º C (32º F to 140º F)
Temperature Coefficient
Less than 0.005% of full scale per degree C for Cal-LO and Cal-HI reference points
Storage Temperature Range
-40 to 85º C (-40 to 185º F)
Humidity Range
0-90% (non-condensing)
Approvals
UL/CUL - Class 1, Division 2, Groups A, B, C and D. Temperature Code T5
CE
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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
Feeder Control Module. User and service personnel should read this chapter before
installing or operating the Feeder Control 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 Hardy Customer
Support Department for parts or service.
Step 4. Be sure to complete the warranty registration on the Hardy web site.
Installing the HI 1769-FC
WARNING Electrostatic discharge may damage semiconductor components in the module. DO NOT
TOUCH THE CONNECTOR PINS, and observe 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.
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Chapter 3
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Installing the Hi 1769-FC onto the CompactlLogix and MicroLogix
1500 Bank
Step 1: Make sure that the module is oriented correctly for installation.
Positioning the Module for Installation
Step 2: Pull Lever B back to the unlock position.
Connector unlock position
Step 3: Gently slide the HI 1769-FC module onto the other module.
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Step 4: When you have the modules aligned, press Lever B towards module A to fasten
the connector to Module A.
Connector in locked position
Step 5. The installation is complete.
Installing the I/O Connector Diagrams
About the Module I/O Connector
The I/O Connector at the front of the module connects the module to the Remote
Terminal (RTA), a load sensor, or the HI 2151T series junction box depending on how
many load sensors are installed in the weigh system.
The pin-out diagram is shown below and can be located on the inside of the module door.
Single Channel
Pin 1 Sheild1
Pin 3 C2-1 Violet
Pin 5 C2+1 Gray
Pin 7 Exc-1 Black
Pin 9 Sen-1 Brown
Pin 11 Sig-1 White
Pin 13 Sig+1 Green
Pin 15 Sen+1 Blue
Pin 17 Exc+1 Red
Module connector pin-out diagram
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Step 1: Open the module door to gain access to the I/O connector.
Module connector installed
Step 2: To make the cable connections easier you can remove the connector from the
module. To remove the connector, use a Phillips screwdriver and the remove the
two (2) Phillips pan head screws that fasten the connector to the module.
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Module connector removed for easier cabling
Step 3: Gently pull he connector off of the board in the module
Step 4: To install the connector reverse steps 3 & 3.
Step 5: Install the cable so it allows the module door to close
Step 6: Check to make sure that the wires are securely connected before operating the
module.
NOTE Most of the problems with modules 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.
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Chapter 3
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Installing the HI 1769-FC on a DIN rail
Step 1: Pull the two DIN rail fasteners out until the snap into the open position.
Rail fasteners in retracted position
Step 2: Place the module on the DIN rail.
Step 3: While holding the module in place, press the two fasteners towards the center of
the module until they both snap onto place.
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Chapter 3
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Rail fasteners in closed position
Step 4: The module is now securely fastened to the DIN rail
Step 5: To remove the module from the DIN rail reverse steps 2 & 3 a bove.
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
WARNING: LOAD CELL CABLE LENGTH HAS BEEN FACTORED INTO C2 CALIBRATION DATA.
HARDY INSTRUMENTS RECOMMENDS THAT YOU DO NOT CUT YOUR ADVANTAGE® OR
ADVANTAGE LITE® LOAD SENSOR CABLE, AS YOUR C2® ACCURACY WILL BE AFFECTED AND
THE WARRANTY WILL BE VOIDED.
HI 1769 Remote Terminal Assembly (HI 1769-XX-RT)
The Remote Terminal Assembly (RTA)
provides connection points between the cable
assembly from the HI 1769-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 If your cable run between the J-box and
the controller does not have sense lines,
you will need to jumper the Sense (-) to
the Excitation (-) and the Sense (+) to the
Excitation (+) for one or both channels.
Jumpers
RTA with jumpers for load cells without
sense lines
RTA Cable Assembly and Jumpers
A six-foot cable connects to the HI 1769-FC module.
RTA cable assembly - HI 1769WS
RTA cable schematic
For CE requirements you will need to install an EMI suppression core around the multistrand portion of the RTA cable.
Step 1: There should be enough of the individual strands of wire exposed to install the
suppression core. If there is not enough room, remove enough of the cable cover until
you can place the suppression core around all the wire strands.
Step 2: Place the suppression core as close to the module door as possible and still be able to
close the door
Step 3: To open the suppression core place a small slotted screw driver behind the latch and pry
the latch sway from the body of the core until it clears both catches.
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Chapter 3
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EMI Suppression Core
Step 4: Open the core until it is wide enough to enclose all the strands of wire.
Suppression Core Open
Step 5: Place all the wire strands in the core and gently close the core until it snaps shut.
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Chapter 3
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Suppression core installed
Hardy HI 215IT Junction Box
Hardy HI 215IT Junction Box Wiring Diagram
NOTE You must have the C2 lines installed to operate the HI 215IT junction box. The C2 wires
act as the IT control 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-Bradley’s RSLogix™ 5000, Allen-Bradley RSLinx®
or RSLinx® Lite for use in the CompactLogix™ system, or RSLogix 500 for the
MicroLogix™ 1500 system.
Power Check
To make or change settings,
there must be power to both the
PLC and the module. Verify that
the LED’s are lit for normal
operation.
Module LED’s
LEDS
Scale Data LED’s
Flashing Green Feeder 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
eeprom
(Backplane Available) Data or blank serial eeprom. Contact HI Customer Support.
Steady Red Internal Hardware watchdog timer fault (e.g. bad Hardware
or Firmware). ASIC is non-operational.
Flashing Red Communication Error.
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Chapter 4
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Setting Up Communications
Linking the MicroLogix 1500 processor with the HI 1769-FC Feeder
Control Module
To set up communication between the MicroLogix 1500 Processor and the Feeder
Control Module you will need to do the following in RSLogix 500
Step1: We assume you have a project open or have created a new project. For
instructions please see your RS LOGIX 500 manual. The setup instructions
begin from this point. Under project, click on the + next to the controller. Click
on “I/O Configuration”. The I/O Configuration dialog box appears.
Step 2: From the I/O Configuration dialog box, under “#” column heading click on #1
or the next open slot number available.
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Chapter 4
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I/O Configuration Dialog Box
Step 3: Click on the “Read IO Config” button. The “Read IO Configuration from Online
Processor” dialog box appears.
Read IO Configuration from Online Processor Dialog Box
Step 4: RSLogix 500 automatically reads the I/O information and enters them into the
configuration text fields.
Step 5: The HI 1769-FC I/O is configured and ready to communicate with the
MicroLogix 1500 processor
Alternate Setup procedures
Linking the MicroLogix 1500 processor with the HI 1769-FC Feeder
Control Module
To set up communication between the MicroLogix 1500 Processor and the Feeder control
Module you will need to do the following in RSLogix 500
Step 1: Under project, click on the + next to the controller
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Chapter 4
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Expanding Controller
Step 2: Click on “I/O Configuration”. The I/O Configuration dialog box appears.
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