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Filler/Dispenser/IBC HI-3010

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1. 28 Wait Timer Parameter 28 About Wait Timer 28 Speed Parameter29 About the Speed Parameter 29 Instrument Configuration 30 Operator ID 31 About Operator ID 31 Instrument ID lt lt lt 22 5 2 4 asias 31 About Instrument ID 31 OK to Fill Input Parameter 32 About OK to Fill Input Parameter lt 32 Discharge Parameters 32 About the Discharge Parameters 32 About Proof Switch 33 About the Auxiliary Device Timer 34 Refill Parameters 34 About the Filler Refill Parameters 34 About the Dispenser IBC Refill Parameters 34 Serial Port Parameters 36 About the Serial Port Setup Parameters 36 Totalizer Parameter 37 About the Totalizer Parameter 37 Unit of Measure Parameters 38 About Unit of Measure 38 Decimal Point Parameter 38 About the Decimal Point Parameter 38 Total Deci
2. 29 SPEED PARAMETER 29 FILL PROOF MENU 29 DUAL SPEED FILLER MENU 29 DUAL SPEED FILLER FILL PROOF MENU 30 FILL PROOF MENU 30 FILL PROOF MENU 30 ADJUST INGREDIENT INGREDIENT 1 SET TO FLOUR 30 SETTING PARAMETERS FOR INGREDIENT 2 30 CONFIGURATION MENU SETUP 31 SETUP MENU OPERATOR ID 31 INSTRUMENT ID PARAMETER 31 INSTRUMENT ID MENU CHEM 3 FILLER 31 OK TO FILL INPUT PARAMETER 32 OK TO FILL MENU SETTING OK TO FILL TIMER 32 SETUP MENU DISCHARGE PARAMETER 33 DISCHARGE MENU AUTO DISCHARGE 33 DISCHARGE MENU OK TO DISCHARGE 33 OK TO DISCHARGE MENU 33 DISCHARGE MENU PROOF SWITCH 33 DISCHARGE MENU SWITCH TIMER 33 DISCHARGE MENU AUXILIARY DEVICE TIMER 34 SETUP MENU REFILL 34 REFILL MENU REFILL 34 REFILL MENU INITIAL REFILL 34 SETUP MENU REFILL 35 REFILL MENU REFILL 35 REFILL MENU INITIAL REFILL 35 REFILL MENU SETTING REFILL PROOF SWITCH 35 REFILL MENU SETTING REFILL SWITCH TIMER 35 REFILL MENU SETTING REFILL WEIGHT 36 REFILL MENU SETTING REFIL
3. Filler Dispenser IBC HI 3010 INSTALLATION AND SERVICE MANUAL Hard Instruments Document Number 0596 0256 01 REV N Start up Verification Installation Calibration 24 7 365 Preventative Emergency Services Maintenance Agreements Local Field Service Hardy has over 200 field technicians in the U S and more positioned throughout the world to assist you in your sup port 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 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 1 Table of Contents Table of Contents Table of Illustrations Chapter 1 Chapter 2 Chapter 3 Table of Contents mmm mmm mm mmm mmm mmm mmm mma i ii ii i 1 eT RR ERa RST la T ed hoe ak e e Ie e id at aa I O Ver V
4. FIG 3 17 DC POWER SUPPLY CONNECTION Step 1 Connect your positive and negative DC voltage lines to the Phoenix connector that plugs into the DeviceNet Connector See Fig 3 17 Step 2 Plug the connector into the DeviceNet Connector at the rear panel NOTE Use DC power source when you have the DC option and do not have the DeviceNet Option The DeviceNet option has its own DC power source Load Point Connections Pz lt 0 N 3 0 2unPERBPS x 3 ZN S 9 BZ sk orus S Z Z ESO sou A a 99922 T i LINK Pa aire U A ji J TR El IL JL 4 LA gt primtenisplay them et smm sa Channel 1 S ae a FIG 3 18 REAR PANEL LOAD POINT CONNEC TIONS C2 Load Point Connection Cable color Code for C2 Load Points left to right facing the rear panel e Shield Ground Wire e C2 Violet C2 Grey e EXC Black e SEN Brown e SIG White e SIG Green e SEN BLUE EXC RED Step 1 Remove the factory installed jumper from the ter minal block if you are connecting an 8 wire cable from the junction box Step 2 Connect the cable Recommended load cell cable Hardy Instruments Prt 6020 0001 wires to the J9 HI 3010 Filler Dispenser IBC 18 Service Manual terminal block according to the cable color chart See Below NOTE To purchase Hardy Load Cell cable contact your local Hardy Representative or Distributor Step 3 Plu
5. 89 Lost OK to Dispense Alarm 89 Fast Gate Did Not Open Alarm 90 Fast Gate Did Not Close Alarm 90 Slow Gate Did Not Open 90 Slow Gate Did Not Close 91 Under Dispense Over Dispense Alarms 91 IBC Dispense Alarms 92 Change IBC Alarm 92 Jog Alarms 92 Jog Gate Did Not Open Alarm 92 Jog Gate Did Not Close Alarm 92 Jog Count Alarm 93 Discharge Alarms 94 Not OK to Discharge Alarm 94 Discharge Gate Did Not Open Alarm 94 Clogged Gate Alarm 94 Discharge Gate Did Not Close Alarm 94 General Troubleshooting Flow Chart Index 95 A Guidelines for Instabilities on Formerly Operating Systems 96 B Guidelines for Instabilities on Formerly Operating Systems Cont d 97 B1 Guidelines for Instabilities on Former Operating Systems Cont d 98 B2 Guidelines for Instabilities on Formerly Operating Systems Mechanical Stability and Configuration Settings 99 C Guidelines for Inst
6. 22 ee ee ee ee ee ee eee 7 About Chapter 2 7 Specifications for a Standard Instrument 7 Specifications for I O Option Boards 8 Profibus Option Board 5 8 ControlNet Option Board 5 9 RIO Option Board 9 EtherNet IP Option Card 9 Specifications for Peripherals Systems Components 10 Installation lt lt lt lt lt lt eee KKK KKK KKK KKK 11 About Chapter 3 11 Unpacking 11 Disassembly and Reassembly Notes and Cautions 11 Mechanical Installation 12 Installing the HI 3010 ina Panel 12 Panel Cutout Specifications 12 Installing the HI 3010 Filler Dispenser 12 Installing the HI 3010 in a Swivel Wall Mount 13 About the Swivel Wall Mount 13 Chapter 4 HI 3010 Filler Dispenser IBC Service Manual Installing Printed Circuit Boards 15 Installing the Smart Diagnostics SD Card 16 Removing Printed Circuit Boards 17 Electrical Installation 17 Cabling and Inter
7. FIG 4 14 INGREDIENT MENU FILL DISPENSE CYCLES PARAMETER FILL DISPENSE CYCLES RANGE 0 9 999 DEFAULT 1 NOTE For continuous fills dispenses set the parameter to 0 Step 1 The cursor is in front of Fill Cycles If you are entering this parameter for the first time use the alphanumeric key pad and enter the number of cycles you want for this ingredient See Fig 4 15 Step 2 Ifa value already exists press the Clear button to clear the previous entry Step 3 Use the alphanumeric key pad and enter the number of cycles for this ingredient In our example we set 15 cycles for the ingredient Flour See Fig 4 15 gt Fi CYCLes 15 E FIG 4 15 FILL DISPENSE CYCLES PARAMETER Step 4 Press the Enter button The cycles are set and the cursor moves to Target Wt See Fig 4 16 Target Weight About Target Weight The Target Weight is the gain in weight Fill or loss in weight value Dispense you want for this ingredient If you want one cycle to fill dispense 100 lbs of an ingredient you set the Target Weight to 100 Keep in mind that the Units Parameter is set in another menu In our example we set the Target Weight to 100 lbs See Fig 4 16 PARAMETER TARGET WEIGHT RANGE 000001 999 999 DEFAULT 1 Step 1 The cursor is in front of Target Weight If you are entering this parameter for the first time use the alphanumeric key pad and enter the target weight for this ingredient See Fig 4 16
8. FIG 7 5 RESUME FILLING FAST DISPLAY 3 Press the Start button to resume fast fill Fast Gate Did Not Close Alarm e Ifthe Fast Fill Gate does not close at the end of a fill the FAST GATE DID NOT CLOSE alarm appears on the display See Fig 7 6 FLOUR AMT 225 36 225 80 ALARA FAST GATE UID nT C LURE JOG KLO FIG 7 6 FAST GATE DID NOT CLOSE 87 CHAPTER 7 Troubleshooting 1 Determine why the Fast Fill Gate did not close and correct the problem 2 Press the Clear button to clear the FLOUR alarm The RESUME FILLING FAST amt 0 00 225 00 de eee RESUME FILLING SLOU PRESS START HL U FLOUR AMT 0 00 225 00 FIG 7 9 RESUME FILLING SLOW RESUME FILLING FAST PRESSSTART JDO ALO 3 Press the Start button to resume slow S filling FIG 7 7 RESUME FILLING FAST DISPLAY Slow Gate Did Not Close Alarm 3 Press the Start button to resume fast 2 7 ALARM CONDITION fill 4 If the target weight is NOT within the s If the Slow Fill Gate does NOT close the target window and you do not have SLOW GATE DID NOT CLOSE alarm the JOG function turned ON the fill is appears on the display See Fig 7 10 not accepted and an UNDER FILL or OVER FILL alarm appears depending on the alarm condition EL DUR TT 3 HINT 205 00 225 00 dd dE IALARASLOUGATE sea ae ALARM CONDITION IMO NOT CLOSE HL U e If the Slow Fill Gate is not open at the time you want to slow fill the SLO
9. Enable Discharge click in the OK to Discharge OFF radio button Step 4 To turn ON Discharge Gate Proof Switch click in N gt the Discharge Gate Proof ON radio button To turn OFF Discharge Gate Proof Switch click in the Dis charge Gate Proof OFF radio button FIG 4 117 INSTRUMENT SETUP PAGE 2 SETTING Step 5 To set the Discharge Gate Timer double click in the WAVERSAVER Discharge Gate Timer field and enter the new time Step 6 To set the OK to Discharge Timer double click in Step 22 To set the entries for page 2 click on the Save the OK to Discharge Timer field and enter the new Parameters button time Step 23 Click on right arrow at the bottom of the page The Step 7 To set the Refill and Discharge parameters click on Refill and Discharge Setup page appears See Fig the Save Parameters button 4 118 Step 8 Click on the right arrow at the bottom of the page Step 9 The Serial Port Setup page appears See Fig 4 119 Configuration Instrument Setup Filler Enter or select the parameters for the fields below Configuration Instrument Setup Filler Refill Discharge Refill G ORE CON Discharge OFF CON Initial Ref ORF CON Auto ites Goir OoN Enter parameters for the fields below OK to Discharge OFF CON Discharge Gate Proof OFF CON Printer Port Discharge Gate Timer seconds R Auto Print OFF gt OK to Discharge Timer seconds fic Baud Rate 300 H S Pi ete HERRERO Parity NONE E J y Da
10. N VESSEL SUPPORTBRACKET NEAR MAXIMUM CENTER OF GRAVITY FOR INHERENT VESSEL STABILITY BIN ACTIVATOR FIG 7 121 TYPICAL LOAD CELL SYSTEM 2 Load Cell Sensor Point is a strain gauge based force transducer which generates an electrical signal propor tional to the load applied to the scale Load cells points can be used any place a person needs to measure pres sure load or torque This can be accomplished by either Tension or Compression type load cells points The load cell point takes as an input the 5 volts DC Excitation Voltage generated by the HI 3010 and depending upon how much weight is applied to the scale generates a milli volt output proportional to the weight 0 10mv DC for 2mv V load cells points or 0 15mv DC for 3mv V load cells points Weight Controller is part of the HI 3010 instrument which among other functions is used to power the load cell s point s take the millivolt sig nal output from the load cell s point s and digitize interpret com municate and display the results as a weight indication Troubleshooting The Network Connec tions and Configuration with the Ping Tool Step 1 The Ping Tool is used from the root directory of the PC Get to the Root directory The Root Directory is the C Prompt Step 2 If you do not know how to get to the Root Direc tory check you Operating System User Guide or Manual for information on how to get to the root directory Se
11. Target Weight Discharge Gate FIG 1 3 DISPENSING INTO A VESSEL FROM A FEEDER 2 3 CHAPTER 1 Overview Load Point Load Point Target Weight Discharge Gate FIG 1 4 DISPENSING LOSS IN WEIGHT FROM A VESSEL TO ANOTHER VESSEL Hardy Web Tech We have implemented Hardy Web Tech our new Online Tech Support Knowledge Base to serve your tech support needs better than ever before Hardy Web Tech helps you immediately find answers to your technical questions Just type in your question and see if your answer exists in our knowledgebase which is populated by interactions with cus tomers like you You can also create your personalized support page and your own support section that you can access 24 7 You can even view and update your entire call history as well as maintain your profile containing your product and system information so we can more effectively meet your needs Last but not least we invite all user feedback Click on the Provide Feedback link to let us know how we re doing What do you like about the product What s missing How do you like our new support site Anything Your comments are important and will help us shape the future direction of our products Connectivity All HI 3000 Series products enable the user to use the select able 10 100 base T Ethernet port or use its embedded web server to link performance diagnostics and setup data to and from your intranet extranet VPN or
12. Jog Parameters 27 JOG Sequence 93 Junction Box 128 Junction Box Wiring 18 K K Load Sharing and Load Sensor Checkout 108 Key Pad 1 Knurled Knobs 17 L Last Cal Time 115 Last Cal Type 114 Lattitude 58 Leakage Current 133 LED Display 1 Left Arrow Button 22 Left Right Arrow Buttons 22 LHS 78 LHS Left Hand Side 78 List of Alarms 85 List of Destinations 81 Live Load 62 Load Cells 57 Load Point cables 21 Load Sensor 119 Load Sensor Number 58 60 Local Relay 81 Lock Washers 11 85 Index Loss in Weight 25 Lost OK to Dispense Alarm 89 Lost OK to Fill Alarm 86 Low Level Sensor 34 LVDT and Half Bridge Load Cells Sensors 18 M M Weight Reading Stops Incrementing 109 Main Board 16 Manual Button 21 Manual Mode 21 Map the Source 81 Mapped Assigned 81 Mapped Data 82 Mapped I O 1 3 Max I O Data Capacity 9 Max Percent Field 50 Max Weight Field 50 Maximum Target Weight Tolerance 50 Maximum Tolerance 26 MB 5 Mean ADC Count 130 mean squared variation 122 129 130 Mechanical Installation 12 Mechanical Noise 3 41 Millivolt 121 Millivolt Reading 121 Millivolt Readings 127 Min Percent Field 50 Min Weight Field 50 Minimum Target Weight Tolerance 50 Minimum Tolerance 26 Minute mm Field 54 Mixed Mapping 78 Mode 119 Monitor Page 49 Month mm Field 55 Motion Error 85 Motion Tolerance 117 Motion Tolerance Field 52 Motion Tolerance Parameter 39 Motor Starters 44 Mounting Kit 11 Multi
13. Network includes the network outputs and inputs for Hardy Control Link Control Net DeviceNet Profibus etc which is only a partial list Hardy Control Link Short In Hardy Control Link Int Out DeviceNet Text Out DeviceNet Int In E a E Process Data includes data parameters such as the following 1 Gross Weight 2 Net Weight 3 Totalizer Total Weight 4 Totalizer Cycles Weight Calibration includes calibration parame ters 1 Zero Weight 2 Span Weight 3 Calibration Type Scratchpad which are empty registers you can do whatever you want with The lists above do not include all the parameters For a list of all the parameters and their addresses please see Appendix A Step 11 Back to our example We want to select Fast Fill which is a control parameter Click on the Control pull down menu See Fig 6 7 Step 12 Click on Fast Fill A Select button appears to the right of the Control pull down menu See Fig 6 8 SOURCES Select one or more from below to complete mapping Clear Selections Local DY Inputs or Control or Instrument Active Target Wt Setup Active Num Cycles Active Ingredient Auxiliary Device or Ingredient Setup or Slow Fill Discharge Alarms Fill Complete Refill Change Bags or Network or Process Data or Calibration or FIG 6 7 CONTROL PULL DOWN MENU SELECTING FAST FILL Gear Soloctions Inp er 3 FIG
14. Unmap FIG 6 33 DEVICENET BOOLEAN IN MAPPED TO OUTPUT RELAY 2 Step 12 Now whatever is sent to DeviceNet Boolean In DI2 1 or Devicenet Int In DIO2 from the Net work will be sent to Output Relay 2 Unmapping Step 1 Click and hold your mouse over the Current Map pings and highlight the mapping you want to delete HI 3010 Filler Dispenser IBC 72 Service Manual Current Mappings MD2 HI2 0 HO2 4 HS087 SY Map Unmap FIG 6 34 HIGHLIGHTING CURRENT MAPPING Current Mappings CMD2 H12 0 HO1 0 HFO62 JOMD2 HI2 0 HO1 0 HFOB2 Unmap FIG 6 35 COPY TO THE MAP TEXT FIELD Current Mappings CMD2 HI2 0 Ea Unmap FIG 6 36 REMOVING MAPPING More Advanced Mapping This section is for those who have some or a lot of experi ence Addressing I O mapping or for those who want more information as to how the mapping works locally and on the network We go into much more detail as to how the map ping works and include instructions for Boolean Analog Mixed and Special Command mapping procedures Mapping is similar to Addressing I O s in a PLC except there are no predefined mappings in the HI 3000 Series Instru ments and you are not mapping the physical location of an 1 O module terminal to a bit location in the processor you are actually mapping values or states in memory to another memory location This difference is important to understand and will be explained later in this chapter In order to u
15. 4 82 iaa TH COONCE MONI ZERO TOLERANCE MENU Use Auto Zero OFF OFON Ten 1 IE CRU tow Ltt gt Auto Zero Time 1 005 FIG 4 82 ZERO TOLERANCE MENU AUTO ZERO TIME Step 14 Press the Clear button to clear the current value Step 15 Use the alphanumeric key pad to enter the new time NOTE Step 6 Zero Tolerance should be set if you are going to use the Discharge Function Setting the zero tol erance sets the parameter that indicates when a vessel is empty after discharging a fill Press the down arrow button until the cursor is in front of Use Auto Zero See Fig 4 80 FIG 4 80 ZERO TOLERANCE MENU USE AUTO ZERO Step 16 Step 17 Press the Enter button to set the entry Press the Exit button to return to the SETUP MENU Tare Limit Parameter About the Tare Limit Parameter The Tare Limit Parameter limits the amount of automatic tare Tare is the artificial zeroing of the weight hopper so that a new weight can be displayed Also the action of adjusting out the know weight of the container from the total indicated weight so that the indicator reads net weight directly PARAMETER TARE LIMIT RANGE 000001 999999 DEFAULT 999999 Step 1 Press the down arrow until the cursor is in front of Tare Limit See Fig 4 83 41 CHAPTER 4 Configuration FIG 4 83 SETUP MENU TARE LIMIT Press the Down arrow until the cursor is in front of Averages See Fig 4 84 Step 1 FIG 4 8
16. Channel 4 for future reference 19 CHAPTER 3 Installation NOTE Ifyou have one load point you must plug it into know the type of instrument the SMM was taken Channel 1 If you have more than one load point from you must make sure that you plug one of the load points into Channel 1 CAUTION Do NoT REMOVE AN SMM WITH THE POWER ON ALWAYS DISCONNECT THE POWER CABLE FROM THE Step 6 If you only have 3 load cells do not use Channel 4 INSTRUMENT BEFORE REMOVING OR INSTALLING THE SECURE MEMORY MODULE Installation of Secure Memory Module SMM Step 1 Disconnect the power cable from the Instrument Step 2 Remove the Secure Memory Module from the instrument ONO Step 3 Install the Secure Memory Module into the new wie R instrument E Step 4 Power up the new instrument N a so FIG 3 20 SECURE MEMORY MODULE SMM Step 7 Slide the module with the notch up into the module housing at the rear panel See Fig 3 20 amp 21 FIG 3 21 INSTALLING THE SECURE MEMORY MODULE Step 8 Press the module in until it stops Do not force the module it should slide in easily Step 9 To remove the module pull the module straight out of the housing See Fig 3 21 Transferring a Secure Memory Module NOTE Make sure that when you move an SMM to another instrument that you know what type of instrument that will receive the SMM For exam ple if you accidently place a Dispenser into a pre viou
17. Dispenser e Always follow proper safety procedures when working on or around the Filler Dis penser Error Messages A D Failure Error Internal Electronics Error Retry A D Convert Error Load Cells input out of range Motion Error Check Settings and Retry Trad Cal Error Error occurred during calibration re calibrate C2 Cal Error Error occurred during calibration re calibrate Too Lo Error Verify that the load cell signal level is 0 15 mV Too Hi Error Verify that the load cell signal level is 0 15 mV No C2 Sensor Instrument did not detect a C2 Load Sensor ICAL Failed Not enough counts between Zero and Span List of Alarms Not OK to FILL Alarm e Ifitis NOT OK TO FILL an alarm appears in the display See Fig 7 1 FLOUR ANT 0 00 225 00 INAT ni THE 11 hut DN OTIL ALARTE FILL KLD FIG 7 1 NOT OK TO FILL 1 The Operator needs to determine why itis NOT OK to FILL by checking for problems with the electrical and or mechanical systems 2 Once the problem has been fixed push the Clear button to clear the Alarm The Filler Dispenser begins filling NOTE The OK to Fill Timer has a preset time to deter mine if it is OK to Fill If the OK to Fill times out it means that the preset time is too short for the process and the NOT OK to FILL Alarm appears with no real alarm conditions You may need to reset the timer if it appears that no electrical or mechanica
18. If you turned the Target Proof Switch ON you need to set the Gate Time Double click in the Gate Time field to highlight the value Type in the new Gate Time parameter The Gate Time parameter is the time it takes for a proof switch to detect that a Gate Opened or Closed If the time to open or close exceeds the Gate Time set ting a gate not open or gate not closed alarm appears in the front panel of the instrument and on the Monitor Page of the Web Browser Double click in the Preact field to highlight the cur rent value Type in the new Preact Value To turn on the Smart Auto Preact function click in the ON radio button To set the Jog on Time e Double click in the Jog on Time field e Type in the new time parameter To set the Jog off time e Double click in the Jog off Time field e Type in the new time parameter To set the Jog count e Click on the Jog Count pull down menu See Fig 4 106 Configuration Adjust Ingredient Instrument ID 52 Hardy Filler Ingredient Number 7 Ingredient Name INGREDIENT 7 Number of Fills 1 Target Wt 100 0000 Target Proof Limit OFF Switch ON Jou Gate Time 5 Jog on Time 2 0000 Preact 1 0000 Jog off Time 1 0000 e Smart Auto Preact OFF Jog Count 6 z CoN 1 Enter Parameters 2 3 4 lt gt 5 6 7 8 9 FIG 4 106 SETTING JOG COUNT Step 24 Step 25 e Click on the jog count you want for your process Now that you have set all the parameters on
19. On time In our example we use 1 00 second Step 4 Press the Enter button to set the entry Step 5 Press the down arrow to move the cursor in front of Jog Count See Fig 4 29 QUD MENU UGG Un Hine 1 005 gt das COUNT 5 JOG DFF TRE LODS FIG 4 29 JOG COUNT PARAMETER Step 6 Press the Clear button to clear the previous entry Step 7 Use the right or left arrow button to increase or decrease the Jog Count value Step 8 Press the Enter button to set the entry Step 9 Press the down arrow button to move the cursor in front of Jog Off Time See Fig 4 30 HI 3010 Filler Dispenser IBC 28 Service Manual Ca C2 Kr Ss 23 wr ca Ca wn cy wy K 22 wn V Cc co co C2 c E 5 3 ra cD C3 Ln FIG 4 30 JOG OFF TIME PARAMETER Step 10 Press the Clear button to clear the previous entry Step 11 Use the alphanumeric key pad to enter the new Jog Off time In our example we used 1 00 second Step 12 Press the Enter button to set the entry Step 13 Press the Exit button to return to the Adjust Ingredi ent 1 Menu Fill Dispense Time Parameter About Fill Dispense Timer The Fill Dispense Timer sets the time limit allowed to com plete one cycle To turn off the timer set the Timer to 0 PARAMETER FILL TIMER RANGE 0 999 DEFAULT 120 SECONDS Step 1 Press the down arrow button until the cursor is in front of Fill Timer See Fig 4 31 Jos gt gt FILL TIMER cus WAIT Timer 4 00
20. RANGE DUAL SINGLE SPEED DEFAULT SINGLE Step 1 Press the down arrow button until the cursor is in front of Speed See Fig 4 33 FILL TIMER tgs WAIT TIRER H De gt Speen SINGLE gt FIG 4 33 SPEED PARAMETER Step 2 Press the right or left arrow button to toggle between Dual Speed and Single Speed e Ifyou select Single Speed press the Enter button The Discharge Time Menu appears See Fig 4 34 gt Proce Suitcs OFF lt S WITCH TIME 55 FIG 4 34 FILL PROOF MENU 1 Press the right or left arrow buttons to toggle between OFF and ON 2 Press the Enter button to set the entry 3 Press the down arrow until the cursor 1s in front of Switch time 4 Use the right or left arrow buttons to increase or decrease the Switch Time In our example we used 5 seconds The Switch Time is the time set to sense that a switch gate valve is open Press the Enter button to set the entry 6 Press Exit to return the Adjust Ingre dient 1 Menu EN e Ifyou select Dual Speed press the enter button The Dual Speed Filler Dispenser Menu appears See Fig 4 35 DUAL SPEED FILLER gt FRST WEIGHT 0 00 Auro Fast Age ON Mane SEQUENTIAL FIG 4 35 DUAL SPEED FILLER MENU 1 Fast Weight Press the right or left arrow to increase or decrease the weight 2 Press the down arrow until the cursor is in front of Auto Fast Adj Press the right or left arrow buttons to toggle between ON and OFF
21. See Fig 4 25 FIG 4 25 TARGET WINDOW PERCENTAGE NOTE Ifyou set the Target Weight parameter in weight when you view the settings in percentage the set weight is automatically converted to the correct percentage and vice versa Step 8 Press the Enter button to set the entry Step 9 Press the down arrow button so the cursor is in front of Target Min See Fig 4 24 Step 10 Press the Clear button to clear the entry Use the alphanumeric key pad to enter the new Max toler ance value either in weight or percentage See Fig 4 25 Step 11 Press the Enter button to set the entry Step 12 Press the Exit button to return to the Adjust Ingredi ent 1 Menu The cursor should be in front of JOG If it is not press the up or down arrow until the cursor is in front of JOG See Fig 4 26 DUST INGREDIENT TARGET WINBOU lun gt gt Jos gt FILL THER us FIG 4 26 ADJUST INGREDIENT 1 JOG Jog Parameters About Jog Parameters The Jog is used when a cycle underfills At the end of a cycle the system waits to determine the status of a fill dispense If there is an underfill i e the fill is below the Target Win dow the system waits and then the jog is turned on The Filler Dispenser jogs for a preset period of time for a preset number of cycles until the fill dispense is within the Target Window If at the end of the jog counts the weight is still not within the Target Window you have the option to go through
22. Serial Number 10 Main board A D Converter C OFF ON Channel 2 Converter OFF ON Channel 3 Converter OFF ON Channel 4 Converter OFF ON Save Parameters FIG 4 132 SMART DIAGNOSTIC CARD CONFIGURATION To enable the channels you want to use in your pro cess click on the radio buttons next to ON See Fig 132 In our illustration we have actuated all 4 channels To disable the channels click on the radio buttons next to OFF See Fig 132 Click on the Save Parameters button to save the configuration To use the Smart Diagnostics Option for trouble shooting a Filling Dispensing IBC system go to Chapter 7 Troubleshooting Using Smart Diag nostics from the Front Panel 57 CHAPTER5 Calibration CHAPTER 5 CALIBRATION About Chapter 5 Chapter 5 pertains to the calibration procedures for the HI 3010 Filler Dispenser Alternatives to any procedures implied or explicitly contained in this chapter are not recom mended In order for the Filler Dispenser to work properly it must be calibrated prior to operation Be sure to follow all the procedures completely to insure that the weights read by the Filler Dispenser are accurate It is very important that the user and service personnel be familiar with the procedures contained in this chapter before installing or operating the HI 3010 Filler Dispenser Getting Started The HI 3010 Filler Dispenser can be calibrated two ways The first is the Hardy
23. Step 12 Press the left or right arrow button to select the Refill Switch time Step 13 Press the Enter button to set the entry Step 14 Press the down arrow button to move the cursor in front of Refill Wt See Fig 4 62 REALL MNU Ref il Swiiner 5s 1000 00 gt Refill W Rgill tiner 60s FIG 4 62 REFILL MENU SETTING REFILL WEIGHT Step 15 Press the Clear button to clear the entry Use the Alphanumeric keypad to enter the new Refill Weight Step 16 Press the Enter button to set the entry Step 17 Press the Down arrow to move the cursor in front of Refill Timer See Fig 4 63 REFILL MNU Ref il Swiiner 5s 1000 00 Ref il W gt Refill Tre 60s FIG 4 63 REFILL MENU SETTING REFILL TIMER Step 18 Press the right or left arrow button to increase or decrease the Refill time Step 19 Press the Enter button to set the entry Step 20 Press the Exit to return to the Main Menu Serial Port Parameters About the Serial Port Setup Parameters The Serial Port Parameters are set to operate the Printer which can print out the status of a fill dispense The Printer prints e Date and time of the Fill Dispense e Instrument ID e Ingredient ID s Each Amount Required Number of Fills Dispenses Requested e User ID e Time each fill began e Amount Requested per fill dispense cycle e Actual amount received per fill dispense cycle e Alarms that occurred and times e Acceptance or Rejection of a fill disp
24. The Destination is Output Relay 1 a State value that is located in the Output Image Table at Address HOO 0 The source is the Fast Fill value that is stored in the Fast Fill memory address HB 1 in the Input Image Table Do not confuse the value with the address So now you have a Destination Address to which you can assign the Source value My Assignment Statement is HO0 0 HI2 1 Output Relay Fast Fill HI 3010 Output Image Output To Actuator i Table o Y A output Relay 1 O 3 Desired State 1 2 O 3 3 O 4 Input Input image Y E Table Fast Fill H12 1 Q 2 value 1 NE HOO O HI2 1 Local Mapping HI 3010 FIG 6 39 MAPPING THE FAST FILL TO OUTPUT RELAY 1 As the instrument scans the Input Image Table it sees the new state value close 1 for the Fast Fill which was set by the instrument s firmware It takes the new state value 1 and sends it to the Output Relay 1 address on the Output Image Table and sets the desired state for the relay to 1 which simultaneously closes the relay that opens the actuator for a valve to begin a Fast Fill Network Input PLC s also have Input Image Tables and Output Image Tables The HI 3010 is a node in a total network and you assign the HI 3010 Filler Dispenser a node address so the Network scanner can identify the instrument WARNING You CANNOT ASSIGN THE SAME ADDRESS TO TWO DIFFERENT NODES THE PL
25. Valid addresses thus range from 0 0 0 0 to 255 255 255 255 a total of about 4 3 billion addresses It is recommended that you leave the Mask Gate and DNS settings alone Contact your Network Administrator if you need to set these parameters PARAMETER ETHERNET RANGE 0 0 0 0 255 255 255 255 DEFAULT 192 168 110 1 Press the Down arrow button until the cursor is in front of Ethernet See Fig 4 94 Step 1 FIG 4 94 SETUP MENU ETHERNET Step 2 Press the Enter button The Ethernet Menu appears with the cursor in front of the IP Address See Fig 4 95 DATE 192 168 1101 FIG 4 95 ETHERNET MENU IP ADDRESS WITH DEFAULT IP ADDRESS Step 3 Press the Clear button to clear the address NOTE Figure 4 96 has the Default IP address You must change this address when starting the instrument for the first time Step 4 Use the alphanumeric key pad to enter the new address Remember there must be a period between each port of the address e g 186 245 263 12 Step 5 This is the only parameter you need to change If you need to change the other parameters contact your Network Administrator for assistance Step 6 Press the Enter button to set the entry Step 7 Press the Exit button to return to the SETUP MENU Step 8 Press the Exit button to return to the Standby Dis play This Completes the Configuration of the Instrument from the Front Panel Configuring the Filler Dispenser from the Web Browser
26. Weight and mV V for the units selected i e lbs kg oz g Checking the Device Data List The Device Data List is a list of all the parameters that were set for the ingredient you are currently using and the instru ment parameters that have been set for this instrument Step 1 From the Standby Display press the Test 9 button The Test and Data Menu appears with the cursor in front of Device Data List See Fig 7 48 FIG 7 48 TEST AND DATA MENU SELECTING DEVICE DATA LIST Step 2 Press the Enter button The Device Data List Dis play appears with the cursor in front of Instrument ID See Fig 7 49 TEST DATA gt IL HARDY FILLER MODEL HI 3010 FIG 7 49 TEST DATA DISPLA Y INSTRUMENT ID MODEL NUMBER S N Step 3 Here you can view the Instrument ID Model Num ber and Instrument Serial Number of the instru ment This is a read only display To change any of the parameters you will have to go to the Setup Menu Instrument ID Press the down arrow button until the next three parameters appears See Fig 7 50 FIG 7 50 TEST DATA DISPLAY PROGRAM VER SION LAST CAL TYPE Step 5 These are read only displays The information is important e PP lt Program Part Number This is the part number of the firmware To order additional copies of the firmware you will need this number This is also additional information available to a service techni cian for troubleshooting e Often a technician needs
27. e 0 120mV V LVDT Type Load Sensors e 120mV V LVDT Type Load Sensors Step 4 Press the down arrow until the cursor is in front of Sensor Type Step 5 If the Sensor Type reads anything other than 0 3mV V use the left or right arrow to select 0 3mV V Step 6 Press the down arrow until the cursor is in front of Cal Type See Fig 5 4 Step 7 If TRAD is visible press the right or left arrow until C2 appears CALIBRATION Sensor Type 0 3nV V1 C2 gt gt Cal Type FIG 5 4 CALIBRATION SELECTING CAL TYPE Step 8 Press the Enter button The C2 CAL Sub menu appears See Fig 5 5 HI 3010 Filler Dispenser IBC 58 Service Manual C2 CAL gt Load Sensor s Ref Point G avity FIG 5 5 C2 CALIBRATION SUB MENU Step 9 The Load Sensor number is a read only field It tells you how many load sensors are connected to the instrument Step 10 Press the down arrow button to move the cursor in front of the Ref Point See Fig 5 6 a The Reference Point is the total live load that is currently on the scale b If you have nothing on the scale the Ref Point is O If you have 5 lbs live load on the scale the Ref Point is 5 NOTE Normally the scale system is clean and ready to receive product This step establishes the gross zero reference C2 CAL Load Sensor s gt Ref Point G avity FIG 5 6 ENTERING THE REFERENCE POINT Step 11 Press the Clr Clear button to clear the entry Step 12 Use the
28. of nominal drop out When the solid state relay is off there will still be 1 3 of the line voltages across the relay so 1t will not drop out For the relay to have 5 of the line across it it and a parallel shunt resistor must be 20 times less resistance than the 30K snubbing network or 1 5K ohms Use less than a 1 67K ohm parallel resistor and now total load is below 1 5K ohm or 80mA General Policies and Information With over 70 years of industrial weighing experience and products in the field Hardy Instruments continues to design manufacture install and support Hardy products worldwide The following paragraphs describe Hardy s customer support services and equipment warranty NOTE Before returning any product to Hardy Instru ments call the Technical Service Department listed below for a Return Authorization Number Have your company name address telephone equipment model number S N and a brief description of the problem ready to give to him In addition please have Appendix A completed and ready to FAX to us before calling FOR FURTHER INFORMATION CONTACT Technical Service Manager Hardy Instruments Inc 9440 Carroll Park Drive Suite 150 San Diego CA 92121 Telephone 858 278 2900 FAX 858 278 6700 Web Site http www hardyinst com E Mail hardysupport hardyinst com Ordering Replacement Parts Contact the Hardy Instruments Sales Department to order replacement parts and option boards Have your equ
29. using the Smart Diagnostics and SD summing card A load sensor output can be considered stable if the readings only vary 0 01mV Applying weight and releasing the weight should show a very rapid Millivolt change A slow Millivolt change can indicate a damaged strain guage Inspect the summing junction box for contamination or damage and replace if necessary Insure the C2 wires are correctly terminated even if you do not have C2 load sensors The IT communications and testing is conducted over the C2 lines Insure the problem is not mechanical Review Section B Remove and replace any load sensor determined to be unstable 103 CHAPTER 7 Troubleshooting E Non Return to Zero Enter Diagnostics Return to ZERO Activate the test and review the results Verify the individual load cell signal outputs The Return to Zero Test is used to determine whether the instrument can still zero a scale based on preset parameters If you pass the Return to Zero Test you are within the sum of the preset Motion and Zero Tolerance settings If you fail you are outside the sum of the preset Motion and Zero Tolerance settings If you fail the test there may be too much build up on the scale and you need to clean the scale or you have scale problems You should do this test whenever you cannot zero the scale The zero tolerance level set in configuration has been exceeded Clean any material from th
30. 000001 999999 003C Refill Duration Timer 0 999 003D Auto Tare time 5 0000 0200 Reference Weight 0 000001 999999 Read Only TABLE 6 2 PARAMETER NUMBER CODE EXPLANATION AND VALID RANGES TABLE 6 2 PARAMETER NUMBER CODE EXPLANATION AND VALID RANGES HI 3010 Filler Dispenser IBC Service Manual 80 Parameter Suffix Code Explanation Valid Range Number Code Explanation Valid Range Hexadecimal pp02 Total 0000001 999999 0201 Span Weight 0 000001 999999 pp03 Cycles 0 9999 Read Only Current Count Read Only 0204 Cal Type 0 C2 A 1 Traditional pp04 Fills 0 9999 Hard Calibration Fill Cycles Menu Read Onl Y pp05 Speed 0 Single 0280 Serial Number 14 Read Only 1 Dual 0281 Model Number HI 3010 pp06 Target Weight 0 000001 999999 Read Only pp07 Preact 0 0000001 999999 0282 Program Part Num 0650 0xxx 01 b Read Onl pp08 Auto Preact 1 YES er Read Only 0 NO 0283 Firmware Revision 1 X XX ae Me Read Only pp09 Target Min Max 0 Weight 1 Percentage 02F0 NO Assignment HFO0 HF12 E Statements Defined DFO0 HF13 PpOA Max Weight 0 000000 999999 HOO 0 HI2 1 c y 0B Min Weight 0 000000 999999 Read Only PP pela ppO0C Max 0 00000 99 9 TABLE 6 2 PARAMETER NUMBER CODE EXPLANATION AND VALID RANGES ppOD Min 0 00000 99 9 Ingredients 1 12 are duplicates and are addressed and for BRE vou ON ume 0 99
31. 12 DEFAULT 8 Press the Down arrow button until the cursor is in front of Set Clock See Fig 4 87 Step 1 76 y ta 20 4 El IZ FIG 4 87 SETUP MENU SET CLOCK Step 2 Press the Enter button The Clock Setup Menu appears with the cursor in front of Set Hours See Fig 4 88 un ar E c2 53 FIG 4 88 CLOCK SETUP MENU SET HOURS Step 3 Press the right or left arrow buttons to change the Hours setting Step 4 Press the Enter button to set the entry Step 5 Press the Down arrow button until the cursor is in front of Set Minutes Step 6 Press the right or left arrow buttons to change the Minutes setting Step 7 Press the Enter button to set the entry Step 8 Press the Down arrow button until the cursor is in front of Set Month See Fig 4 89 43 CHAPTER 4 Configuration FIG 4 89 CLOCK SETUP MENU SET MONTH Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 Step 16 Step 17 Press the right or left arrow buttons to change the Month setting Press the Enter button to set the entry Press the Down arrow button until the cursor is in front of Set Day Press the right or left arrow buttons to change the Day setting Press the Enter button to set the entry Press the Down arrow button until the cursor is in front of Set Year Press the right or left arrow buttons to change the Year setting Press the Enter button to set the entry Press the Down
32. 122 128 Choose Display Screen 121 Choose Instrument Display 123 Clear Button 21 22 86 Clogged Gate Alarm 94 Closed Containers 11 85 Common Mode Rejection 8 Common Mode Voltage Range 8 Compression Gasket 12 Configuration Menu 23 55 61 Configuration Options Page 55 Configuration Page 50 55 63 Configuration Smart Diagnostics Card 56 Configuring Ingredients from the Browser 47 Configuring Ingredients from the Front Panel 24 Configuring the Filler Dispenser from the Web Browser 46 Confirmation Page 127 Connectivity 3 Connector 11 85 Control of the Rack_Size and Starting_Quarter Combi nations 9 Control Output 81 Controllable Inputs 81 Controlled Static Environment 11 85 Core Technologies 57 Corrective Action 60 Current Cycle 22 Current Fill Dispense 22 Cut Off Frequencies 42 Cycle 7 PQRS Button 23 D Data Bits 36 Data Bits Pull Down Menu 54 Data Menu 127 Daughter Card 4 Day dd Field 54 DCS 2 Decimal Point Parameter 38 Decimal Point Pull Down Menu 51 Defaults Display 123 Device Data List 114 DeviceNet 7 Devicenet Address 120 DeviceNet Input and Output Tables 77 Index DeviceNet Input Table 75 79 DeviceNet Interface 3 DeviceNet Network 44 DeviceNet Output Table 79 DeviceNet Parameters 44 DeviceNet Tables 78 Diagnostic Menus 114 Diagnostics 114 120 126 127 130 Diagnostics Display 121 127 Diagnostics Menus 114 Diagnostics Page 126 Dimensions of the Panel Cutout 12 Disass
33. 3 Press the down arrow until the cursor is in front of Mode Press the right or left arrow buttons to toggle between Sequential or Simultaneous 4 Press the down arrow until the cursor is in front of Fill Proof Menu See Fig 4 36 DUAL SPEED FILLER Auro Fast Abe DN Moce SINULIANECUS gt FILL Proof Menu gt FIG 4 36 DUAL SPEED FILLER FILL PROOF MENU 5 Press the Enter button the Fill Proof Menu appears See Fig 4 37 l L gt Fast SUITOR OFF Stow SWITCH OFF FAST SUITCH TAR 55 FIG 4 37 FILL PROOF MENU 6 Set the Fast Switch Press the right or left arrow buttons to toggle between OFF and ON 7 Press the down arrow until the cursor 1s in front of Slow Switch 8 Set the Slow Switch Press the right or left arrow buttons to toggle between OFF and ON 9 Press the down arrow until the cursor is in front of Fast Switch Tmr Timer 10 Press the right or left arrow buttons to increase or decrease the Fast Switch Timer This is the time you want the Fast Switch to remain on 11 Press the Enter button to set the entry 12 Press the down arrow until the cursor is in front of Slow Switch Tmr Timer See Fig 4 38 FILL PROUP MENU gt Siow SUITCH DFF FAST SWITCH TAR 55 Stow SWITCH TAR Ss FIG 4 38 FILL PROOF MENU 13 Press the right or left arrow buttons to increase or decrease the Slow Switch Timer This is the time you want the Slow Switch to remain on HI 3010 Filler
34. All connectors securely fastened All the functions of the Filler Dispenser operate the same no matter what the interface First let s get familiar with configuring the Filler Dispenser from the front panel of the instrument See Fig 4 1 Help Dialog About the Help Dialog As you move through the setup configuration menus you may on occasion need assistance If you need help do the following Step 1 Use the up and down arrows and move the cursor in front of the Menu Item you want help on Step 2 Press the Help button either on the front Panel and a Help Dialog appears The Help Dialog tells you what the Menu Item is used for or other descriptive information to help you enter the right parameters for the current menu item Step 3 Push the clear button again to return to the current menu Configuring the Filler Dispenser from the Front Panel ER AS FIG 4 1 FRONT PANEL Front Panel Display The Front Panel Display is a 4 line x 20 Alphanumeric char acter LCD The screen displays all the menus for Configur ing Calibrating and Operating the HI 3010 Filler Dispenser Button Functions Start Button The Stop button if pressed once will pause the filling or dis pensing process If the Stop Button is pressed twice 1t stops the process and puts the Filler Dispenser in a standby mode which it will maintain until another button is pressed H
35. C2 Second Generation calibration which requires no test weights Hardy C2 Calibration is one of the Core Technologies We will describe the C2 Cali bration process in this chapter The second calibration tech nique is called the traditional calibration which requires certified test weights It is important to note that the proce dures contained in this section either explicitly stated or implied should be followed to guarantee the performance of the instrument Alternatives to the procedures listed here are not recommended Before you can calibrate the instrument you first need to check to see if the system is ready to be calibrated Binding Due a visual check to see if the load cells have been installed so that nothing is binding the load cell or other parts of the weighing system Make sure that nothing is draped over the scale or vessel such as a hose electrical cord tubes or other objects Step 1 CAUTION BINDING ON A SCALE VESSEL OR LOAD CELL DOES NOT ALLOW THE LOAD CELL FREE VERTICAL MOVE MENT AND MAY PREVENT THE INSTRUMENT FROM RETURN ING TO THE ORIGINAL ZERO REFERENCE POINT Step 2 Check to see that the load cell is mounted so that 100 of the load Vessel with Contents vertically passes through the load cell See Fig 5 1 Direction of the applied load Vessel z wA COF NE B T ro ED S QS Do 6
36. Dispenser IBC 30 Service Manual 14 Press the Enter button to set the entry 15 Press the Exit button to return to the Dual Speed Filler Menu 16 Press the Exit button to return to the Adjust Ingredient 1 Menu See Fig 4 39 l UST INGREDIENT gt FLOUR INGREDIENT O INGREDIENT J FIG 4 39 ADJUST INGREDIENT INGREDIENT 1 SET TO FLOUR Step 3 If this is the only ingredient you are configuring press the Exit button to return to the Configuration Menu Step 4 If there are more ingredients used in this process or you want to set up ingredients for other processes press the down arrow until the cursor is in front of Ingredient 2 See Fig 40 ADULT INGREDIENT Es con CLOUR Iurocnicar 2 gt INGREDIENT C lurmeni car I PAR Id 2 FIG 4 40 SETTING PARAMETERS FOR INGREDIENT 2 Step 5 Press the Enter button and repeat the configuration process until you have configured all the ingredi ents you want for your process es You can set up to 12 ingredients Instrument Configuration The Instrument Configuration process sets up the instrument to operate as a scale and the setup for the operating parame ters required for your filling dispensing process This includes setting WAVERSAVER Scale Capacity Units of Measure Motion tolerance and other instrument parameters required for your Filling Dispensing process Here is where the permanent parameters are entered All the parameters configured except t
37. EET Eastern Europe 3 BT Baghdad Kuwait Nairobi Kenya Riyadh Saudi Arabia Moscow Russia 3 30 Tehran Iran 4 Abu Dhabi UAE Muscat Tblisi Volgograd Kabul 4 30 Afghanistan 5 5 30 India 6 6 30 Cocos Islands 7 8 CCT China Coast Shanghai China Hong Kong China Beijing China 9 JST Japan Standard Tokyo Japan Osaka Japan Taipei Taiwan 9 30 Darwin Australia Adelaide Australia Australian Central Standard 10 GST Guam Standard 10 30 Lord Howe Island 11 11 30 Norfolk Island TABLE 4 2 GREENWICH TIME ZONES GMT GMT Civilian Time Zones Cities 12 IDLE International Date Line Wellington NZ East Fiji NZST New Zealand Standard Marshall Islands 13 Rawaki Island 14 Line Islands WEST OF GREENWICH 1 WAT West Africa Azores Cape Verde Islands 2 AT Azores 3 Brasilia Brazil Buenos Aires Argentina Georgetown Guyana 3 30 Newfoundland 4 AST Atlantic Standard Caracas Venezuela La Paz 5 EST Eastern Standard Bogota Colombia Lima Peru New York NY USA 6 CST Central Standard Chicago Illinois USA Mexico City Mexico Saskatchewan Canada 7 MST Mountain Standard Phoenix Arizona Denver Colorado 8 Pacific Standard Seattle Washington Portland Oregon San Francisco CA 9 YST Yukon Standard 10 AHST Alaska Hawaii Standard CAT C
38. Excitation Monitor Current less than 10 Power and Utility Requirements Voltage Universal Power Supply 50 60 Hz e 120 240 VAC 10 e 12 24 VDC Frequency e 47 63 Hz Power e 10 Watts maximum with options Watts available for DeviceNet Power e 15 Watts Common Mode Voltage Range e 2 5 VDC Common Mode Rejection e 100dB 50 60Hz Environmental Requirements Operating Temperature Range e 10 to 50 C 14 to 122 F Storage Temperature Range e 20 to70 C 4 to 158 E Temperature Coefficient e Less than 0 005 of full scale per degree C for zero and span Humidity Range N 0 90 non condensing Approvals CE e UL e CUL Instrument Local I O e 5 mappable inputs optically isolated e 4 mappable outputs 48 240 VAC Form A Electronic e 3rd party mappable over DeviceNet Physical Characteristics Panel Mount Model HI 3010 PM Depth e 8 03 203 96mm Back of the Bezel to rear cable clearance HI 3010 Filler Dispenser IBC 8 Service Manual Case Dimensions 6 125 H x 8 56 W x 6 03 D 155 57mmH x 217 42mmW x 1 53 16mmD Front Panel Dimensions e 7 686 H x 9 40 W x 0 625 D 195 22mm H x 247 39mm W x 15 87mmD Panel Cutout Dimensions e 6 75 H x 8 94 W 1775mm H x 227mm W Case Material e GE Cycolac Type KJW Flame Retardant ABS Acrylanitrile Butadiene Styrene Weight e 4 6 pounds 2 1 Kilograms Rating Front Panel NEMA 4 Seal Wall Mount HI 3010 MB Bas
39. FIELD 73 REMOVING MAPPING 73 INPUT FUNCTION 74 OUTPUT FUNCTION 74 MAPPING THE FAST FILL TO OUTPUT RELAY 1 75 DEVICENET OUTPUT 76 DEVICENET OUTPUT 76 HARDY CONTROL LINK NETWORK MAPPING 77 CONFIGURATION MENU I O MAPPING 81 BASIC I O MAPPING OK TO FILL SELECTION 81 OK TO FILL MENU ITEM NOT MAPPED 81 ITEM SELECTION MENU NOT MAPPED SELECTED 81 ITEM SELECTION MENU INPUT 1 SELECTED 81 OK TO FILL MENU INPUT 1 MAPPED 82 OK TO FILL SOURCE MAPPED 82 OK TO FILL MAP INDICATION 82 OK TO FILL MENU INPUT 1 MAPPED 82 HI 3010 Filler Dispenser IBC VI Service Manual FIG 6 52 ITEM SELECTION SELECTING NOT MAPPED 82 FIG 6 53 OK TO FILL MENU ITEM UNMAPPED 82 FIG 6 54 BASIC I O MAPPING OK TO FILL UNMAPPED 82 FIG 6 55 HARDY CONTROL LINK NETWORK CONNECTED TO A CONTROLNET DEVICENET PROFIBUS NETWORK 83 Chapter 7 Troubleshooting 85 FIG 7 1 NOTOKTOFILL 85 FIG 7 2 LOST OK TO FILL ALARM FAST FILL 86 FIG 7 3 LOST OK TO FILL ALARM SLOW FILL 86 FIG 7 4 FAST FILL GATE DID NOT OPEN ALARM 86 F
40. FIG 4 100 EDIT INGREDIENT PULL DOWN MENU Configuration Adjust Ingredient Instrument ID Hardy Filler Ingredient Number 8 Ingredient Name INGREDIENT 7 Number of Fills fi Target Wt 100 00 Target Proof Limit OFF Switch Con T Gate Time 5 Jog on Time 2 0000 Preact jooo Jog off Time 1 0000 OFF Smart Auto Preact Jog Count by k E Enter Parameters lt gt FIG 4 101 CONFIGURATION ADJUST INGREDIENT Step 6 Lets stop a moment and look at this page See Fig 4 101 You see the Instrument ID in the upper left hand corner of the graphic The Hardy Filler tells us that the instrument is a filler If it was a Dis penser it would say Hardy Dispenser or if it was an IBC Dispenser it would say Hardy IBC Dis penser The Browser gets this information from See Fig 4 101 Step 7 each instrument You also see two arrows towards the bottom of the page These are navigation arrows To go forward click on the right arrow To go back click on the left arrow You also see Ingredient Number 7 which we selected in the previous web page You can con tinue with this ingredient number or you can change to another ingredient by clicking on the pull down menu and selecting another ingredient number Changing the Ingredient Name Click in the Ingredient Name field Click and hold the left button down while moving the cursor over the Ingredient name so that the Ingredient name is completely highlighte
41. Fig 6 17 Ingredient C0 Setup or Alarms excu El Network _ Select FIG 6 17 ALARMS SELECTING OVERFILL ALARM Step 5 Click on the Alarms pull down menu Select Over fill See Fig 6 17 Click on the Select button to the right of the Alarms pull down menu See Fig 6 17 The Overfill Alarm address appears in the Assignment State ment to the right of the equals sign which means it is a Source See Fig 6 18 Step 6 Current Mappings HOO 1 HI2 2 HO0 2 H12 3 HOO 3 HI2 15 HO1 5 HI0 1 DIO2 HFIO RSO1 HFIO HOO 0 HI2 1 HO1 4 HI0 3 HO0 2 H13 13 Unmap Operators Equals The equates a single Destination with one or more Sources And The Provides the Boolean AND or the Analog TIMES Operatc or The Provides the Boolean OR or the Analog PLUS Operator bi Not The Provides the Boolean NOT or the Analog MINUS Operatc Comma The is used to concatenate mapping equations Mapping Symbols Click here to view a list of mapping symbols Click here for an expanded map FIG 6 18 OVERFILL ALARM HI3 13 ENTERED IN THE MAPPING ASSIGNMENT STATEMENT Step 7 To add another Source to the Assignment Statement and make it a Boolean or Statement click on the Or button below the Assignment Statement A plus sign appears to the right of the Overfill Address See Fig 6 19 HO0 2 HI3 13 Map Unmap Operators Equals The equates a single Destination with one or mor
42. Go to K load sharing TEST COMPLETE or Contact Technical Support 105 CHAPTER 7 Troubleshooting F a Verify Individual Load Cell Readings Using Smart Diagnostics SMART DIAGNOSTICS is a built in system diagnostics utility that enables the operator to rapidly troubleshoot a weighing system from the front panel RI PDA or Web Browser of the HI 3030 Used with an HI Voltage amp SD card you can read each individual load cell in mV Weight mV Y and weight to determine if a load sensor is malfunctioning or not connected Read and record each load cell s Activate the Signal output test and review the results All signal levels fall within the 0 to 15mV range Millivolt reading is The Millivolt range is slow or 0 0 mV It outside the may be a negative 0 to 15 mV range reading Use a multi meter to confirm Check Wiring Replace the load cell if the unit signal readings are out of tolerance Apply weight and insure all signal voltages increased the same amount Check for mechanical reasons or replace load cell G A D Failure Error HI 3010 Filler Dispenser IBC Service Manual There are two places during Traditional Cal where an error can occur ZERO and SPAN Traditional Calibration AID Failure Error The difference between zero and span is less than 100 counts ZERO Y The new Zero Reference ZRCNT is larger than the original Span FSCNT 1 At
43. HELO HO0 0 dump 0 Sources Page C ek here for an expanded map 4 gt FIG 6 5 OUTPUT RELAY 1 ADDRESS HO0 0 Step 8 You have now selected the Destination Step 9 Click on the Jump to Sources Page button to select the Source you want for this destination See Fig 6 5 The Configuration Mapping Setup 2 page appears See Fig 6 6 aen lE oo Ear L a S g o RE meae C X Seok ee riin Brar tan Configuration Mapping Setup 2 arra 4 gt INSTRUMENT Mardy Filer Panan ts Cwemancrs Pugo dre pinang a FIG 6 6 CONFIGURATION MAPPING SETUP 2 Step 10 Let s take a moment to look at this page e Local Inputs include the 5 input contact closures provided by the HI 3010 e Control includes the following which is only a partial list 1 Slow Fill 2 Fast Fill 3 Refill 4 Discharge e Instrument Setup includes parameters for setting up the instrument itself and includes the following which is only a par tial list 1 Zero Tolerance 2 Auto Zero Tolerance 3 Waversaver 4 Tare Limit Value Ingredient Setup include parameters for setting up the ingredients to fill or dis charge and includes the following which is only a partial list 1 Auto Preact On 2 Fills 3 Fill Time 4 Slow Gate Time Alarms includes all the alarms for filling and discharging and includes the following which is only a partial list 1 Motion 2 Lost OK to Fill 3 ADC Error 4 Lost OK to Dispense
44. INSTRUMENT 15 FIG 3 13 MAIN CONTROLLER BOARD INSTALLED WITH REAR PLATE 16 FIG 3 14 REAR PLATE FASTENERS 16 FIG 3 15 STANDOFF LOCATIONS 16 FIG 3 16 POWER WIRING DIAGRAM 17 FIG 3 17 DC POWER SUPPLY CONNECTION 18 FIG 3 18 REAR PANEL LOAD POINT CONNECTIONS 18 FIG 3 19 JUNCTION BOX CONNECTIONS 18 FIG 3 20 SECURE MEMORY MODULE SMM 19 FIG 3 21 INSTALLING THE SECURE MEMORY MODULE 19 Configuration 21 FIG 4 1 FRONT PANEL 21 FIG 4 2 PRINT SCREEN DEFAULT 22 FIG 4 3 DIRECTIONAL BUTTONS 22 FIG 4 4 LIST SELECTION ENTER BUTTON 22 FIG 4 5 WELCOME DISPLAY 23 FIG 4 6 INSTRUMENT SELECTION SCREEN WITH FILLER SELECTED DEFAULT 23 FIG 4 7 PROMPT CONFIRMING SELECTION 23 FIG 4 8 STANDBY DISPLAY 23 FIG 4 9 CONFIGURATION MENU ADJUST INGREDIENT 24 FIG 4 10 ADJUST INGREDIENT SUB MENU INGREDIENT 1 24 FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FI
45. Ing 1 Button 22 2 ABC Button 22 Setup 3 DEF Button 23 Amount 4 GHI 23 Units 5 JKL Button 23 6 MNO Button 23 Cycle 7 PQRS Button 23 8 TUV Button 23 Test 9 WXYZ Button 23 User _ blank Button 23 O amp P Button 23 Selecting Configuration Menus 23 Configuring Ingredients from the Front Panel 24 About Configuring Ingredients 24 Ingredient Name Parameter 24 Fill Cycles 25 About Fill Dispense Cycles 25 Target Weight 25 About Target Weight 25 Target Preact e 25 About Target Preact 25 About Smart Preact 25 Target Window 26 About Target Window 26 Jog Parameters 27 11 ili Table of Contents About Jog Parameters 27 Fill Dispense Time Parameter 28 About Fill Dispense Timer
46. Point should be 0 000 a The Reference Point is the total weight that is currently on the scale b If you have nothing on the scale the Ref Point is 0 If you have 5 Ibs on the scale the Ref Point is 5 To clear the entry move the cursor over the current reference weight which highlights the weight value Use your keyboard to type in the new value In our example we entered 3 00 See Fig 5 15 If you do not want to enter a Gravity Correction Factor go on to Step 14 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 Step 16 Step 17 Step 18 To enter the Gravity Correction Factor get the fac tor value from the Gravity Correction Factors table on pages 58 and 59 Double click in the Gravity Correction Factor field See Fig 5 14 Type in the value In our example we entered 1 002102 which is the Gravity Correction Factor for Mexico City Enter the value you selected from the table Click on the Do C2 Calibration button A page telling you that the C2 Calibration com pleted OK appears See Fig 5 15 Cal completed OK Back FIG 5 16 CAL COMPLETED OK Click on Back to return to the Calibration page Click on Home to return to the Filler Dispenser Home page C2 calibration is complete Traditional Calibration From the Front Panel About Traditional Calibration Traditional Calibration is the method of calibration that uses test weights We recommend that the test weig
47. RTI RTO RIO Allen Bradley Remote I O tables Used if you have an RIO option card The RIO table is 64 words long of which the first 32 are mapped to and from the network The rest is used as a scratchpad area for short commands NOTE The block transfer area immediately follows dis crete area and depends on rack size selected RI RO RIO input output addressed as bits RFI RFO RIO input output addressed as floats RSI RSO RIO input output addressed as 16 bit integers RII RIO RIO input output addressed as 32 bit integers RTI RTO RIO input output addressed as text Cl CO CFI CFO CSI CSO Cll ClO CTI CTO Communications Network tables Used if you have a Communications option card The Communications Input table is 125 words long The Communications Output table is 127 words long but the first two words are reserved if ControlNet otherwise 125 words long CI CO Communications Network input output addressed as bits CFI CFO Communications Network input output addressed as floats CSI CSO Communications Network input output addressed as 16 bit integers CII CIO Communications Network input output addressed as 32 bit integers CTI CTO Communications Network input output addressed as text HI 3010 Weight Controller 138 Service Manual Index Symbols Clean Primary Line 17 Scale Capacity 116 Numerics O amp Button 23 1 to 1 Configuration 81 10 1
48. Rate 3600 lt Patity NONE gt Data Bits eea Le EMEN 4 gt FIG 4 121 PRINTER PORT SETUP PARITY HI 3010 Filler Dispenser IBC 54 Service Manual Step 5 To select the Data Bits e Click on the Data Bits pull down menu See Fig 4 122 e Click on the Data Bits you want for your process Configuration Instrument Setup Filler Enter parameters for the fields below Printer Port Auto Print OFF E Baud Rate asoo E Parity NONE E Data Bits 7 E 4 gt FIG 4 122 PRINTER PORT SETUP DATA BITS Step 6 Click on the Save Parameters button to set the entries Step 7 Click on the right button The Set Date Clock page appears See Fig 4 123 Configuration Instrument Setup Filler Enter parameters for the fields below Set Date Clock Minute mm 39 Hour hh 9 Day dd 21 Month mm f1 Year yyyy 2003 Timezone tt 8 Save Parameters 8 PST 5 EST O GMT 1 CET lt 4 FIG 4 123 INSTRUMENT SETUP SET DATE SET CLOCK SET TIMEZONE Set Date Clock Parameters Step 1 Double click in the Minute mm field Enter the cur rent minutes Step 2 Double click in the Hour hh field Enter the current minutes Step 3 Double click in the Day dd field Enter the current day 55 Step 4 Step 5 Step 6 Step 7 CHAPTER 4 Configuration Double click in the Month mm field Enter the cur rent month Double click in the Year yyyy field Enter the Cur rent year Dou
49. SIZE you are limited to three characters a Step 4 To select the Units of Measure click on the Units of Step 8 To set the Decimal Point position Measure pull down menu See Fig 4 112 Step 5 Click on the units you want for your process Click on the Decimal Point pull down menu See Fig 4 114 e Click on the Decimal Point position you Configuration Instrument Setup Filler want for your process Enter or select the parameters for the fields below Instrument ID 52 Hardy Filler Operator ID DNM Units of Measure lb 5 Scale C ity le cale Capacity kg as g Grad Size ps Decimal Point 2 FIG 4 112 UNITS OF MEASURE Configuration Instrument Setup Filler Enter or select the parameters for the fields below Instrument ID 52 Hardy Filer Operator ID DNM Units ofMeasure fib E Scale Capacity jaon Grad Size Decimal Point Totalizer Total Decimal Point Number of Averages Motion Tolerance Z Ke PIH boe se he FIG 4 114 INSTRUMENT SETUP SELECTING THE DECIMAL POINT POSITION HI 3010 Filler Dispenser IBC 52 Service Manual Step 12 To turn the OK to Fill Input ON click in the OK to Fill Input ON radio button To turn the OK to Fill Input OFF click in the OK to Fill Input OFF radio button Step 13 To adjust the OK to Fill Timer double click in the OK to Fill Timer field and enter the new time Step 14 Click on the Set Parameters button to set the entries Step
50. STABILITY TEST DISPLAY 129 7 111 STABILITY TEST TESTING DISPLAY 129 7 112 SYSTEM STABILITY TEST DISPLAY PASS 129 7 113 TEST RESULTS PER CHANNEL 130 7 114 TEST RESULTS FOR CHANNEL 1 130 7 115 STABILITY TEST RESULTS CHANNEL 3 FAILED 130 7 116 STABILITY TEST RESULTS CHANNEL 3 MEAN ADC COUNIS OUT 130 7 117 HOME PAGE SELECTING OPERATION 131 7 118 OPERATION CHOOSE ONE SELECTING DIAGNOSTICS 131 7 119 OPERATION SMART DIAGNOSTICS 131 7 120 OPERATION SMART DIAGNOSTICS WEIGHT AND VOLTAGE PAGE 131 7 121 TYPICAL LOAD CELL SYSTEM 132 7 122 SCR SWITCHING LOAD CIRCUIT 133 VIII 1 CHAPTER 1 Overview CHAPTER 1 OVERVIEW General Introduction to the Hardy Filler Dis penser IBC HI 3010 Service Manual This Service Manual provides installation setup and trouble shooting procedures for the HI 3010 Filler Dispenser IBC For information on network setup optional cards security and Email see the HI 3000 Series Operation and Installation Manual To get the maximum service life from this product techni cians should use this instrument in accordance with recom mended practices either implied or expressed in this manual Before using the Filler Dispenser IBC all service personnel should read and understand all cautions w
51. Simultaneously press the lt Ctrl gt key and the letter lt C gt key to stop the signals Exiting the Root Directory Step 1 Type exit at the root directory prompt C exit Step 2 Press the Enter key About Solid State Relays With Light Loads There have been installations where solid state relays have been used and failed to shut off a solenoid or relay when de energized The actual problem comes from the internal snub bing network in parallel with the Silicon Controlled Rectifier SCR which does the actual switching This network pres ents an impedance of 30K ohms which means with 120 volts across it will pass 4mA of AC current SCR SWITCHING LOAD CIRCUIT The SCR itself presents no leakage current Some solid state relay manufactures specify 20mA minimum load This is based on the presumption a relay or solenoid will drop out with only 4mA through it which is not always true That may not be true When switching a light load with a solid state relay across the line you must look at the rated drop out current of the load and if it is less than 4mA it may not turn off The solution is to put a loading resistor in parallel with the light load to be sure leakage current is sufficiently shunted away from the coil HOT SOLID STATE RELAY 15000 ohm NEEDED RELAY SHUNT COIL NEUTRAL FIG 7 122 SCR SWITCHING LOAD CIRCUIT 135 CHAPTER 7 Troubleshooting Assume a load like a relay with a coil of 15 000 ohms and of 5
52. Smart Diag Ctrl 55 Smart Diagnostics 4 127 Smart Diagnostics SD Card Configuration from the Front Panel 55 Smart Diagnostics Card 5 Smart Diagnostics Card Configuration from the PDA 55 Smart Diagnostics Card Configuration from the Web Browser 55 Smart Diagnostics Card Menu 55 Smart Diagnostics Rear Plate 17 Smart Preact 118 SMM 4 19 SMM Secure Memory Module 1 Solenoid 126 Solid State Relay 134 Solid State Relays 133 Spacers 11 85 Span Value 62 115 Span Weigh 63 Span Weight Field 63 Special Command Mapping 78 Specifications 7 Specifications for Peripherals Systems Components 10 Speed 118 Speed Parameter 29 Speed Pull Down Menu 50 Stability Test 4 122 129 130 Stand Alone Controller 1 Standard Interfaces 7 Standard SPST Form A Setpoint Relays 7 Standby Display 23 114 Standby Mode 21 Standoffs 16 START Button 92 Start Button 21 State Logging 125 State Logging Function 125 State Logging Function ON 125 Storage Temperature Range 8 Sum 4 Support Section 1 Switch Time 29 Switch Timer 32 Switching a Light Load 133 Swivel Bracket 13 Swivel Mount 13 Swivel Mount HI 3010 MB 8 Swivel Mount Brackets 13 Swivel Mounted 1 Syntax 78 System Integrity Check and Fault Determination From the Front Panel 114 System Integrity Check and Fault Determination From the PDA 126 System Support 134 T Tare Limit 52 117 Tare Limit Parameter 40 Target Preact 25 118 Target Preact Set Point 2
53. Target Proof Limit OFF Switch om S Gate Time 5 Jog on Time 2 0000 Preact 1 0000 Jog off Time fi 0000 OFF Smart Auto Preact Jog Count ls CON Enter Parameters y FIG 4 104 CONFIGURATION INGREDIENT NAME CHANGE Step 9 Type in the new name In our example we typed Flour See Fig 4 105 Configuration Adjust Ingredient Instrument ID 52 Hardy Filler Ingredient Number HE Ingredient Name For o Timers Fill Timer ha 7 Wait timer 2 000000 Tolerance weight E Percent Weight Min 1 0000 Min Weight ficooo Max fr 0000 Max Weight fr 0000 Speed Single E Enter Parameters lt p gt FIG 4 105 CONFIGURATION INGREDIENT NAME FLOUR Step 10 Click on the Number of Fills Double click in the field so that the value is completely highlighted Step 11 Type in the number of fills you want for this ingre dient Step 12 Click in the Target Wt field Click and hold the left button down while moving the cursor over the Tar get weight value so that the Target weight is com pletely highlighted 49 CHAPTER 4 Configuration Step 13 Step 14 Step 15 Step 16 Step 17 Step 18 Step 19 Step 20 Step 21 Step 22 Step 23 Type in the Target Weight you want for this ingredi ent To turn On the Target Proof Limit Switch click in the ON radio button or to turn off the Target Proof Limit Switch Click click in the Off radio button
54. The Filler Dispenser allows the user to configure the instru ment from their Web Browser It does not make any differ ence which browser you use The only requirement is an Ethernet Card RJ45 connectors on each end of an Ethernet Cable which is connected between to the Ethernet card in your computer and to the RJ45 connection at the rear panel of the Filler Dispenser See the HI 3000 Series Operation and Installation Manual Section Cabling Installation for installation and setup instructions Step 1 Open your Web Browser Step 2 Type in the Instruments IP address in the Address field of your browser For example http 159 236 456 25 See Fig 4 96 Do not enter the quotation marks Step 3 Once the IP address is entered press Enter on your computer keyboard The System Web page appears and you are ready to use the instrument via the Ethernet See Fig 4 97 ana http 4 159 236 456 25 FIG 4 96 ENTER IP ADDRESS IN BROWSER ADDRESS FIELD FIG 4 97 SYSTEM WEB PAGE Step 4 Click on Configuration See Fig 4 97 The Con figuration Web Page appears See Fig 4 98 HI 3010 Filler Dispenser IBC 46 Service Manual Configuration Adjust Ingredient Instrument Setup Calibration Basic Mapping Advanced Mapping Security FIG 4 98 CONFIGURATION WEB PAGE 47 CHAPTER 4 Configuration Configuring Ingredients from the Browser About Configuring Ingredients You will notice that the Instrument is di
55. The best choice for a source is a Boolean network selection In our example we selected DeviceNet Boolean In However you can select any of the Network Sources When you select a non Boolean source you are creating a mixed map Go to the Mixed Mapping Section below for more informa tion Step 7 Double click in the Word text field and put in the word number Double click in the Bit text field and enter the bit number In our example we selected Word 2 bit 1 See Fig 6 30 Network DeviceNet Int In El or Process C J Data word Selec FIG 6 30 NETWORK SELECTING NON BOOLEAN DEVICENET INT IN Step 8 Click on DeviceNet Boolean In or DeviceNet Int In to select it as the Source for the Assignment Statement See Fig 6 31 Step 9 Click in the Word text box and type in the number Ret Step 10 Click on the Select button to save the source Current Mappings CMD2 H12 0 CFO2 HFI4 CFO4 HFI16 HOO 0 HI2 0 HO1 0 H10 0 HO0 0 DI2 1 Unmap Operators 1 FIG 6 31 ASSIGNMENT STATEMENT MAPPING DEVICENET BOOLEAN IN DI2 1 TO OUTPUT RELAY 2 HO0 1 Current Mappings HOO 1 HI2 2 HOO 3 HI2 15 HO1 5 HIO 1 HO1 1 HI0 2 HOO 0 HI2 1 HO1 4 HI0 3 HOO 2 HI3 13 HI3 15 EIO2 H00 1 D102 Unmap FIG 6 32 ASSIGNMENT STATEMENT MAPPING DEVICENET INT IN DIO2 TO OUTPUT RELAY 2 HO0 1 Step 11 Click on Map to save the mapping See Fig 6 33 HO1 0 H10 0 H00 0 D12 1 Map
56. all the fill cycles depending on your application The refill vessel will probably have level sensors indicating a high and low level When you turn on the Refill the instrument sees the low level sensor for example that is calling for more material It opens a gate or valve until the material level reached the high level sensor at which time it closes the gate If you turn on the Initial Refill it will make sure that you have enough material at the first fill cycle The Refill can operate at any time during filling to make sure that the refill vessel has enough material for a fill cycle s NOTE You must map the High and Low Level Sensors to the instrument PARAMETER REFILL RANGE OFF ON DEFAULT OFF PARAMETER INITIAL REFILL RANGE OFF ON DEFAULT OFF HI 3010 Filler Dispenser IBC 34 Service Manual Step 1 Press the down arrow button until the cursor is in front of Refill See Fig 4 54 SETUP MENU DISCHARGE OFF gt gt REFILL gt SERIAL PORT gt FIG 4 54 SETUP MENU REFILL Step 2 Press the Enter button The Refill Menu appears with the cursor in front of Refill See Fig 4 55 FIG 4 55 REFILL MENU REFILL Step 3 Press the right or left arrow buttons to toggle between ON and OFF Step 4 Press the enter button to set the entry Step 5 Press the down arrow button to move the cursor in front of Initial Refill See Fig 4 56 FIG 4 56 REFILL MENU INITIAL REFILL Step 6 Press the
57. alphanumeric key pad to enter the weight that is currently on the scale typically zero Step 13 Press the down arrow button until the cursor is in front of Gravity See Fig 5 7 About The Gravitation Correction Factor Objects weigh less about 0 5 at the equator then they weigh at each pole because the force of gravity is less at the equator then at the North or South Pole This is due in part to the effect of the earth s rotation and the shape of the earth at the equator Therefore objects at the equator are 21 Km further from the Earth s center than objects at the poles For example if you weigh 100 pounds at the North Pole on a spring scale you weigh 99 65 pounds at the equator Depending on the latitude of your location you would weigh somewhere in between For those who need the gravity correction factor you can set it here The table below shows the gravitation correction factor In various 59 CHAPTER5 Calibration cities around the world Mexico City 1 002102 is the lowest and Oslo 0 998726 and Helsinki 1 001405 are the highest Table 1 Gravity Correction Factors am ee are E Amsterdam 0 999369 Los Angeles 1 001028 Athens 1 000684 Madrid 1 000461 Auckland 1 000782 Manila 1 000461 NZ Bangkok 1 002392 Mexico City 1 002102 Brussels 0 999503 New York 1 000433 Buenos 1 001004 Oslo 0 998726 Aires Calcutta 1 00191 Ottawa 1 000007 Cape Town 1 0
58. are taken before and during installation Step 2 The Filler Dispenser comes with a NEMA 4 amp 4X rated compression gasket Slide the gasket over the rear of the instrument until the gasket is flush with the back side of the front panel See Fig 3 3 Panel Mount Collar W Captive Screws ff Panel Gasket _ Enclosure Front Panel FIG 3 3 PANEL MOUNT INSTALLATION Step 3 Gently slide the Filler Dispenser with the gasket into the cutout in the enclosure front panel or door until the gasket is flush with the enclosure front panel See Fig 3 4 Be sure to secure the instru ment with both hands when installing Step 4 Line up the instrument s tapped holes with the through holes in the enclosure front panel 13 CHAPTER 3 Installation CAUTION ONCE THE GASKET IS COMPRESSED IT SHOULD NOT BE USED AGAIN WHENEVER THE FILLER DIS PENSER IS REMOVED FROM THE PANEL RE INSTALL WITH A NEW GASKET Compression Gasket Mo 3 II Tz jl tor T Rear Panel Front Panel FIG 3 4 NEMA 4 GASKET FLUSH AGAINST THE FRONT PANEL OF THE ENCLOSURE Step 5 Gently slide the Panel Mount Collar over the rear of the instrument See Fig 3 3 Step 6 Push the captive screws through the holes in the Enclosure Front Panel and install the screws into the tapp
59. arrow button until the cursor is in front of Timezone See Fig 4 90 CLOCK SETUP MENU Set Day 02 Set Year 2003 gt Tnezone 8 FIG 4 90 CLOCK SETUP MENU SET GMT About Timezones Greenwich Mean Time There are 25 integer World Time Zones from 12 through 0 GMT to 12 Each one is 15 of longitude as measured East and West from the Prime Meridian of the World which is at Greenwich England Some countries have adopted non standard time zones usually a 30 minute offset Each Time Zone is measured relative to Greenwich Eng land Civilian designations which are used for all HI 3000 Series Instruments are typically three letter abbreviations e g EST for most time zones Below is a list of the abbre viated time zones with the GMT time adjustment You will see the time zone ranges in the e mail header Use Table 4 2 to determine your time zone and to set the Timezone for the HI 3010 Filler Dispenser IBC GMT Civilian Time Zones Cities GMT GMT Greenwich Mean UT Universal UTC Universal Co ordinated WET Western Europe London England Dublin Ireland Edinburgh Scotland Reykjavik Iceland Casablanca Morocco EAST OF GREENWICH 1 CET Central Europe Paris France Berlin Germany Amsterdam Holland Brussels Belgium Vienna Austria Madrid Spain Rome Italy Bern Switzerland Oslo Norway Athens Greece Helsinki Finland Istanbul Turkey Jerusalem Israel Harare Zimbabwe 2
60. command interface in mapping Use an Assignment Statement of the form CMDO in_table out_table In_table is an input image table defining where the com mand is written Out_table defines where the reply data is written Example CMDO DI0 0 DO0 0 This Assignment Statement says the command will be writ ten to the DeviceNet input image table at word offset 0 and the reply data is written to the DeviceNet output image table at word offset zero It is legal to omit the Out_table Example CMDO0 DI3 0 This assignment statement says that the command will be written to the DeviceNet input image table at word offset 3 but no reply data will be written 79 CHAPTER 6 Mapping Command Interface Parameter Numbers Code Explanations and Valid Ranges CAUTION THESE VALUES AND EXPLANATIONS CAN CHANGE ALWAYS CHECK ON THE HARDY WEB SITE FOR THE NEWEST COMMAND INTERFACE LIST BEFORE USING THE COMMAND INTERFACE NOTE Data is handled based on the method used writ ing data to the unit If data is written using the Command Interface See Below the data is inter preted based on the displayed units However if data is directly mapped into the unit the unit assumes lbs pounds and converts the entered data to the displayed units Parameter Number Code Explanation Valid Range Hexadecimal A K R 0001 Operator ID DFD 000
61. display Also enters the letters A B C in uppercase and a b c in lower case then the number 2 NOTE Pushing the button once enters an uppercase A Pushing the button a second time enters an uppercase B third time a C Push the button a fourth time and a lowercase a is entered Push the button a fifth time and a lowercase b is entered When the button is pushed a seventh time the number 2 is entered You need to push the buttons rapidly If you delay too long the instru ment accepts the alphanumeric character and moves the cursor to the left preparing for the left entry If this happens use the left arrow button to erase the current entry and enter another charac ter This is true for all the alphanumeric buttons 23 CHAPTER 4 Configuration Setup 3 DEF Button This button enables you to access the configuration and setup menus Also enters the number 3 and the letters D E E Amount 4 GHI Enables you to change the amount of the ingredient while in the standby mode Also enters the number 4 and the letters C H I Units 5 JKL Button Enables you to change the units of measure Lbs Kg oz g while in the standby mode of operation Also enters the inte ger 5 and the letters J K L 6 MNO Button Enters the integer 6 and the letters M N O Cycle 7 PQRS Button Enables you to change the number of cycles fills or dis penses while in the standby mode Also enters the integer 7 and letters P Q R
62. gate stuck shut alarm means the fill gate is stuck closed You want one Out put Relay to energize or de energize if either one of these conditions exists Lets map the multiple sources to Output Relay 3 Our Assignment Statement looks like this Destination Source 1 Source 2 Output Relay 3 Overfill Alarm Slow Gate Stuck Shut Alarm In this Assignment Statement we use a boolean operator in boolean Assignment Statements mean or This means that if either the Overfill Alarm or the Slow Gate Stuck Shut Alarm occur Relay 3 will be energized or de ener gized depending on what you want the relay to do Here s the process Step 1 From the Configuration Mapping Setup 1 page click on the Local Output pull down menu and select Output Relay See Fig 15 Step 2 In the Relay text field type number 3 See Fig 6 15 Clear Selections oar Output Reley El Relay 3 Select Comos E FIG 6 15 MAPPING SETUP 1 PAGE SELECTING OUTPUT RELAY 3 Step 3 Click on the Select button to select the Destination Output Relay 3 Current Mappings HOO 1 HI2 2 HOO 2 HI2 3 HOO 3 HI2 15 HO1 5 HI0 1 HO1 1 HI0 2 DIO2 HFIO RSO1 HFIO HOO O0 HI2 1 HO1 4 HI0 3 HOD 2 Jump to Sources Page FIG 6 16 OUTPUT RELAY 3 HO0 2 ENTERED IN THE ASSIGNMENT STATEMENT AS A DESTINATION Step 4 Click on the Jump to Sources Page button See Fig 6 16 The Mapping Setup 2 Page appears See
63. instrument so that the backplane connector is facing the instru ment See Fig 3 11 Step 1 FIG 3 11 MAIN CONTROLLER BOARD INSTALLA TION LINING UP BOARDS WITH THE SLOTS Step 2 Gently slide the circuit board into the slots making sure that the each side of the PC board is in the proper slot See Fig 3 12 FIG 3 12 MAIN CONTROLLER BOARD INSTALLA TION SLIDING THE BOARD INTO THE INSTRU MENT Gently push the PC board all the way into the instrument until the backplane connector is con nected to the backplane Install the Main Board rear plate See Fig 3 13 Step 3 Step 4 e Place the Main Board rear plate so that the threaded holes on each side of the instrument chassis are aligned e Screw a panhead screw 4 40 into the threaded hole on the instrument chassis Do not tighten e Screw the panhead screws that attach the rear plate to the Main Board until they are finger tight e Use a Phillips head screw driver and tighten all the installed screws until snug CAUTION Do NOT OVERTIGHTEN FIG 3 13 MAIN CONTROLLER BOARD INSTALLED WITH REAR PLATE Step 5 Installation of all the PC Boards used in any HI 3000 Series Instrument requires the same proce dures Installing the Smart Diagnostics SD Card NOTE For Configuration Instructions go to Chapter 4 Options Configuration Smart Diagnostics Con figuration Step 1 Unp
64. interface allows instrument capabilities to be com municated remotely to and from a Siemens or other Profibus compatible processor AC AC input power for the HI 3000 Series remote mount instru ment to act as a booster power supply for multiple instru ments on Devicenet RIO Allen Bradley Remote I O interface allows full instrument capabilities to be communicated remotely to and from an Allen Bradley processor Smart Diagnostics SD Smart Diagnostics consists of a daughter card See Fig 1 5 and rear panel that is attached to the main board in all instru ments The Smart Diagnostics card enables the user to attach three 3 additional load cells to the HI 3000 Series instru ment for a total of four This option enables the user to e Read individual C2 load Sensor certifica tion data e Perform a Stability Test e Display load sensor weight and voltage readings from the front panel and web e Perform a return to Zero test e Set Factory Defaults e From the Front Panel or Web Page turn On Off individual load sensors and dis plays individual weights mV V milli volts volt and mV millivolts To get price and availability for the Smart Diagnostics option contact your local Hardy Representative or the Hardy Service Center HARDY SVARTDIAGNOSICS PWA O HARDY 0535 0502 MN OPTION o unn Bun Bu mmm mem a Ss ER sE Mam Bo og ep Sata se T S
65. letter in the table name HFI is a table of Hardy defined floating point numbers An analog variable is addressed with the syntax below tablename word offset The offset is an offset in words in the case of the DeviceNet tables The offsets in Hardy tables have various predefined meanings e HFIO is Gross Weight e HEI is Net Weight e other offsets to be determined When an analog Assignment Statement is evaluated all value types get converted to float The final result is then converted to the type of the LHS Left Hand Side Mixed Mapping It is permissible to have analog variables appear in Boolean Assignment Statements and to have Boolean variables in analog Assignment Statements We call a mixed Assign ment Statement Boolean if its LHS Left Hand Side of the sign is a Boolean term and Analog if its LHS is an ana log term The interpretation is as follows A Boolean variable in an analog Assignment Statement is converted to 1 0 or 0 0 An Analog variable in a Boolean Assignment Statement is TRUE if it is greater than zero 0 and FALSE if it is less than or equal to zero 0 For Example You want to change the state actuate of a relay when the Net Weight exceeds a fixed amount value Special Command Mapping Command Interface consists of e 16 bit words s WordO Command s Word 1 Parameter ID s Words 2 amp 3 Data The commands defined are the following WRITEINTEGER
66. of each of the parameters that concern your application and the weigh system Help is just a click away in the event you should not understand the information on the display or need a description of the parameter Secure Memory Module SMM The Secure Memory Module stores critical configuration up to 12 material configurations calibration and setup data of the HI 3010 Filler Dispenser IBC thereby protecting this information from corruption During system operation when anew parameter is entered the SMM automatically updates the value in its memory Data stored in one HI 3010 can be restored in another HI 3010 by physically transferring the SMM to the new instrument The SMM is conveniently accessible from the instruments rear panel Relays The HI 3010 has four standard AC solid state electronic relays that can be used to open or close valves or gates or turn motors mixers vibration equipment heaters coolers etc on or off Serial Port One standard RS 232 serial port which can be configured to transmit weight data to a serial printer Baud rates are user selectable at 600 1200 2400 4800 9600 or 19 200 Options JB Enables the instrument to sum four load sensor inputs to act as a built in summing box HI 3000 RC Rear cap for the HI 3000 Series controllers Upgrades the entire assembly to a NEMA 4X rating by enclosing all the rear panel connectors HI 3010 Filler Dispenser IBC 4 Service Manual PB Profibus
67. on any of the printed circuit boards in the instru ment e Always follow proper safety procedures when working on or around the instru ment WARNING IF A LITHIUM BATTERY IS REPLACED WITH AN INCORRECT TYPE IT MAY CAUSE AN EXPLOSION WHICH WILL CAUSE PROPERTY DAMAGE OR PERSONAL INJURY Mechanical Installation Installing the HI 3010 in a Panel Panel Cutout Specifications Enclosure Size Requirements e Overall depth of the enclosure must be a minimum of 8 5 to allow for the 2 clear ance between the rear panel of the HI 3010 Filler Dispenser and the inside surface of the rear panel of the enclosure See Fig 3 1 e There must be a 1 clearance completely around the bezel and other installed units Bezel A 1 te I a a J L E 7 E Y dls soy tks ey S Rear Panel U dK 2 0 Front Panel FIG 3 1 REAR PANEL CLEARANCE REQUIRE MENT Dimensions of the panel cutout See Fig 3 2 HI 3010 Filler Dispenser IBC 12 Service Manual e 8 94 06 227 076mm 1 52mm Wide e 6 625 06 168 26mm 1 52mm High LR 8 94 227 076 T 6 625 168 26 FIG 3 2 PANEL CUTOUT DIMENSIONS Installing the HI 3010 Filler Dispenser Step 1 Make sure that all Electrostatic Discharge ESD precautions
68. protect equipment from environmental damage Make sure openings are sealed to keep water and environmental contaminates from damaging Instrument Cabinet or Enclosure Summing Card Load Cells Conduit Runs Covers are properly installed J Electrical Inspection Verify the proper voltage level has been supplied Apply power to the controller only if supply voltage is correct Does the scale reflect a weight change Cabling To verify proper load cell operations go to K HI 3010 Filler Dispenser IBC 108 Service Manual DO NOT POWER UP THE CONTROLLER UNTIL INPUT VOLTAGES CAN BE VERIFIED Check the specification label attached to the weight controller chassis 110 VAC 220 VAC or 24 VDC Use a meter to verify neutral ground and Hot are proper Computer grade power Use active filters for motor noises and spikes Use isolation transformers to combat surges and sags Isolated from SCR and motor control circuits Use a common earth ground a Keep ground cable runs as short as possible b Excessive ground cable runs can act as an antenna for AC noise c Install grounding straps around load cells to direct static away from the load cell and directly to ground d Install ground straps on the input and discharge piping and the vessel to a common earth ground Verify the front display illuminates Completes the Initialization process Displays a weight reading This weight value will not be correct if a calibration pr
69. readings to the instrument If you do not get a reading for one or pos sibly two or more load sensors Channel 3 for example reads 0 00 mV or the millivolt reading is either larger or smaller than it should be and you know that the Load Sensors are connected to the instrument the individual load sensor cable is discon nected from the load sensor or the load sensor is malfunctioning With this information you can quickly determine what the problem is and where it is located either from the Front Panel or Web Browser If the Millivolt readings are not fine enough to determine the problem select the Millivolt Volt readings Step 8 Press the Exit button to return to the Totals Display Step 9 See Fig 105 To read the Millivolt Volt reading for finer trouble shooting press the down arrow until the cursor is in front of the Millivolt Volt mV V reading for the selected scale See Fig 105 VOLTAGE amp WEIGHT 20M gt gt AL 30 mW N gt 72 01b gt FIG 7 105 TOTAL MILLIVOLT VOLT READING Step 10 Press the Enter button The Scale Millivolt Volt for individual Scale Load Sensor readings display appears See Fig 7 106 FIG 7 106 INDIVIDUAL MILLIVOLT VOLT DISPLAY If all the load sensor readings are 0 00 mV V there is something wrong between the HI 3000 Series instrument and the load sensor The cable is disconnected or some thing is wrong such that it is not transmit ting the Millivolt Vol
70. right or left arrow button to toggle between OFF and ON Step 7 Press the Enter button to set the entry Step 8 Press the Exit button to return to the SETUP MENU About the Dispenser IBC Refill Parameters The Refill pertains to the Dispensing vessel and is actuated by the Refill Weight Parameter The Dispense vessel must have enough material to complete one whole dispense cycle If Refill is on prior to starting a dispense cycle the instru ment checks the weight in the vessel If the weight in the vessel is below the Refill Weight it initializes the Refill func tion and refills the vessel to the preset Refill Weight then starts the dispense cycle s The Refill must occur in a preset 35 CHAPTER 4 Configuration period of time by setting the Refill Duration parameter If the Refill takes more time than the preset Refill Duration the dis pense is paused and an alarm appears In addition to the Refill parameters you can set the Proof Switch to ON to determine that the refill gate or valve is open The Switch Time sets the time it takes for the Proof Switch valve or gate to open If the time exceeds the preset Switch Time an alarm appears saying that the Proof Switch did not open PARAMETER PROOF SWITCH RANGE OFF ON DEFAULT OFF PARAMETER SWITCH TIME RANGE 0 99 SECONDS DEFAULT 5 SECONDS PARAMETER REFILL WEIGHT RANGE 0 01 999999 DEFAULT 1000 0 PARAMETER REFILL DURATION RANGE 0 99 SECONDS DEFAULT 60 SECONDS St
71. the DeviceNet output image table e HI isthe Hardy input image table e HO isthe Hardy output image table e RI is RIO input image table e RO 19 RIO output image table The RIO input and output images tables are mapped to phys ical external devices using RSLogix DeviceNet and Con trolNet input and output image tables are mapped to physical external devices using Rockwell Software s RS NetWorx The Hardy input and output image tables have pre defined meanings for certain bits within the tables NOTE Make sure you use RS NetWorx for DeviceNet and RS NetWorx for ControlNet They are two different applications A Boolean variable is addressed with the syntax below tablename word offset bit offset Example DIO 3 is bit 3 in the DeviceNet input table word 0 Analog Mapping An analog variable is one that can have many different val ues The HI 3010 Filler Dispenser supports float 16 bit inte ger and 32 bit integer analog variable types There are three 3 analog operations supported The sym bols are the same as the Boolean operations but with differ ent meanings e Multiply The symbol for Multiply is 6699 e Add The symbol for Add is e Negate the symbol for Negate is ce 99 Analog tables are given 3 letter names as follows DFI DFO DSI DSO DII DIO all refer to DeviceNet tables where the item is a float a short integer or a 32 bit integer depending on the second
72. the internet Receive alarms via e mail or over WAP enabled devices including cellular phones A DeviceNet interface allows multiple applications to be viewed and controlled from a display and additional 3rd party I O to be easily added to the filling dis pensing system The controller has a single RS 232 serial port configured as a printer port Setup Wizards Setup Wizards enable the user to walk through the instru ment set up On board Help files are just a key press or click away Mapped I O Mapped I O saves wiring costs by distributing the I O where you need it at the process or in the control room The con troller is a DeviceNet Scanner and the DeviceNet Scan table is configured using RS Networx Optional interfaces for Allen Bradley Remote I O Profibus and Analog provide communications to PLC and DCS systems WAVERSAVER Typically mechanical noise from other machinery in a plant environment is present in forces larger than the weight forces trying to be detected The HI 3010 is fitted with WAVERSAVER technology which eliminates the effects of vibratory forces present in all industrial weight control and measurement applications By eliminating the factor of vibratory forces the controller is capable of identifying the actual weight data WAVERSAVER can be configured from the front panel to ignore noise with frequencies as low as 0 25 Hz One of four higher additional cut off frequencies may be selected to
73. this web page click on the Enter Parameters button to set the entries Click on the right arrow at the bottom of the Web page to go to the next page of the Adjust Ingredient setup parameters See Fig 4 107 Configuration Adjust Ingredient Instrument ID 52 Hardy Filler Ingredient Number pH Ingredient Name Flor Timers Fill Timer 120 Wait timer 2 000000 Tolerance weight E Percent Weight Min 1 0000 Min Weight fr o000 Max mooo Max Weight ficooo Speed Single E Enter Parameters lt gt FIG 4 107 ADJUST INGREDIENT 7 PAGE 2 Step 26 Step 27 Step 28 Step 29 Here again the Ingredient Number and the new ingredient name Four are automatically selected Double click in the Fill Timer field Enter the new Fill Time parameter Double click in the Wait Timer field Enter the new Wait time parameter Click on the Target Weight Tolerance pull down menu to select Weight or Percentage for the Toler ance setting See Fig 4 108 Click on Weight or Percentage to select the parameter Configuration Adjust Ingredient Instrument ID 52 Hardy Filler Ingredient Number F Ingredient Name Flour Timers Fill Timer 120 Wait timer 2 000000 Tolerance weight E Percent ETA Weight Min 0000 Min Weight ooo Max ooo gt Max Weight fr 0000 Speed Single E 4 gt FIG 4 108 TARGET WEIGHT TOLERANCE PULL DOWN MENU Step 30 If you choose weight e Double c
74. this menu Step 23 Press the up or down arrow until the cursor is in NOTE front of Zero Tolerance e The Zero Tolerance is the variance in gross weight to declare that a discharge is complete in a Filler operation Dispenser and IBC use timed discharges e To clear the Zero Tolerance press the Clr Clear button e Use the alphanumeric key pad and enter the new Zero Tolerance e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Step 24 Press the up or down arrow until the cursor is in front of Auto Zero Tolerance s The Auto Zero Tolerance are the allowable units from calibration zero to zero at start when Auto Zero Tolerance is ON e To change the Auto Zero Tolerance press the Clr Clear button e Use the alphanumeric key pad and enter the new Auto Zero Tolerance e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Step 25 Press the up or down arrow until the cursor is in front of Auto Zero Time e The Auto Zero Time is the maximum number of seconds that it takes the Auto Zero to complete e To change the Auto Zero Time press the right or left arrow buttons to increase or decrease the time e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Step 26 Press the down arrow button unti
75. to know the pro gram version to determine if the correct version is being used A Hardy Technical Support Technician will ask what version of software you are currently using to determine the source of a problem You can find the version here e The Last Cal Type will tell you what Cali bration was done on the instrument This is important when you are not getting the readings you configured the instrument for Press the down arrow button until the next three menu items are displayed See Fig 7 51 amp 7 52 Step 6 TEST DATA gt LALIB D AT SH CALIB B AT 19 CALIB D AT 46S TEST DATA gt LALIB D ON DAL 5 CABIDA MONTH Ic CALIS D IN R 2001 FIG 7 52 TEST DATA LAST CALIBRATION DA Y Step 7 MONTH YEAR e The Last Cal time is important to deter mine if the instrument needs calibration to correct a problem with the scale If a cali bration has not been done for a long time it 1s time to re calibrate the instrument Press the down arrow button until the next three menu items are displayed See Fig 7 53 TEST DATA gt LALIBRATOR Jan UNiTs LB WAVERSAVER 100 Hz FIG 7 53 TEST DISPLAY CALIBRATOR UNITS Step 8 Step 9 WAVERSAVER The Calibrator is read only However you can change the Units and the WAVERSAVER settings from this menu Press the up or down arrow until the cursor is in front of Units e This display shows the last selected Unit Press t
76. to verify the milli volt levels Review Mechanical and Electrical Flow charts for additional tips B1 Proceed with Technical Support Calibration 110 111 CHAPTER 7 Troubleshooting N Blank Screen 1 Check for proper power at the source connection 2 Check the circuit breaker at the source Measure AC Power at l 6 OK Measure the excitation Check the power fuse located inside voltage atJ 1 the case 5 VDC OK Contact Hardy Instrument Disconnect all the Technical Service connectors from the 800 821 5831 back panel except power Replace the 2 5 amp slo blow fuse and supply power Measure the PPYP Excitation voltage atJ1 5 VDC Does the fuse blow out again 1 Reconnect the jacks one at a time checking the 5 VDC excitation 2 If reconnecting any jack effects the 5 VDC check for wiring errors Display OK Contact Technical Service Monitor system for proper operation Check out complete HI 3010 Filler Dispenser IBC 112 Service Manual O Display Stuck on a Screen Power Down then Power Up Able to change Screen Remove all connectors Other than the power connector Yes Able to change Screen Yes Disconnect the power cable Remove the back plate with printed circuit boards Push the EPROM down into its socket until it is securely seated Yes change Screen Monitor system for proper operation Check o
77. trademark of the Allen Bradley Corporation Built in Smart Diagnostics Knowledge base learns how your system operates and auto tunes it for maximum throughput to finish your process faster Alarms alert you to problems or potential problems that can affect your process The Filler Dispenser IBC has Internet Wizards that walk you through the instrument set up while on board help files are just a key press away Typical Applications e Filling a Vessel Using a Feeder Filling is the adding gain in weight of a material into a container on a scale See Fig 1 1 e Filling into a Vessel from another Vessel See Fig 1 2 e Dispensing A Vessel Using a Feeder Dis pensing is the adding of a material by loss in weight from a vessel on a scale to a container which is off the scale See Fig 1 3 e Dispensing from a vessel to another ves sel See Fig 1 4 Refill Gate g 08590 65 00 High Level Prox Rs Feeder Fast amp Slow Speed Sx 0 9 O60 a Sdo o o 9 290 ES ee 368 Ce o Low Level Prox Z 3 Load Points FIG 1 1 FILLING A VESSEL USING A FEEDER HI 3010 Filler Dispenser IBC Service Manual Fill Gate Discharge Gate FIG 1 2 FILLING INTO A VESSEL FROM ANOTHER VESSEL Refill Gate Refill Point kod Initiates based on difference between Gross Weight Product in bin and Target Weight Feeder Fast amp Slow Speed Load Points
78. units Mapping to an HI 3010 with a pre 2 3 Firmware Ver sion HI 3010 s with firmware versions older than 2 3 send UDP packets with data at fixed locations Some of these words correspond to words contained in the 2 3 version Hardy Control Link Table as shown below 2 3 Word Pre 2 3 Contents 0 HIO digital inputs 1 HI1 Status Word 2 HI2 State Machine Output Word O 3 HI3 Alarms Word 0 4 HI4 Alarms Word 1 586 Gross Wt Floating Point 788 Net Wt Floating Point 9 Packet Sequence Number TABLE 6 1 HI 3010 Therefore a version 2 3 HI 3010 can pick up Gross Wt from a pre 2 3 HI 3010 node let s say Node 7 from 7FI5 Net Weight at 7FI7 State Machine output word HI2 at 7SI2 Alarm word 0 at 7SI3 Mapping to an Output Relay In English we might say Connect the Ingredient Fast Fill Command to Relay Output 1 e Relay Output 1 is the Destination e Fast Fill is the Source In Assignment Statement form this mapping would look like this e Destination Source or e Output Relay 1 Fast Fill From the Web Browser let s go through the process Step 1 From the Filler Dispenser Home Page click on Configura tion See Fig 6 1 The Config uration Page appears See Fig 6 2 FIG 6 1 HOME PAGE SELECTING CONFIGURATION Step 2 Click on Mapping Setup See Fig 6 2 The Con figuration Mapping Setup Page appears All the pull down menus include all the Destinations for
79. want to force See Fig 7 93 PRESS ENTER TO FORCE OUTPUT RELAY 2 gt OUTPUT RELAY 3 gt OUTPUT RELAY 4 gt FIG 7 93 OUTPUT RELAY DISPLAY SELECTING OUTPUT RELAY 2 Step 6 Press the Enter button to activate the output relay you have chosen The Output Relay Forced Closed display appears See Fig 7 94 e All the output relays on the instrument are Normally Open so activation will close the relay OUTPUT RELAY 1 FORCED CLOSED PRESS EXIT TD CLEAR AND FIG 7 94 OUTPUT RELAY 1 FORCED CLOSED DISPLAY Step 7 Press the Exit button to return to the Output Relay Display e Ifyou want to select another Output Relay do so now HI 3010 Filler Dispenser IBC 126 Service Manual e If you do not want to select another Output Relay press the Exit button to return to the Diagnostics display Step 8 Press the Exit button again to return to the Diagnos tics display State Logging The State Logging function is user selectable and when on prints the various states the Filler Dispenser goes through in a fill This will give you a written record of the states the instrument went through during a Fill or Dispense This is useful information when troubleshooting the instrument and your process Press the up or down arrow buttons until the cursor Step 1 1s in front of States Logging See Fig 7 95 FIG 7 95 DIAGNOSTICS DISPLA Y SELECTION STATE LOGGING OFF Step 2 Use the lef
80. 00 Base T Ethernet Connection 45 10 100 BaseT Ethernet 1 14 AWG Power Line 17 2 ABC Button 22 30K Snubbing Network 134 32 Bit Integer 78 32 Bit Integer Analog Variable Types 77 3rd Party I O 3 4AN 4 55 Updates Per Second 41 6 MNO Button 23 8 TUV Button 23 9 Terminal Block 18 A A Guidelines for Instabilities on Formerly Operating Systems 96 A D Convert Error 85 A D Counts 115 A D Failure Error 85 A1 Guideline for Instablilities on Formerly Operating Systems Cont d 97 About Basic Mapping 65 About Chapter 2 7 About Configuring Ingredients 24 47 About Diagnostics 114 About Fill Dispense Cycles 25 About Fill Dispense Timer 28 About Instrument ID 31 About IP Addresses 45 About Jog Parameters 27 About Motion Tolerance 39 About OK to Fill Input Parameter 32 About Operator ID 31 About Proof Switch 33 About Setting the Clock 42 About Smart Preact 25 About Solid State Relays With Light Loads 126 133 About Target Preact 25 About Target Weight 25 About Target Window 26 About the Auxiliary Device Timer 34 About the Averages Parameter 41 About the Decimal Point Parameter 38 About the DeviceNet Parameters 44 About the Discharge Parameters 32 About the Ethernet Parameters 45 Index About The Gravitation Correction Factor 58 About the Help Dialog 21 About the Refill Parameter 34 About the Scale Capacity Parameter 41 About the Serial Port Setup Parameters 36 About the Speed Parameter 29 About t
81. 0104 Paris 0 999048 Chicago 0 99922 Rio de Janeiro 1 001884 Copenhagen 0 999075 Rome 1 000326 Nicosia 1 00093 San Francisco 1 000702 Jakarta 1 002631 Singapore 0 99877 Frankfurt 0 999579 Sydney 1 00104 Istanbul 1 000406 Taipei 1 001741 Havana 1 001872 Tokyo 1 000886 Helsinki 1 001405 Vancouver BC 0 999653 Kuwait 1 001405 Washington 1 000601 DC Lisbon 1 000615 WellingtonNZ 0 999399 London 0 999445 Zurich 0 999821 In general if your location is between the 45th parallel and the equator the gravity correction is greater than 1 0 Because the gravity is less at these attitudes you are adding for example 1 006 for an error that is 06 For locations between the 45th parallel and the North or South Pole your correction factor is less than 1 0 for example 9994 for an error that is 06 NOTE You must perform a C2 Calibration after setting the Gravity Correction factor or the correction factor won t work NOTE Ifyou do not want to set the Gravity Correction Factor go to Step 14 C2 CAL Ref Point gt Gavity Do C2 Cal ibr ation FIG 5 7 GRAVITY CORRECTION FACTOR Step 14 Press the Clear button to clear the entry See Fig 5 8 C2 CAL Ref Point gt Gavity Do C2 Cal ibr ation FIG 5 8 GRAVITY CLEARING ENTRY Step 15 From the Gravity Corrector Factors table select the city correction factor closest to your location Use the keypad to enter the selected value In our example we entered 1 002102 which is the
82. 05 FIG 4 31 FILL TIMER PARAMETER Step 2 You can press the right or left button to increase or decrease the Fill time or press the Clear button to clear the current entry and use the alphanumeric key pad to enter the new Fill Timer parameter In our example we used 120 seconds Step 3 Press the Enter button to set the entry Wait Timer Parameter About Wait Timer The Wait Timer parameter is the time after a fill dispense cycle you want the system to wait in order to allow the sys tem to settle and calculate the fill dispense weight to see of the fill dispense is within the Target Window before moving 29 CHAPTER 4 Configuration onto another fill dispense function To shut off the Wait Timer set the parameter to 0 PARAMETER WAIT TIMER RANGE 0 999 9 DEFAULT 2 00 Step 1 Press the down arrow button until the cursor is in front of Wait Timer See Fig 4 32 gt WAIT HER 4 0005 SPEED DUAL gt FIG 4 32 WAIT TIMER PARAMETER Step 2 Press the Clear button to clear the current entry Step 3 Use the alphanumeric key pad to enter the new Wait Timer parameter In our example we used 4 000 seconds Step 4 Press the Enter button to set the entry Speed Parameter About the Speed Parameter The Speed Parameter sets the Fill Dispenser to a Dual Speed Filler Dispenser Fast amp Slow or a Single Feed Filler Dis penser Set this parameter based on what your process requires PARAMETER SPEED PARAMETER
83. 1 1 HIO 2 DIOO HFI1 DIO2 HFIO RSO1 HFIO HOO 0 HI2 1 HO1 4 Jump to Sources Page FIG 6 12 OK TO FILL HO1 4 SELECTED AS A DESTINATION Step 4 Click on the Jump to Sources Page button The Configuration Mapping Setup 2 page appears See Fig 6 13 69 CHAPTER6 SOURCES Select one or more from below to complete mapping Clear Selections Local Inputs LLecel Input Input f4 Select or Control z FIG 6 13 CONFIGURATION MAPPING SETUP 2 PAGE SELECTING LOCAL INPUT 4 AS THE SOURCE Step 5 Click on the Local Inputs pull down menu Click on Local Inputs An Input text box appears with a Select button to the right See Fig 6 13 Step 6 Double Click in the Input text box and type in the number 4 Step 7 Click on the Select button Step 8 The Mapping Assignment Statement is complete See Fig 6 14 OK to Fill HO1 4 Input contact 4 HI0 3 Current Mappings ON HOOOUHI2 1 l O STHETO HOR 1HT0 2 ROT 4 HI03 Map Unmap FIG 6 14 COMPLETED ASSIGNMENT STATEMENT Step 9 Click on the Map button The Input Contact 4 is now mapped to Ok to Fill Mapping Multiple Sources Now that you know how to map a single source to a destina tion we can move onto multiple sources mapping Lets say you want to energize or de energize Output Relay 3 if the filling process might experience an overfill or a slow gate stuck shut alarm The overfill alarm means that the fill resulted in excess ingredient s The slow
84. 12 ingredients press the down arrow until the cursor is in front of Clear All Totals See Fig 4 73 FIG 4 73 CLEARING ALL TOTALS FOR ALL 12 INGREDIENTS HI 3010 Filler Dispenser IBC 38 Service Manual Step 11 Press the Enter button All totals are cleared Step 12 Press the Exit button to return to the SETUP MENU Unit of Measure Parameters About Unit of Measure The Unit of Measure Parameter sets the scale to either Eng lish or Metric units The Selections are s Pounds Ib e Ounces 0z e Kilograms kg e Grams g NOTE Changing the units of measure converts all parameter settings to the selected units PARAMETER UNIT OF MEASURE RANGE LB KG OZ G DEFAULT LB Step 1 Press the down arrow button until the cursor is in front of Unit of Measure See Fig 4 74 SETUP MENU TOTALIZER ON gt UNIT nr TMERSURE LE Decimal POINT 2 FIG 4 74 SETUP MENU UNIT OF MEASURE Step 2 Press the right or left arrow buttons to make your selection Step 3 Press the Enter button to set the entry Decimal Point Parameter About the Decimal Point Parameter The Decimal Point Parameter is set to determine the resolu tion you want for a fill dispense Here you set the location of the decimal point for the weight resolution The higher the number the farther to the left the decimal point moves and the higher the resolution of the scale It is important to note that setting the resolution does effect the overall
85. 15 Click on the right arrow at the bottom of the page to go to Instrument Setup page 2 See Fig 4 116 Configuration Instrument Setup Filler Enter or select the parameters for the fields below Zero l lt Tolerance fi 0 0000 Use Auto Zero OFF C ON Auto Zero ro 0000 Auto Zero Tolerance Tolerance a Time fi 0000 Tare Limit 99999900 WAVERSAVER 1 00 Hz 8 Infrared x AN Enable OFF ON Aux Device Timer fi 0 Step 9 To turn ON the Totalizer click in the On radio but ton To turn OFF the Totalizer click in the OFF radio button Step 10 To set the Total Decimal Point Position Save Parameters e Click on the Total Decimal Point pull down menu See Fig 4 115 e Click on the Total Decimal Point position you want for your process Configuration Instrument Setup Filler Enter or select the parameters for the fields below Instrument ID 52 Hardy Filler Operator ID DNM Units of Measure lb y Scale Capacity 440 0 Grad Size 1 S Decimal Point 2a Totalizer OFF ON Total Decimal Point 07 Number of Averages Motion Tolerance 2 hoo OK to Fill Input E FOON OK to Fill Timer S FIG 4 115 INSTRUMENT SETUP SETTING TOTAL DECIMAL POINT POSITION lt gt FIG 4 116 INSTRUMENT SETUP PAGE 2 Step 16 To set the Zero Tolerance double click in the Zero Tolerance field and enter a new Zero Tolerance parameter Step 17 To turn ON Use Auto Zero Tolerance click in the Use A
86. 2 Instrument ID Max 19 characters 0003 OK to Fill Timer 0 999 0004 WAVERSAVER 0 None 5 25 Hz 4 50 Hz 3 1 0 Hz 2 3 50 Hz 1 7 50 Hz 0005 Number of Averages 1 250 0006 Zero Tolerance 0 000001 999999 0007 Units of Measure O 1lb 1 Kg 2 9 3 0Z 0008 Decimal Point 0 5 0009 Total Decimal Point 0 5 000A Grad Size 0 1 1 2 2 5 3 10 4 20 5 50 6 100 7 200 8 500 9 1000 000B Print Total 1 YES 0 NO 000C Auto Print 1 YES 0 NO 000D Motion Tolerance 01 999999 000E Auto Zero Tolerance 000001 999999 000F Capacity 000001 999999 Parameter Number Code Explanation Valid Range Hexadecimal 0010 Infrared Enable 1 ON 0 OFF 0011 Active Target Weight 000001 999999 0012 Active Num Cycles 0 cont or 1 999999 0013 OK to Fill Input 1 YES 0 NO 0014 Discharge 1 YES 0 NO 0015 Auto Discharge 1 YES 0 NO 0016 OK to Discharge 1 YES 0 NO 0017 Aux Device Time 0 999 0018 Discharge Gate 1 YES 0 NO Proof 0019 Discharge Gate 0 99 Timer seconds 001A Use Auto Zero 1 YES 0 NO 001B Auto Zero Toler 01 9 99 ance Time 001C Tare Limit 999999 0000 0022 Refill 1 YES 0 NO 0023 Initial Refill 1 YES 0 NO 0024 OK to Discharge 0 999 Timer seconds 002A Baud Rate 0 300 1 1200 2 2400 3 4800 4 9600 5 19200 002B Parity 0 None 1 Odd 2 Even 002C Data Bits 0 7 bits 1 8 bits 0038 Proof Switch 1 YES 0 NO 0039 Gate Timer 0 99 seconds 003B Refill Weight
87. 22 Update Rate 7 User Guide 11 User _ blank Button 23 Using Smart Diagnostics From the Front Panel 127 Using Smart Diagnostics From the Web Browser 130 Using Solid State Relays with Light Loads 126 V Vibratory Forces 42 View Input States 124 Voltage amp Weight 121 127 Voltage amp Weight Displays 120 VPN 1 VPN Virtual Private Network 45 Ww Wait Timer 118 Wait Timer Display 91 Wait Timer Field 49 Wait Timer Parameter 28 Waiting On Display 87 Wall Mount 13 WAP Enabled Devices 3 Warranty 134 HI 3010 Filler Dispenser IBC Service Manual Washers 11 85 Watts Available for DeviceNet Power 8 WAVERSAVER 3 7 115 WAVERSAVER 1 3 30 WAVERSAVER Technology 3 Web Browser 46 128 Weight 127 Weight Hopper 40 Weight Value 61 Wiring Harness 11 85 WRITEFLOAT 78 WRITEINTEGER 78 WRITESTRING 78 Written Record 125 Y Year yyyy Field 55 Z Zero Count 115 Zero Ct 62 Zero Point 62 Zero Tolerance 116 Zero Tolerance Field 52 Zero Tolerance Parameter 39 Zero Value 62 INSTRUMENT 9440 Carroll Park Drive Suite 150 San Diego CA 92121 Telephone 1 800 821 5831 FAX 858 278 6700 Web Address http www hardyinstruments com Copyright February 2002 Dynamic Instruments All Rights Reserved Printed in the U S A
88. 34 PARAMETER NUMBER 78 PARAMETER VALUE 78 Parameters 114 PARAMID 78 Parity 36 Parity Pull Down Menu 54 Pass Display 122 PB 4 PC Boards 16 PDA 128 Performance Diagnostics 1 Phillips Head Screw Driver 16 Physical Characteristics 8 Pick List 22 Ping Tool 133 PING Utility 133 PLC 2 Power 8 Power and Relay Circuit Card 17 Power and Utility Requirements 7 Power Input J1 17 Power Supply 9 PP Program Part Number 114 Preset Time 86 Pre Startup 124 Print Button 22 Print Current Fill Menu 22 Printed Circuit Boards 11 85 Printer Baud Rate 119 Printer Data Bits 119 Printer Parity 119 Printer Port 3 53 Process Weighing 1 Profibus 2 6 Profibus Process Fieldbus 6 Profibus Interface 4 Program Version 114 Programmable Logic Controllers PLC 5 Proof Switch Alarm 32 Provide Feedback Link 3 Push Buttons 44 R Read Only 115 READINTEGER 78 Rear Cover 13 Rear Plate 5 Reassembly 11 85 Re Calibrate 115 Recommended Load Cell Cable 18 Ref Point 58 Reference Point 58 Reference Weigh 61 HI 3010 Filler Dispenser IBC Service Manual Reference Weight 61 Reference Weight Field 61 Refill 34 89 Refill And Discharge Setup Page 53 Refill High Set Point 89 Refill OFF Radio Button 53 Refill Parameter 34 Refill Timeout Alarm 89 Refill Time Out Parameter 89 Refill Vessel 34 Relay Output 81 Remote I O 5 Removing Printed Circuit Boards 17 Repairs 11 85 Resolution 7 121 RESUME FILLING FAST 86 RESUME FILLING SLOW
89. 4 vi Table of Illustrations Chapter 1 Chapter 3 Chapter 4 Table of Illustrations Overview 5 2 eee ee ee te KKK ee eee 1 FIG 1 1 FILLING A VESSEL USING A FEEDER 2 FIG 1 2 FILLING INTO A VESSEL FROM ANOTHER VESSEL 2 FIG 1 3 DISPENSING INTO A VESSEL FROM A FEEDER 2 FIG 1 4 DISPENSING LOSS IN WEIGHT FROM A VESSEL TO ANOTHER VESSEL 3 FIG 1 5 SMART DIAGNOSTICS CARD 5 FIG 1 6 SMART DIAGNOSTICS REAR PANEL 5 Installation 11 FIG 3 1 REAR PANEL CLEARANCE REQUIREMENT 1 2 FIG 3 2 PANEL CUTOUT DIMENSIONS 12 FIG 3 3 PANEL MOUNT INSTALLATION 12 FIG 3 4 NEMA 4 GASKET FLUSH AGAINST THE FRONT PANEL OF THE ENCLOSURE 13 FIG 3 5 INSTALLING THE SWIVEL MOUNT TOA HORIZONTAL SURFACE 13 FIG 3 6 FILLER DISPENSER INSTALLING IN A SWIVEL MOUNT 14 FIG 3 7 FILLER DISPENSER INSTALLED IN A SWIVEL MOUNT 14 FIG 3 8 INSTALLING THE SWIVEL MOUNT TO A VERTICAL SURFACE 14 FIG 3 9 FILLER DISPENSER INSTALLING IN A SWIVEL WALL MOUNT 15 FIG 3 10 FILLER DISPENSER INSTALLED IN A SWIVEL WALL MOUNT 15 FIG 3 11 MAIN CONTROLLER BOARD INSTALLATION LINING UP BOARDS WITH THE SLOTS 15 FIG 3 12 MAIN CONTROLLER BOARD INSTALLATION SLIDING THE BOARD INTO THE
90. 4 SETUP MENU AVERAGES Step 2 Press the Clear button to clear the current entry Step 3 Use the alphanumeric key pad to enter the new Tare Limit value Step 4 Press the Enter button to set the entry Averages Parameter About the Averages Parameter This setting is to aid in ignoring the effects of material impact If material is not entering or exiting the scale evenly weight fluctuations can be seen Applications requiring very quick weight readings should reduce this setting to it s mini mum If the weight is unstable due to material impacting increase the averages This sets the number of weight read ings that will be used to compute the displayed weight The average is a sliding average so that a new average is avail able for display at every reading The Filler Dispenser does 55 updates per second which translates to an update approximately every 20 milliseconds If you average enough weight readings the weight loss or gain remains smooth If you average the weight too much you can cause over filling Here is an example of 5 averages reading 5 Engineering Units EU 20ms 20ms 20ms 20ms 20ms 0 0 0 0 5 0 0 0 5 5 0 0 5 5 5 0 5 5 5 5 5 5 5 5 5 1 2 3 4 5 5 EU in 100ms TABLE 4 1 5 AVERAGES READING 5 EU PARAMETER AVERAGES RANGE 1 250 DEFAULT 1 Step 2 Press the right or left arrow buttons to increase or decrease the number of averages Step 3 Press the Enter button to s
91. 5 Target Weight 25 117 Target Weight Tolerance Pull Down Menu 49 Target Weight Tolerance 26 Target Window 26 118 Target Window Wt 118 Target Window Wt 118 Target Window Wt 118 Target Window Weight 118 Target Window Weight 118 Target Window Weight 118 Technical Support Department 1 Temperature Coefficient 8 Tension or Compression Type Load Cells 132 terminal blocks 18 Test and Data Menu 114 120 Test Button 4 Test Channel 1 Button 131 Test Data Display 120 Test Results FAIL 130 PASS 129 Test Weight 62 Test 9 button 127 Test 9 WXYZ Button 23 Texas Instruments 6 The Secure Memory Module 4 The WAVERSAVER Parameter 41 Tied 17 Too Hi Error 85 Too Lo Error 85 Total Decimal Pont Parameter 39 Total Load 134 Totalizer 52 Totalizer Parameter 37 Totals 22 Trad Cal Error 85 Traditional 7 Traditional Cal Menu 62 Traditional Calibration 4 57 62 Traditional Calibration From the Front Panel 61 Traditional Calibration From the Web Page 63 Troubleshooting 85 Troubleshooting Techniques 134 Troubleshooting The Network Connections and Config uration with the Ping Tool 133 TRUE 78 U UNDER FILL 87 UNDERDISPENSE ALARM 92 Underfill Overfill Alarm 88 UNDERFILL ALARM 88 UNDERFILL Condition 93 Unit of Measure Parameters 38 Units 115 Units of Measure 23 Units of Measure Pull Down Menu 51 Units 5 JKL Button 23 Universal Power Supply 17 Unmap 82 Unpacking 11 Up down Arrow Buttons
92. 5 IS 2 e S A S S S v SN N E SA Cee gt o Z r y gt PA FIG 5 1 PROPERLY INSTALLED LOAD CELL WITH NO BINDING Electrical Check Procedures Step 1 Check to see that there is power to the controller a If there is power to the controller The front panel display should be lit b Ifthe display appears with a value the unit is ready for calibration Step 2 Check to see that all communication and power cables are securely fastened to the connectors on the rear panel C2 Calibration From the Front Panel Step 1 Press the Setup 3 button The Configuration Menu appears See Fig 5 2 Step 2 Press the down arrow until the cursor is in front of CALIBRATION See Fig 5 2 Step 3 Press the Enter button The CALIBRATION Menu appears with the cursor in front of CAL TYPE C2 See Fig 5 3 NOTE Ifthe cursor is in front of CAL TYPE TRAD press the left or right arrow buttons until CAL TYPE C2 appears CONFIGURATION MENU ROUUSTINGREDIENT gt SETUP sa gt CALIBRATION gt FIG 5 2 CONFIGURATION MENU SELECTING SETUP CALIBRATION gt Sensor Type 0 3nV V1 Q gt Cal Type FIG 5 3 CALIBRATION MENU C2 CAL CAUTION FOR HARDY ADVANTAGE AND ADVANTAGE LITE C2 LOAD CELLS YOU MUST SELECT 0 3MV V ONLY SELECTING OTHER SENSOR TYPES WILL CREATE INCOR RECT WEIGHT READINGS There are four 4 Sensor Type choices e 0 3mV V C2 Load Sensors Only 3mV V Non C2 Load Sensors
93. 51 4 114 INSTRUMENT SETUP SELECTING THE DECIMAL POINT POSITION lt nato Soe a ler 52 4 115 INSTRUMENT SETUP SETTING TOTAL DECIMAL POINT POSITIONS cemento ea Ses me 52 4 116 INSTRUMENT SETUP PAGE 2 52 4 117 INSTRUMENT SETUP PAGE 2 SETTING WAVERSAVER 53 4 118 INSTRUMENT SETUP REFILL AND DISCHARGE PAGE 53 Chapter 5 Chapter 6 HI 3010 Filler Dispenser IBC Service Manual FIG 4 119 INSTRUMENT SETUP PRINTER PORT 53 FIG 4 120 INSTRUMENT SETUP SERIAL PORT 54 FIG 4 121 PRINTER PORT SETUP PARITY 54 FIG 4 122 PRINTER PORT SETUP DATA BITS 54 FIG 4 123 INSTRUMENT SETUP SET DATE SET CLOCK SET TIMEZONE 54 FIG 4 124 CONFIGURATION MENU SELECTING OPTIONS 55 FIG 4 125 OPTIONS SELECTING SMART DIAGNOSTICS CONTROL 55 FIG 4 126 SMART DIAGNOSTICS CARD MENU CHANNELS 1 2 3 55 FIG 4 127 SMART DIAGNOSTICS ENABLING CHANNEL 1 55 FIG 4 128 SMART DIAGNOSTICS CARD MENU CHANNEL 2 3 4 55 FIG 4 129 HOME PAGE SELECTING CONFIGURATION 56 FIG 4 130 CONFIGURATION PAGE SELECT OPTIONS 56 FIG 4 131 CONFIGURATION OPTIONS SELECTING SMART DIAGNOSTICS CARD CONFIGURATION 56 FIG 4 132 SMART DIAGNOSTIC CARD CONFIGURATION 56 Calibration 2 2 2 e eee eee 57 FIG 5 1 PROPERLY INSTALLED LOAD CELL WITH NO BINDING 57 FIG 5 2 CONFIGURATION MEN
94. 6 8 SELECTING FAST FILL SOURCE Step 13 Click on the Select button to select Fast Fill as the Source See Fig 6 8 Current Mappings HO0 0 H12 1 HOO 1 HI2 2 HOO 2 HI2 3 HOO 3 HI2 15 HO1 4 HI0 0 HO1 5 HI0 1 HO1 1 HIO 2 DIOO HFI1 DIO2 HFIO RSO1 HFIO Unmap ho0 0 H121 FIG 6 9 MAPPING IS COMPLETE Step 14 The Assignment Statement is complete You will now see in the Current Mappings text box HOO 0 HI2 1 See Fig 6 9 Step 15 Click on the Map button You have now mapped Fast Fill to Output Relay 1 Notice that the new mapping is included in the list of current mappings See Fig 6 10 HI 3010 Filler Dispenser IBC 68 Service Manual 3 4 H1235 HO1 4 HI0 0 HC IFIO HOO 0 HI2 ie uni FIG 6 10 MAPPED FAST FILL TO OUTPUT RELAY 1 Example 2 Mapping to an Input There are 5 contact closure inputs designed into the HI 3010 You want to map Input Contact 4 to OK to Fill Our Assign ment Statement is e Destination Source e Ok to Fill HO1 4 Input 4 HI0 3 Step 1 On the Configuration Mapping Setup 1 page click on the Control pull down menu See Fig 6 11 DESTINATIONS Clear Selections Select FIG 6 11 DESTINATIONS SELECTING OK TO FILL Step 2 Click on Ok to Fill A Select button appears See Fig 6 11 Step 3 Click on the Select button See Fig 6 11 Current Mappings HOO 1 HI2 2 HOO 2 HI2 3 HOO 3 HI2 15 HO1 4 HI0 0 HO1 5 HI0 1 HO
95. 87 Return to Factory Defaults Button 127 Return to Zero Test 123 RIO 4 RIO Baud Rate 9 RIO Supported Features 9 RJ45 Connectors 46 Root Directory 133 RS 232 4 RS Networks 3 RS 232 Serial Port 3 S Save Parameters Button 53 56 Scale Capacity 116 Scale Capacity Field 51 Scale Capacity Parameter 41 SCR SWITCHING LOAD CIRCUIT 133 Screws 11 85 Secure Memory Module 19 Secure Memory Module SMM 4 Security Violation 60 Selectable Predetermined 6 Selecting Configuration Menus 23 Sensitivity Specifications 116 Sensor Type 58 Sensor Type choices 58 Sensor Weight And Voltage 4 Sensors 44 Serial Number 120 Serial Port 4 Serial Port Device 53 Serial Port Parameters 36 Serial Port Pull Down Menu 53 Serial Port Setup Page 53 Serial RS 232 7 Service Manuals 11 Set Clock Parameter 42 Set Date Clock Page 54 Index Set Date Clock Parameters 54 set point value Target Weight 25 Set the Span Value 62 Setup Data 22 Setup Wizards 3 Setup 3 DEF Button 23 Setup Configuration Menus 21 Short Integer 78 Siemens 6 Silicon Controlled Rectifier 126 Silicon Controlled Rectifier SCR 133 Simple Operator Interfaces 44 Single Speed 29 Sliding Average 41 Slotted Head Screwdriver 13 Slow Fill Proof Switch 119 Slow Fill Proof Timer 119 Slow Gate Did Not Close 91 Slow Gate Did Not Close Alarm 87 Slow Gate Did Not Open 90 Slow Gate Did Not Open Alarm 87 Small Fasteners 11 85 Small Logic Controllers SLC 5
96. 9200 Step 5 Press the Enter button to set the entry Step 6 Press the down arrow button until the cursor is in front of Parity See Fig 4 67 Haun RATE 3600 gt PARITY NONE Data BITS 8 FIG 4 67 PRINTER PORT MENU PARITY Step 7 Press the right or left arrow buttons to select Parity The Selections are NONE e ODD EVEN Step 8 Press the down arrow until the cursor is in front of Data Bits See Fig 4 68 Haun RATE 3600 PARITY NONE gt Dare Bis 8 FIG 4 68 PRINTER PORT MENU DATA BITS Step 9 Press the right or left arrow buttons to select the Data Bits you want The Selections are 8 e 7 Step 10 Press the enter button to set the entry Step 11 Press the down arrow until the cursor is in front of Auto Print See Fig 4 69 PRINTER PORT MENO Parity NONE Data BITS H gt AUTO PRINT ON X FIG 4 69 PRINTER PORT MENU AUTO PRINT Step 12 Press the right or left arrow buttons to toggle between OFF or ON Step 13 Press the Enter button to set the entry Step 14 Press the Exit button two 2 times to return to the SETUP MENU Totalizer Parameter About the Totalizer Parameter Setting the Totalizer to ON sets the Totalizer function for all 12 ingredients This function calculates the total amount of material by weight that was used during the fill You can also Clear the Totalizer either for each ingredient or for all ingre dients PARAMETER TOTALIZER RANGE ON OFF
97. 990599 9 matted as follows ppOF Jog Count 0 9 e ppss pp10 Jog Off Time 0 1 99 9 pp11 Fill time 0 999 Where pp is the prefix for the ingredient EE number HEX pp12 Wait Timer 0 00000 999 9 pp13 Mode 0 Sequential Where ss is the suffix ingredient param 1 Simultaneous eter HEX pp14 Fast Target Weight 0 000001 999999 00 Prefix Ingredient Number 1 03ss pp15 Auto Fast NZ Ingredient Number 2 07ss 7 Ingredient Number 3 OBss pp16 Fast Gate Time 0 99 Ingredient Number 4 OFss aaa Ingredient Number 5 03ss pp17 Fast Limit Switch 1 YES 0 NO Ingredient Number 6 17ss Ingredient Number 7 1Bss pp18 Slow Limit Switch 1 YES Ingredient Number 8 1Fss 0 NO Ingredient Number 9 238s pp19 Slow Gate Time 0 99 Ingredient Number 10 2788 Ingredient Number 11 2Bss Ingredient Number 12 2Fss Suffix Code Explanation Valid Range pp01 Ingredient Name ONE 19 Charac ters TABLE 6 3 INGREDIENTS 1 12 TABLE 6 3 INGREDIENTS 1 12 Mapping From the Front Panel Mapping assigns controllable Inputs and Outputs to any point on a Local Controller Mapping can be done from the Front Panel or the Browser 81 CHAPTER 6 Mapping A Control Output can be mapped Assigned to a Local Relay For example For a to 1 Configuration If OK to Fill is the destination the source can be Input 1 When the HI 3010 Filler Dis penser receives an OK to Fill signal Input 1 is activated which might stop a motor
98. C 76 Service Manual PLC Input Image Table Output Image PS Mapping to OK to Fill on HI 3010 FIG 6 40 DEVICENET OUTPUT HI 3010 DeviceNet Node 1 Input Image Table TOL Alarm Output 2000 Outpul Image Teple Boolean Word 3 Mapping to the DeviceNet Light Bar FIG 6 41 DEVICENET OUTPUT Hardy Control Link Network Mapping If an HI 3010 Node 1 does not have any Output Relays available you can select another node s Output Relay HI 3010 Node 2 has an output relay available This requires that you first map Node 1 and Node 2 separately so that the input contact in Node 1 can be mapped directly to the Output Relay in Node 2 See Fig 6 42 Step 2 You need to set up communication between Node 1 and Node 2 You can do this by going to the HI 3010 Web Page select Configuration select Hardy Control Link For complete instructions to setup communications between instruments go to the HI 3000 Installation and Operation manual Hardy Control Link Ethernet Network Setting Node Addresses for HI 3000 Series Instruments from the Browser Step 3 Step 4 Step 5 At node 2 you need to map the Output Relay 3 state value in the Output Image Table to the Hardy Boolean In address in the Input Image Table See Fig 6 42 Green Arrows At node 1 you need map Input Contact 1 in the Input Image Table to Hardy Boolean O
99. C CANNOT DETERMINE WHICH NODE IT IS COMMUNICATING WITH THIS CAN RESULT IN PROPERTY DAMAGE OR PERSONAL INJURY The Network scanner scans each node s Output Image Table to read the values that are located there If there are values in the nodes Output Image Table it reads the values to the PLC s Input Image Table which makes the data available to the PLC for processing Here again you can assign the data in the node s output image table to an address in the PLC input image Table So if you want the net weight to be displayed in the PLC s output screen you have already assigned the Net Weight value located in the Input Image Table to the Output Image Table The PLC Scanner reads the Net Weight value in the nodes s Output Image Table and moves the value to a word location in the Input Image Table on the PLC The Input Image Table Net Weight value is then output let s say to the PLC screen Network Output When the Network Scanner writes values to the nodes it does this by taking the data located in the PLC Output Image Table and writes the values to another nodes Input Image Table Once the value is in the node s Input Image Table it becomes a source and can be mapped to any destination in the HI 3010 See Fig 6 40 HI 3010 DeviceNet Node 1 Input Image Table Output 2000 m OK To Fill Boolean T N d Output Ifhage Table Table HI 3010 Filler Dispenser IB
100. CHAPTER 7 Troubleshooting A Guidelines for Instabilities on Formerly Operating Systems A STABILITY TEST Confirms the Health of the internal A D converter circuits Enter Diagnostics STABILITY TEST Activate the test and review the results The internal A D converter has a hardware problem There isn t a port defined or enabled Cycle power and re run Check the test If the second Continue Configuration test fails contact checking for settings under mechanical options Hardy Instruments problems Technical Support HI 3010 Filler Dispenser IBC 98 Service Manual B Guidelines for Instabilities on Formerly Operating Systems Contd Check for Electrical Stability Check for Mechanical Stability Check Configuration settings for stability 99 CHAPTER 7 Troubleshooting B1 Guidelines for Instabilities on Former Operating Systems Cont d Electrical Physical Grounding All common equipment share a common ground point Keep the ground cable length to earth ground as short as possible Install a new ground rod if the cable length is excessive Cable Cuts or breaks in the loadcell cable insulation allow moisture to wick into the cable and loadpoints This can setup stray capacitance charges and allow ground currents to exist This could create a highly intermittent situation Vessel Fill and discharge piping Ground all to a common point to eliminate electrical differ
101. DEFAULT OFF PARAMETER CLEAR TOTALIZER RANGE 0 12 INGREDIENTS DEFAULT INGREDIENT 1 Step 1 Press the down button until the cursor is in front of Totalizer See Fig 4 70 SETUP MENO SERIAL PORT gt gt TOTALIZER ON LINIT OF MEASURE LB FIG 4 70 SETUP MENU TOTALIZER Step 2 Press the right or left arrow buttons to toggle between OFF or ON Step 3 If you select ON you have turned on the Totalizer for all 12 ingredient selections Step 4 To clear the Totalizer for all 12 ingredients or for each individual ingredient press the Enter button The Totalizer Menu appears See Fig 4 71 FIG 4 71 TOTALIZER MENU CHOOSING INGREDIENT TOTALIZER NUMBER Step 5 Press the left or right arrow buttons to select the Ingredient Totalizer you want to view Step 6 Press the Enter button The Totalizer Number Menu appears with the cursor in front Total Wt See Fig 4 72 In our example we selected Ingredient Total izer 1 TOTALIZER NUMBER gt TOTAL UT 100 45 Totat CT 25 A te nm pa 70 3 pa ce rd m 20 FIG 4 72 TOTALIZER NUMBER MENU Step 7 Total WT and Total CT are read only Step 8 To Clear the Totals for Ingredient Number 1 s Press the down arrow until the cursor is in front of Clear Totalizer e Press the Enter button The Total WT and Total CT entries turn to 00 00 Step 9 Press the Exit button to return to the Totalizer Menu Step 10 To clear all totals for all
102. Devicenet Address Lists the address of the Node Address of the instrument you are checking Step 54 Press the Exit button to return to the Test Data Dis play Step 55 Press the Exit button to return to the Test and Data Menu See Fig 7 70 TEST ANG DATA MENO gt DEVICE DATA LIST HIAGNUSTILS FIG 7 70 TEST AND DATA MENU Diagnostics Voltage amp Weight Displays Press the down arrow until the cursor is in front of Diagnostics See Fig 7 71 Step 1 HI 3010 Filler Dispenser IBC 122 Service Manual TEST AND DATA MENO U LB DEVICE DATA LIST 2 469 0 03 gt GIAGNUSTICS FIG 7 71 TEST AND DATA MENU SELECTING FIG 7 74 MILLIVOL T AND WEIGHT READING DIAGNOSTICS e The mV and Weight is a coarser reading Step 2 Press the Enter button The Diagnostics Display than the mV V and Weight The reading is appears with the cursor in front of Voltage amp sufficient to balance the corners of your Weight See Fig 7 72 scale e This reading allows you to determine if the problem is in the instrument internal or in a load sensor s external The specifi cation range for the Filler Dispenser is 0 DIAGNOSTICS 15 mV If you are getting a reading outside gt Vorrase 6 LEIGHT gt this range the problem is probably the load 2 cell electrical If you are getting a read STABILITY TEST za ing between 0 15 mV the reading is nor FACTORY DEFAULTS gt mal Step 6 Press the Exit button to return to the Ch
103. Dispenses HSO24 Ingr 12 Fills or Dispenses HSO25 Ingr 1 Auto Preact On O no 1 yes HSO36 Ingr 12 Auto Preact On HSO37 Ingr 1 Tolerance Selection 0 weight 1 percent HSO48 Ingr 12 Tolerance Selection HSO49 Ingr 1 Jog Count max permitted jogs HSO60 Ingr 12 Jog Count HSO61 Ingr 1 Fill or Dispense Time s max allowed time for operation HSO72 Ingr 12 Fill or Dispense Time s HSO73 Ingr 1 Auto Fast On 0 no 1 yes automatic adjustment of fast wt for dual speed units HSO84 Ingr 12 Auto Fast On HSO85 Ingr 1 Fast Gate Time s max time for fast gate proof sw to verify gate operation HSO96 Ingr 12 Fast Gate Time s HSO97 Ingr 1 Fast Proof Switch On O don t use fast gate proof sw 1 use proof sw HSO108 Ingr 12 Fast Proof Switch On HSO109 Ingr 1 Slow Proof Switch On O don t use slow gate proof sw l use proof sw HSO120 Ingr 12 Slow Proof Switch On HSO121 Ingr 1 Slow Gate Time s max time for slow gate proof sw to verify gate operation HSO 132 Ingr 12 Slow Gate Time s HSO133 OK to Fill OK to Dispense timer s max time to wait for OK to Fill signal HSO134 Totalizer On O no 1 yes HSO135 Auto Print On O no 1 yes HSO136 OK to Fill Input O don t wait for OK to Fill l do wait for it HSO137 Discharge Enable O don t enter discharge sequence 1 enter discharge sequence HSO138 AutoDischarge Enable 0 wait for Discharge com
104. E ALARM Determine why the Slow Dispense Gate did not close and correct the problem 2 Press the Clear button to clear the alarm The wait timer display appears See Fig 7 30 e Press the Start button to resume dispense 1 Slow Gate Did Not Open e If the Slow Dispense Gate does NOT open the SLOW GATE DID NOT OPEN alarm appears on the display See Fig 7 27 BERRIES AM 20 00 20 80 CSELES 1 23 LB ANT 19 23 20 00 l IRLARMSLOUGATE Under Dispense Over Dispense Alarms FIG 7 27 SLOW GATE DID NOT OPEN ALARM 1 Determine why the Slow Dispense Gate did not open and correct the problem 2 Press the Clear button to clear the alarm The wait timer display appears See Fig 7 28 If the target weight is NOT within the tar get window and you do not have the JOG function turned ON the dispense is not accepted and an UNDERDISPENSE or OVERDISPENSE alarm appears depend ing on the alarm condition See Fig 7 31 amp 7 32 BERRIES ANT 20 00 20 00 CYCLES 1 23 LB DERRIES WAIT TIMER gigs AMT cU tc c0 00 L IUNDERDISPENSE LB ALARM HLB FIG 7 28 WAIT DISPLAY S Slow Gate Did Not Close FIG 7 31 UNDERDISPENSE ALARM e If the Slow Dispense Gate does NOT close the SLOW GATE DID NOT CLOSE alarm appears on the display See Fig 7 29 FIG 7 32 OVERDISPENSE ALARM e OVERDISPENSE ALARM press the Clear button to clear the alarm The Accept the Dispense display appears See F
105. EST Step 2 Press the Enter button The Return to Zero Test dis play appears See Fig 7 85 FIG 7 85 RETURN TO ZERO TEST DISPLAY Step 3 To perform the test press the Enter button In a few seconds a display appears telling you if the instru ment has passed or failed 125 CHAPTER 7 Troubleshooting e If you Pass the Test the Pass display appears See Fig 7 86 RU RETURN TO Z IPAS DROSS LIT U A TOLERANCE 20 00 ES Ln Z iu FIG 7 86 RETURN TO ZERO TEST PASS e If instrument Fails the test the Fail display appears See Fig 7 87 You may need to do the following 1 Check the scale for excess material 2 Check your Motion and Zero Toler ance settings They might be set too low for your process FIG 7 87 RETURN TO ZERO FAIL Step 4 Press the Exit button to return to the Diagnostics display View Input States The Input States display shows whether or not the instru ments has any inputs activated A 1 means the input is active and a 0 means it is not Step 1 Press the up or down arrow buttons until the cursor is in front of View Input States See Fig 7 88 FACTORY DEFRULTS gt RETURN TO ZERO gt gt View INPUT STATES gt FIG 7 88 DIAGNOSTICS VIEW INPUT STATES Step 2 Press the Enter button The Input States display appears See Fig 7 89 FIG 7 89 INPUT STATES DISPLAY INPUT 2 AND 4 ACTIVE Step 3 Press the Exit button to re
106. FF Step 1 The cursor is in front of Target Preact See Fig 4 18 PILL CYCLES 5 TARGET LT 14 00 gt TARGET PREACT gt FIG 4 18 TARGET PREACT PARAMETER Step 2 Press the Enter button The Target Preact Menu appears See Fig 4 19 TARGET PREACT MENU gt PREACT 100 LB SAARTPRERCT OFF FIG 4 19 TARGET PREACT SUB MENU Step 3 Step 4 Press the Clear button to clear the previous entry Use the alphanumeric key pad and enter the Target Preact Value for this ingredient In our example we used 3 00 lbs as the Target Preact See Fig 4 20 TARGET PREACT MENU gt PREACT 3 00 L SMART PREACT OFF FIG 4 20 TARGET PREACT MENU SET PREACT Step 5 Press the down arrow button to move the cursor in front of Smart Preact See Fig 4 21 Use the left or right arrow to toggle between OFF and ON In our example we turned the Smart Preact ON See Fig 4 21 Step 6 HI 3010 Filler Dispenser IBC 26 Service Manual ta 1 r 3 zu AS 3 i 70 AS DS Jn A CA rr ZZ FIG 4 21 TARGET PREACT MENU SMART PREACT Step 7 Press the Exit button to get back to the Adjust Ingredient 1 Menu Target Window About Target Window The Target Window is the weight tolerance for an ingredient There is a Maximum tolerance and a Minimum tolerance set ting The Maximum tolerance is the weight above the target weight you can accept you your process The Minimum is the weight below the target
107. Front Panel 61 About Traditional Calibration 61 Traditional Calibration From the Web Page 63 Mapping 2 2 2222 2 eee eee 65 About Mapping 65 Mapping to an HI 3010 with a pre 2 3 Firmware Version 65 Mapping to an Output Relay 65 Example 2 Mapping to an Input 69 Mapping Multiple Sources 69 Simple Network Mapping 71 Mapping to a Network Output 71 Mapping a Network Input to a Local Output 71 Unmapping 72 More Advanced Mapping 73 Glossary of Mapping Terms 73 Rules for Hardy Control Link Mapping 74 Local Input 74 Local Output 74 Volatile and Non Volatile Memory 74 A Definition of Mapping 74 Local Mapping Example 75 Local Mapping Output 75 Network Input 75 Network Output 76 Hardy Control Link Network Mapping 76 Boolean Mapping 77 Anal
108. G FIG FIG FIG 4 11 4 12 4 13 4 14 4 15 4 16 4 17 4 18 4 19 4 20 4 21 4 22 4 23 4 24 4 25 4 26 4 27 4 28 4 29 4 30 4 31 4 32 4 33 4 34 4 35 4 36 4 37 4 38 4 39 4 40 4 41 4 42 4 43 4 44 4 45 4 46 4 47 4 48 4 49 4 50 4 51 4 52 4 53 4 54 4 55 4 56 4 57 4 58 4 59 4 60 4 61 4 62 4 63 4 64 4 65 HI 3010 Filler Dispenser IBC Service Manual INGREDIENT 1 SUB MENU ENTER INGREDIENT NAME 24 CLEARING INGREDIENT NAME 24 INGREDIENT NAME ENTERED FLOUR 24 INGREDIENT MENU FILL DISPENSE CYCLES 25 FILL DISPENSE CYCLES PARAMETER 25 INGREDIENT MENU TARGET WEIGHT 25 TARGET WEIGHT PARAMETER 25 TARGET PREACT PARAMETER 26 TARGET PREACT SUB MENU 26 TARGET PREACT MENU SET PREACT 26 TARGET PREACT MENU SMART PREACT 26 INGREDIENT SETUP MENU SELECTING TARGET WINDOW WEIGHT 26 INGREDIENT SETUP MENU SELECTING TARGET WINDOW PERCENTAGE 27 TARGET WINDOW WEIGHT 27 TARGET WINDOW PERCENTAGE 27 ADJUST INGREDIENT 1JOG 27 ADJUST INGREDIENT 1JOG 28 JOG MENU DEFAULT SETTINGS 28 JOG COUNT PARAMETER 28 JOG OFF TIME PARAMETER 28 FILL TIMER PARAMETER 28 WAIT TIMER PARAMETER
109. I1 Instrument Status Word HI1 0 A D error HI1 1 A D failure HI1 5 Real time clock failure HI1 6 In Motion HI1 8 NVR Failure HI1 9 Infrared Failure HSI2 Filler Dispenser Outputs bits HI2 0 HI2 15 HI2 0 Auxiliary Device HI2 1 Fast Fill or Fast Dispense HI2 2 Slow Fill or Slow Dispense HI2 3 Discharge HI2 4 Fill Complete or Dispense Complete HI2 5 Refill HI2 6 Change Bags HD 15 Any Alarm HSI3 Filler Dispenser Outputs bits HI3 0 HI3 15 HI3 0 AutoZero Failed or Bag Change Alarm HI3 1 Discharge Gate clogged or Refill Timeout HI3 2 Discharge Gate Stuck Open HI3 3 Discharge Gate Stuck Shut HI3 4 Feed Timeout HI3 5 Fast Gate Stuck Open HI3 6 Fast Gate Stuck Shut HI3 7 Lost OK to Fill or Lost OK to Dispense HI3 8 Jog Count Alarm HI3 9 Jog Gate Stuck Open HI3 10 Jog Gate Stuck Shut HI3 11 Not OK to Discharge HI3 12 Not OK to Fill or Not OK to Dispense HI3 13 Overfill or Over Dispense HI3 14 Slow Gate Stuck Open HI3 15 Slow Gate Stuck Shut HSI4 Filler Dispenser Outputs bits HI4 0 HI4 15 HI4 0 Tare Limit alarm or Over Refill HI4 1 Underfill or Under Dispense HI4 2 Disp Gate Open at Refill HI4 3 Refill Stuck Open HI4 4 Refill Stuck Shut HI4 5 Tare Timeout HI4 6 Insufficient Material HI4 7 Imbalance HSI5 Command Status Word This 16 bit word holds the result status of mapped commands HSI5 15 Command Status Data Val
110. IG 7 5 RESUME FILLING FAST DISPLAY 86 FIG 7 6 FAST GATE DID NOT CLOSE 86 FIG 7 7 RESUME FILLING FAST DISPLAY 87 FIG 7 8 SLOW GATE DID NOT OPEN ALARM 87 FIG 7 9 RESUME FILLING SLOW 87 FIG 7 10 SLOW GATE DID NOT CLOSE ALARM 87 FIG 7 11 WAIT TIMER DISPLAY 87 FIG 7 12 WAIT DISPLAY 88 FIG 7 13 UNDERFILL ALARM 88 FIG 7 14 OVERFILL ALARM 88 FIG 7 15 ACCEPT FILL DISPLAY 88 FIG 7 16 OVER REFILL ALARM 88 FIG 7 17 REFILL TIME OUT ALARM 89 FIG 7 18 DISPENSE STANDBY DISPLAY 89 FIG 7 19 NOT OK TO DISPENSE 89 FIG 7 20 LOST OK TO DISPENSE ALARM FAST DISPENSE 89 FIG 7 21 LOST OK TO DISPENSE ALARM SLOW DISPENSE 90 FIG 7 22 FAST DISPENSE GATE DID NOT OPEN ALARM 90 FIG 7 23 RESUME DISPENSING FAST DISPLAY 90 FIG 7 24 FAST DISPENSEON 90 FIG 7 25 FAST GATE DID NOT CLOSE 90 FIG 7 26 RESUME DISPENSE DISPLAY 90 FIG 7 27 SLOW GATE DID NOT OPEN ALARM 91 FIG 7 28 WAIT DISPLAY 91 FIG 7 29 SLOW GATE DID NOT CLOSE ALARM 91 FIG 7 30 WAIT DISPLAY 91 FIG 7 31 UNDERDISPENSE ALARM 91 FIG 7 32 OVERDISPENSE ALA
111. ISPENSER INSTALLING IN A SWIVEL MOUNT Step 3 Screw the two 2 fastener knobs into the threaded FIG 3 7 FILLER DISPENSER INSTALLED IN A holes on each side of the Filler Dispenser until the SWIVEL MOUNT brackets are snug against the instrument See Fig 3 6 amp 3 7 Step 7 Use four 4 1 4 x 20 fasteners to fasten the swivel mount to a vertical surface See Fig 3 8 CAUTION Do NOT OVERTIGHTEN Step 4 To rotate the instrument in the swivel mount loosen the two fastener knobs Step 5 Rotate the instrument to the position you want Step 6 Re tighten the fastener knobs FIG 3 8 INSTALLING THE SWIVEL MOUNT TOA VERTICAL SURFACE Step 8 Place the Filler Dispenser between the Swivel Mount brackets so that the threaded holes in the instrument are aligned with the slots in the Swivel bracket See Fig 3 9 15 CHAPTER 3 Installation NOTE When wall mounted the unit should support a 14 pound weight for one minute without coming loose or damaging the equipment G FIG 3 9 FILLER DISPENSER INSTALLING IN A SWIVEL WALL MOUNT Step 9 Screw the two fastener knobs into the threaded holes on each side of the Filler Dispenser until the brackets are snug against the instrument See Figs 3 9 amp 3 10 FIG 3 10 FILLER DISPENSER INSTALLED IN A SWIVEL WALL MOUNT Installing Printed Circuit Boards From the back of the instrument align the PCB board with the housing slots in the
112. ISPLAY PRINTER DATA BITS NUMBER OF LOAD SENSORS LOAD SENSOR 119 LOAD SENSOR DISPLAY SERIAL NUMBER CAPACITY SENSITIVITY MV V 120 SENSITIVITY INPUT RESISTANCE OUTPUT RESISTANCE 120 TEST DATA DISPLAY LOAD SENSOR IP ADDRESS DEVICENET ADR 120 TEST AND DATA MENU 120 TEST AND DATA MENU SELECTING DIAGNOSTICS 121 DIAGNOSTICS DISPLAY SELECTING VOLTAGE amp WEIGHT 5 E cre tat te Bie A Pere a g i 121 DIAGNOSTICS DISPLAY CHOOSE DISPLAY SCREEN 121 MILLIVOL T AND WEIGHT READING 121 MILLIVOLT VOLT AND WEIGHT READING 121 DIAGNOSTICS DISPLAY SELECTING STABILITY TEST 122 STABILITY TEST DISPLAY 122 SYSTEM STABILITY TEST DISPLAY PASS 122 SYSTEM STABILITY TEST DISPLAY FAIL 122 DIAGNOSTICS DISPLAY FACTORY DEFAULTS 123 FACTORY DEFAULTS DISPLAY 123 FUNCTION OK DISPLAY 123 INSTRUMENT SELECTION DISPLAY 123 FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG HI 3010 Filler Dispenser IBC Service Manual 7 84 DIAGNOSTICS DISPLAY SELECTING RETURN TO ZERO TEST 123 7 85 RETURN
113. L CYCLES 15 FIG 4 16 INGREDIENT MENU TARGET WEIGHT Step 2 Ifa value already exists press the Clear button to clear the previous entry Step 3 Use the alphanumeric key pad and enter the target weight for this ingredient In our example we used 100 00 Ibs See Fig 4 17 FIG 4 17 TARGET WEIGHT PARAMETER Step 4 Press the Enter button The Target Weight is set and the cursor moves to Target Preact See Fig 4 18 Target Preact About Target Preact Target Preact is the number of units above or below the set point value Target Weight at which time you want the relay to trip Use as an in flight compensation value for the time it takes for a valve gate to close or a conveyor to stop You want to set the Target Preact to start closing stopping so that when it closes or stops completely the Target Weight Set Point is reached About Smart Preact Smart Preact is an automatic function that calculates the loss in weight gain in weight during a cycle to determine if the Target Preact Set Point is set so that the cycle is within the Target Weight Tolerance If it is not the instrument auto matically calculates a new Target Preact so that the next cycle is hitting the Target Weight While the Smart Preact is on the Filler Dispenser continues to determine the Smart Preact Set Point maintaining and or improving Fill Dispense accuracy PARAMETER TARGET PREACT RANGE 000001 999 999 DEFAULT 1 0 SMART PREACT O
114. L DUS AMT 0 00 225 00 UNDERFILL ALARTA HLD FIG 7 13 UNDERFILL ALARM FLOUR AMT 0 00 225 00 IOVERFILL ALARTA HLD FIG 7 14 OVERFILL ALARM e OVERFILL ALARM press the Clear but ton to clear the alarm The Accept the Fill display appears See Fig 7 15 At this time you can 1 Accept the fill by pressing the START button 2 Physically remove some of the mate rial until it meets the target window requirements and then press the START button HI 3010 Filler Dispenser IBC 88 Service Manual 3 The instrument returns to the Waiting On Display repeats the motion check autozeros autotares and or checks the OK to Fill processes and begins fill cycle number 2 FLOUR AMT ech 80 ec5 00 TOACCEPT FILL LB PRESSSTART HLD FIG 7 15 ACCEPT FILL DISPLAY e UNDERFILL ALARM press the Clear button to clear the alarm the Accept the Fill display appears At this time you can 1 Accept the fill by pressing the START button 2 Physically add some of the material until it meets the target window requirements and then press the START button 3 The instrument returns to the Waiting On Display repeats the motion check autozeros autotares and or checks the OK to Fill processes and begins fill cycle number 2 e Ifthe gain in weight is NOT within the tar get window and the JOG function is turned ON the Filler Dispenser automatically does the following 1 If the out of target window is a
115. L TIMER 36 SETUP MENU SERIAL PORT 36 SERIAL PORT MENU PRINTER PORT SETUP 36 Table of Illustrations FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG 4 66 PRINTER PORT MENU BAUD RATE 37 4 67 PRINTER PORT MENU PARITY 37 4 68 PRINTER PORT MENU DATA BITS 37 4 69 PRINTER PORT MENU AUTO PRINT 37 4 70 SETUP MENU TOTALIZER 37 4 71 TOTALIZER MENU CHOOSING INGREDIENT TOTALIZER NUMBER 38 4 72 TOTALIZER NUMBER MENU 38 4 73 CLEARING ALL TOTALS FOR ALL 12 INGREDIENTS 38 4 74 SETUP MENU UNIT OF MEASURE 38 4 75 SETUP MENU DECIMAL POINT 39 4 76 SETUP MENU TOTAL DECIMAL POINT 39 4 77 SETUP MENU MOTION TOLERANCE 39 4 78 SETUP MENU ZERO TOLERANCE 40 4 79 ZERO TOLERANCE MENU ZERO TOLERANCE 40 4 80 ZERO TOLERANCE MENU USE AUTO ZERO 40 4 81 ZERO TOLERANCE MENU AUTO ZERO TOLERANCE 40 4 82 ZERO TOLERANCE MENU AUTO ZERO TIME 40 4 83 SETUP MENU TARELIMIT 41 4 84 SETUP MENU AVERAGES 41 4 85 SETUP MENU
116. LL Contact closure input 5 means assign the state Open 0 or Closed 1 of Contact 5 contained in the Contact Closure input 5 memory address in the Input Image Table and move it to the OK TO FILL address in the Output Image Table See Fig 6 38 Local Output Outputs interface with indicators motor starters solenoids and other actuators connected to the HI 3010 Remember Outputs can be a Destination and a Source See Destination definition in the Glossary of Mapping Terms Data Table 76543210 Output 0 Output Image 1 Input Image 9 Q 2 3 1 E 2 O Output Device Y S 0 Address 0 3 FIG 6 38 OUTPUT FUNCTION e Each output has an address associated with 1t e This address describes the physical loca tion that the output device is connected to e This address also describes the data table location where the desired state of the out put device is stored e The desired state of each output is trans ferred from the output image table to the output point during the I O Scan every 1 55th of a second See Fig 6 38 For Example Relay out 3 FAST FILL means assign the desired state Open 0 or Closed 1 located at the Fast Fill Address in the input image table and move it to the Relay out 3 address in the Output Image Table See Fig 6 38 Volatile and Non Volatile Memory It is important to understand that the data stored in the Ou
117. Mapping Security 12 CONFIGURATION PAGE Step 2 Click on Calibration The Calibration Sub menu appears See Fig 5 13 Configuration Calibration Instrument ID Hardy Filler Sensor Type 0 3mV V L C2 Calibration Load Sensor Number 0 Recone 0000 Conecto 1000000 weight S sadaa L Factor Do C2 Calibration FIG 5 13 C2 CALIBRATION SUB MENU Step 3 The Load Sensor number is a read only field It tells you how many load sensors are connected to the instrument If this number does not reflect with the actual number of load sensors go to Chapter 7 Troubleshooting Step 4 To choose the type of sensor for this instrument click on the pull down list next to Sensor Type See Fig 5 14 61 CHAPTER 5 Calibration Instrument ID Hardy Filler Sensor Type 0 3mVV M 0 3mV V FIG 5 14 SENSOR TYPE PULL DOWN LIST Step 5 Step 6 Step 7 Click on the Sensor type you are using for this application In our example we selected 0 3mV V sensors Click on the Save button to save the selection To enter the Reference Weight click in the Refer ence Weight field See Fig 5 15 C2 Calibration Load Sensor Number 0 Reference pe 1 002102 weight Gerin s Do C2 Calibration L FIG 5 15 C2 CALIBRATION ENTERING NOTE Step 8 Step 9 NOTE REFERENCE WEIGHT The Reference Point 3 000 is for demonstration purposes only The recommended Reference
118. OFF LOCATIONS Step 11 Gently push the pins into the connector making sure that the standoffs are aligned with the standoff holes in the Main board When the standoffs are flush with the Main board Step 12 Use a phillips head screw driver and install the four 4 phillips screws that fasten the main board to the 17 CHAPTER 3 Installation four 4 standoffs Tighten until snug do not over tighten Step 13 Use a Phillips head screw driver and install the three 3 phillips screws that fasten the Smart Diag nostics rear plate to the Main board Step 14 Install the two 2 thumb screws that fasten the Smart Diagnostics rear plate to the Main board Step 15 Line the Smart Diagnostics Card and the Main board with the guide slots on either side of the chas sis Step 16 Gently slide the Smart Diagnostics assembly back into the HI 3000 Series instrument Step 17 Install the two 2 phillips screws that fasten the Smart Diagnostics rear plate to the chassis Step 18 Plug the Load Cell connectors into the Channel inputs at the rear panel Step 19 Install the communication cables Step 20 Install the Secure Memory Module Installation complete NOTE For Configuration Instruction for Smart Diag nostics go to Chapter 4 Smart Diagnostics Con figuration Removing Printed Circuit Boards Step 1 Unplug all the cables that are connected to the instrument Use a Phillips head screw driver and remove the two 2 pan he
119. OK 64 Mapping sett ttt rt et eee 65 FIG 6 1 HOME PAGE SELECTING CONFIGURATION 65 FIG 6 2 CONFIGURATION PAGE SELECTING MAPPING SETUP 66 FIG FIG FIG 6 3 CONFIGURATION MAPPING SETUP 1 SELECTING A DESTINATION essen onthe tada Ee Gee ence 66 6 4 LOCAL OUTPUT SELECTING OUTPUT RELAY 1 67 6 5 OUTPUT RELAY 1 ADDRESS HO0 0 67 IV V Table of Illustrations FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG 6 6 6 7 6 8 6 9 6 10 6 11 6 12 6 13 6 14 6 15 6 16 6 17 6 18 6 19 6 20 6 21 6 22 6 23 6 24 6 25 6 26 6 27 6 28 6 29 6 30 6 31 6 32 6 33 6 34 6 35 6 36 6 37 6 38 6 39 6 40 6 41 6 42 6 43 6 44 6 45 6 46 6 47 6 48 6 49 6 50 6 51 CONFIGURATION MAPPING SETUP 2 67 CONTROL PULL DOWN MENU SELECTING FAST FILL 68 SELECTING FAST FILL SOURCE 68 MAPPING IS COMPLETE 68 MAPPED FAST FILL TO OUTPUT RELAY 1 69 DESTINATIONS SELECTING OK TO FILL 69 OK TO FILL HO1 4 SELECTED AS A DESTINATION 69 CONFIGURATION MAPPING SETUP 2 PAGE SELECTING LOCAL INPUT 4 AS THE SOURCE 69 COM
120. PLETED ASSIGNMENT STATEMENT 69 MAPPING SETUP 1 PAGE SELECTING OUTPUT RELAV gest 20 Syste eee en 70 OUTPUT RELAY 3 HO0 2 ENTERED IN THE ASSIGNMENT STATEMENT AS A DESTINATION 70 ALARMS SELECTING OVERFILL ALARM 70 OVERFILL ALARM HI3 13 ENTERED IN THE MAPPING ASSIGNMENT STATEMENT 70 ADDING BOOLEAN OR TO THE ASSIGNMENT STATEMENT 2 2 3 0 20522 sich A A EN 70 ALARMS SELECTING SLOW GATE SHUT ALARM 70 SLOW GATE SHUT HI3 15 ADDED AS THE SECOND SOURCE TO THE ASSIGNMENT STATEMENT 71 MULTIPLE SOURCE MAP 71 NETWORK SELECTING DEVICENET INT OUT 71 DEVICENET INT OUT DIO2 SET AS DESTINATION 71 PROCESS DATA SELECTING GROSS WEIGHT 71 ASSIGNMENT STATEMENT MAPPING GROSS WEIGHT HF12 TO DEVICENET INT OUT DIO2 71 LOCAL OUTPUT SELECTING OUTPUT RELAY 2 72 OUTPUT RELAY 2 HO0 1 SET AS DESTINATION 72 NETWORK SELECTING DEVICENET BOOLEAN IN 72 NETWORK SELECTING NON BOOLEAN DEVICENET INATA V S629 202 Seascape ae ee e Ee 72 ASSIGNMENT STATEMENT MAPPING DEVICENET BOOLEAN IN DI2 1 TO OUTPUT RELAY 2 HO0 1 72 ASSIGNMENT STATEMENT MAPPING DEVICENET INT IN DIO2 TO OUTPUT RELAY 2 HO0 1 72 DEVICENET BOOLEAN IN MAPPED TO OUTPUT RELAY 2 a eret Sisto Ss Soe a a ene eh ioe pce Sees E 72 HIGHLIGHTING CURRENT MAPPING 73 COPY TO THE MAP TEXT
121. RATE 9600 PRT PARITY NONE FIG 7 65 TEST DATA DISPLAY SLOW FILL PROOF TIMER PRT BAUD RATE PORT PARITY NOTE Slow Fill Proof Timer is the last item in the Test Data Ingredient Menus Step 49 Slow Fill Proof Timer Printer Baud Rate Printer Parity are read only e Slow Fill Proof Timer If the Slow Fill Proof Switch is ON the set time it takes for the switch to safely open or close e Printer Baud Rate Indicates the Baud Rate for the printer e Printer Parity Indicates the parity setting for the printer Odd Even None Step 50 Press the down arrow button until the next three menu items are displayed See Fig 7 66 CU FIG 7 66 TEST DATA DISPLAY PRINTER DATA BITS NUMBER OF LOAD SENSORS LOAD SEN SOR Step 51 Printer Data Bits Number of Sensors Load Sensor are read only however you can select a load sensor to view Printer Data Bits Indicates the Data Bit setting for the printer 121 CHAPTER 7 Troubleshooting Number of Sensors The number of sen sors detected by the instrument in the Fill ing Dispensing system 1 Load Sensor The instrument will read C2 load sensors certification information only 2 The instrument displays sensor num ber as a default 3 If you want to look at the certified specifications for other load sensors press the up or down arrows to move the list of sensors The instrument can detect a maximum of 8 sensors 4 To view the certified s
122. RM 91 FIG 7 33 ACCEPT DISPENSE DISPLAY 92 FIG 7 34 CHANGE IBC ALARM 92 FIG 7 35 JOG GATE DID NOT OPEN ALARM 92 FIG 7 36 TO JOG AGAIN PRESS START DISPLAY 92 FIG 7 37 JOG GATE DID NOT CLOSE ALARM 92 FIG 7 38 JOG 1 DISPLAY 93 FIG 7 39 JOG DISPLAY JOG 1 2 0 SECONDS 93 FIG 7 40 JOG DISPLAY COMPLETED ONE JOG SEQUENCE CHECKING WEIGHT 93 FIG 7 41 JOG PAUSED 1 0 SECOND INTO THE JOG SEQUENCE 93 FIG 7 42 JOG COUNT ALARM 93 FIG 7 43 JOG DISPLAY JOG AGAIN 93 FIG 7 44 NOT OK TO DISCHARGE ALARM 94 FIG 7 45 DISCHARGE GATE DID NOT OPEN ALARM 94 FIG 7 46 CLOGGED DISCHARGE GATE ALARM 94 FIG 7 47 DISCHARGE GATE DID NOT CLOSE ALARM 94 vil Table of Illustrations FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG FIG 7 48 7 49 7 50 7 51 7 52 7 53 7 54 7 55 7 56 7 57 7 58 7 59 7 60 7 61 7 62 7 63 7 64 7 65 7 66 7 67 7 68 7 69 7 70 7 71 7 72 7 73 7 74 7 75 7 76 7 77 7 78 7 79 7 80 7 81 7 82 7 83 TEST AND DATA MENU SELECTING DEVICE DATA LIST 114 TEST DATA DI
123. RY DEFAULTS SET SELECT APPLICATION TYPE NOTE This procedure is useful when you want to con vert the instrument from a filler to a dispenser or IBC dispenser and vice versa Step 7 Click on the Save button to set the factory defaults for the application you selected Click on Back to return to the previous page The previous page appears Click on the left arrow to return to the Operation Diagnostics page Step 10 Click on Home to return to the Filler Dispenser Home Page Step 8 Step 9 Smart Diagnostics Using Smart Diagnostics From the Front Panel Press the Test 9 button The Test and Data Menu appears See Fig 7 101 Step 1 FIG 7 101 TEST AND DATA MENU SELECTING DIAGNOSTICS Step 2 Press the down arrow until the cursor is in front of Diagnostics See Fig 7 102 HI 3010 Filler Dispenser IBC 128 Service Manual Step 3 Press the Enter button The Smart Diagnostics Dis play appears with the cursor in front of Voltage amp Weight See Fig 7 103 SMART DIAGNOSTICS gt Voltage amp Wight Stabil ity Test Fact or y Def aults FIG 7 102 SMART DIAGNOSTICS DISPLAY SELECTING VOLTAGE amp WEIGHT Step 4 Smart Diagnostics enables you to read total or indi vidual load sensor s Millivolt Millivolt Volt or Weight Reading e The mV reading is a coarser reading than the mV V or Weight The mV reading is sufficient to balance the corners of your scale or vessel e These readings allow yo
124. S 8 TUV Button Enters the integer 8 and the letters T U V Test 9 WXYZ Button Enables you to enter the selftest or diagnostics mode Also enters the integer 9 and letters W X Y Z User _ blank Button Enables you to change the 3 digit user code while in the standby mode Also enters a dash underscore _ at comma and period symbols ULUS NT Button Enables you to enter the left side of a parentheses enter the right side of a parentheses asterisk plus sign amper sand amp apostrophe and the integer 0 NOTE Whenever you see gt arrow in a menu it means that there is a sub menu that you need to go to in order to set the parameters Selecting Configuration Menus When the Filler Dispenser first starts up the function selec tion display appears See fig 4 5 Houl I BEUSEDe PRESSENTER KESTO CHoose FIG 4 5 WELCOME DISPLAY Press the Enter button The Instrument Selection screen displays See Fig 4 6 Step 1 FIG 4 6 INSTRUMENT SELECTION SCREEN WITH FILLER SELECTED DEFAULT Step 2 To move the cursor up and down press the up and down arrows until the cursor is in front of the instrument you want to select Press the Enter button A prompt asking if you are sure this is the instrument you want appears See Fig 4 7 Step 3 FIG 4 7 PROMPT CONFIRMING SELECTION Step 4 If this is the instrument you want to use press the Enter
125. SCALE CAPACITY 41 4 86 SETUP MENU WAVERSAVER 42 4 87 SETUP MENU SET CLOCK 42 4 88 CLOCK SETUP MENU SET HOURS 42 4 89 CLOCK SETUP MENU SET MONTH 43 4 90 CLOCK SETUP MENU SETGMT 43 4 91 SETUP MENU DEVICENET 44 4 92 DEVICENET MENU BAUD RATE 45 4 93 DEVICENET MENU NODE ADDRESS 45 4 94 SETUP MENU ETHERNET 45 4 95 ETHERNET MENU IP ADDRESS WITH DEFAULT IPADDRESS acer a oe ace ai 45 4 96 ENTER IP ADDRESS IN BROWSER ADDRESS FIELD 46 4 97 SYSTEM WEB PAGE 46 4 98 CONFIGURATION WEB PAGE 46 4 99 CONFIGURATION ADJUST INGREDIENT WEB PAGE 47 4 100 EDIT INGREDIENT PULL DOWN MENU 47 4 101 CONFIGURATION ADJUST INGREDIENT 47 4 102 CONFIGURATION PULL DOWN MENU 48 4 103 CONFIGURATION ADJUST INGREDIENT 48 4 104 CONFIGURATION INGREDIENT NAME CHANGE 48 4 105 CONFIGURATION INGREDIENT NAME FLOUR 48 4 106 SETTING JOG COUNT 2 523 425 s 2 2 eee 49 4 107 ADJUST INGREDIENT 7PAGE2 49 4 108 TARGET WEIGHT TOLERANCE PULL DOWN MENU 50 4 109 SPEED SELECTION seria e e 50 4 110 CONFIGURATION PAGE SELECT INSTRUMENT SETUP 50 4 111 INSTRUMENT SETUP FILLER 51 4 112 UNITS OF MEASURE 22 cocoa e 51 4 113 INSTRUMENT SETUP SELECTING GRAD SIZE
126. SPLAY INSTRUMENT ID MODEL NUMBER S N Sie cc ht tie cicada cea oer eye ve 114 TEST DATA DISPLAY PROGRAM VERSION LAST CALTYPE esa oui vie eo ate ate a beat ee 114 TEST DATA LAST CALIBRATION TIME 115 TEST DATA LAST CALIBRATION DAY MONTH YEAR 115 TEST DISPLAY CALIBRATOR UNITS WAVERSAVER 115 TEST DATA DISPLAY GRADUATION SIZE SPAN VALUE ZERO COUNT 50 pss ls 115 TEST DATA DISPLAY SPAN COUNT C2 SENSITIVITY SCALE CAPACITY ose d eis See rod 116 TEST DATA DISPLAY ZERO TOLERANCE AUTO ZERO TOLERANCE AUTO ZERO TIME 116 TEST DATA DISPLAY TARE LIMIT MOTION TOLERANCE AVERAGES oo e 117 TEST DATA INGREDIENT DISPLAY INGREDIENT FILL CYCLES TARGET WEIGHT 117 TEST DATA INGREDIENT DISPLAY TARGET PREACT SMART PREACT TARGET WINDOW WT 118 TEST DATA INGREDIENT DISPLAY TARGET WINDOW WT TARGET WINDOW WT TARGET WINDOW UO Er Bea E n aae A ee Gece ed ees Bae 118 TEST DATA INGREDIENT DISPLAY JOG ON TIME JOG COUNT JOG OFF TIME 50 ee 118 TEST DATA INGREDIENT DISPLAY FILL TIMER WAIT TIMER SPEED eee os et ee ee Se 118 TEST DATA INGREDIENT DISPLAY FAST FILL PROOF SWITCH FAST FILL PROOF TIMER FAST FILL WEIGHT 119 TEST DATA INGREDIENT DISPLAY AUTO FAST ADJUST MODE SLOW FILL PROOF SWITCH 119 TEST DATA DISPLAY SLOW FILL PROOF TIMER PRT BAUD RATE PORT PARITY 119 TEST DATA D
127. T DISPLAY FAIL NOTE In our example we show that the Means squared variation is greater than 5 0 but the average reading is within tolerance 1 Disconnect the power cord and recon nect the power cord to restart the instrument 2 Repeat the Stability test 3 If the instrument Fails the Stability Test again contact Hardy Instruments Inc Technical Support for assistance Step 4 Press the Exit button to return to the Diagnostics display Factory Defaults CAUTION IF YOU CHOOSE FACTORY DEFAULTS ALL DATA WILL BE LOST MAKE ABSOLUTELY SURE THAT THIS IS WHAT YOU WANT TO DO BEFORE CHOOSING THIS OPTION DO NOT USE THIS FUNCTION IN AN EFFORT TO CORRECT ANY MALFUNCTIONS IN THE OPERATION OF THE INSTRUMENT Step 1 Press the up or down arrow buttons until the cursor is in front of Factory Defaults See Fig 7 80 VOLTAGE b WEIGHT gt STABILITY TEST gt gt FACTORY DEFRULTS gt FIG 7 80 DIAGNOSTICS DISPLA Y FACTORY DEFAULTS e Resetting the Default Parameters is used when you want to change the instrument from a Filler to a Dispenser or an IBC dis penser and vice versa s It is required that the security access to this menu is High HD Step 2 Press the Enter button The Factory Defaults dis play appears See Fig 7 81 LUST ARE YoU SURE IE 50 PRESS ENTER FIG 7 81 FACTORY DEFAULTS DISPLAY Step 3 Press the Exit button if you do not want to set the Factory Defaults The Diagnostics displ
128. TO ZERO TEST DISPLAY 123 7 86 RETURN TO ZERO TEST PASS 124 7 87 RETURN TO ZERO FAIL 124 7 88 DIAGNOSTICS VIEW INPUT STATES 124 7 89 INPUT STATES DISPLAY INPUT 2 AND 4 ACTIVE 124 7 90 DIAGNOSTICS DISPLAY FORCE OUTPUTS 124 7 91 WARNING FOR FORCE OUTPUTS 124 7 92 OUTPUT RELAY DISPLAY SELECTING OUTPUT RELAY cess ep Bess A cab eae BL 125 7 93 OUTPUT RELAY DISPLAY SELECTING OUTPUT RELAY 2 dco a SR K 125 7 94 OUTPUT RELAY 1 FORCED CLOSED DISPLAY 125 7 95 DIAGNOSTICS DISPLAY SELECTION STATE LOGGING OFF 125 7 96 DIAGNOSTICS DISPLAY STATE LOGGING ON 125 7 97 SCR SWITCHING LOAD CIRCUIT 126 7 98 OPERATION DIAGNOSTICS 126 7 99 SET FACTORY DEFAULTS 126 7 100 FACTORY DEFAULTS SET SELECT APPLICATION TYPE 127 7 101 TEST AND DATA MENU SELECTING DIAGNOSTICS 127 7 102 SMART DIAGNOSTICS DISPLAY SELECTING VOLTAGE 8 WEIGHT 127 7 103 TOTAL MILLIVOLT READING 127 7 104 INDIVIDUAL CHANNEL DISPLAY MILLIVOLTS 128 7 105 TOTAL MILLIVOLT VOLT READING 128 7 106 INDIVIDUAL MILLIVOLT VOLT DISPLAY 128 7 107 SCALE WITH TOTALS WEIGHT LB SELECTED 128 7 108 INDIVIDUAL WEIGHT DISPLAY 129 7 109 DIAGNOSTICS DISPLAY SELECTING STABILITY TEST 129 7 110
129. U SELECTING SETUP 58 FIG 5 3 CALIBRATION MENU C2 CAL 58 FIG 5 4 CALIBRATION SELECTING CAL TYPE 58 FIG 5 5 C2 CALIBRATION SUB MENU 58 FIG 5 6 ENTERING THE REFERENCE POINT 58 FIG 5 7 GRAVITY CORRECTION FACTOR 59 FIG 5 8 GRAVITY CLEARING ENTRY 59 FIG 5 9 GRAVITY CORRECTION FACTOR MEXICO CITY 59 FIG 5 10 DO C2 CALIBRATION 59 FIG 5 11 CONFIGURATION MENU SELECTING SETUP 60 FIG 5 12 CONFIGURATION PAGE 60 FIG 5 13 C2 CALIBRATION SUB MENU 60 FIG 5 14 SENSOR TYPE PULL DOWN LIST 61 FIG 5 15 C2 CALIBRATION ENTERING REFERENCE WEIGHT 61 FIG 5 16 CAL COMPLETED OK 61 FIG 5 17 CONFIGURATION MENU CALIBRATION 61 FIG 5 18 CALIBRATION MENU 62 FIG 5 19 CALIBRATION TRADITIONAL 62 FIG 5 20 TRADITIONAL CALIBRATION ZERO VALUE 62 FIG 5 21 DO TRADITIONAL CALIBRATION ZERO 62 FIG 5 22 TRADITIONAL CALIBRATION SPAN VALUE 62 FIG 5 23 TRADITIONAL CALIBRATION SPAN 62 FIG 5 24 CONFIGURATION MENU SELECTING SETUP 63 FIG 5 25 CONFIGURATION PAGE 63 FIG 5 26 CALIBRATION SUB MENU 63 FIG 5 27 CAL LOW COMPLETED OK 63 FIG 5 28 CAL HIGH COMPLETED
130. W GATE FIG 7 10 SLOW GATE DID NOT CLOSE ALARM DID NOT OPEN alarm appears on the dis play See Fig 7 8 1 Determine why the slow Fill Gate did not close and correct the problem 2 2 Press the Clear button to clear the erate alarm The Wait Timer display Cae 2 appears See Fig 7 11 AMI eee 00 2e5 00 ALARM SLOWGATE IDIDNOT OPEN HLD L FLOUR AMI 22 00 225 08 cur a Cf FIG 7 8 SLOW GATE DID NOT OPEN ALARM G 233 96 WAN TIMER 230 1 Determine why the Slow Fill Gate did f not open and correct the problem 2 Press the Clear button to clear the FIG 7 11 WAIT TIMER DISPLAY alarm The RESUME FILLING SLOW display appears See Fig 7 3 If the fill is within the target window 9 and you do not have the Discharge Function turned ON See Discharge Function above the instrument returns to the Waiting On Display repeats the motion check autozeros autotares and or checks the OK to Fill processes and begins fill cycle num ber 2 then 3 4 and so on See Fig 7 11 4 Ifthe fill is within the target window and it is the last fill cycle of a fill sequence the instrument goes to Standby and the Standby Display appears See Fig 7 12 Other Wait Displays that can appear are as follows e Waiting for Motion to settle e Waiting for Log Off to expire e Waiting for fill dispense to continue FLOUR AMT REQ 225 00 Le CYCLES 56 OROSSuUT 100 00 OFF FIG 7 12 WAIT DISPLAY Underfill Overfill Alarm E
131. Web Browser 46 Configuring Ingredients from the Browser 47 About Configuring Ingredients 47 Chapter 5 Chapter 6 HI 3010 Filler Dispenser IBC Service Manual Changing the Ingredient Name 48 Changing the Ingredient Name 48 The Browser Ingredient Setup is Complete 50 Instrument Setup from the Browser 50 Refill Parameters 53 Discharge Parameters 53 Serial Port Parameters 53 Set Date Clock Parameters 54 The Browser Instrument Setup is Complete 55 Options Configuration 55 Smart Diagnostics SD Card Configuration from the Front Panel 55 Smart Diagnostics Card Configuration from the Web Browser 55 Calibration eS a e 9 NS ee SSS A Say ee ee See 57 About Chapter 5 57 Getting Started 57 Binding 57 Electrical Check Procedures a 57 C2 Calibration From the Front Panel 57 About The Gravitation Correction Factor 58 C2 Calibration From the Web Page 60 Traditional Calibration From the
132. When OK to Fill is activated it tares the scale to Net zero PARAMETER ZERO TOLERANCE RANGE 000001 999999 DEFAULT 10 0 PARAMETER USE AUTO ZERO TOLERANCE RANGE OFF ON DEFAULT OFF PARAMETER AUTO ZERO TIME RANGE 01 9 99 SECONDS DEFAULT 1 00 SECOND Step 1 Press the down button until the cursor is in front of Zero Tolerance See Fig 4 78 FIG 4 78 SETUP MENU ZERO TOLERANCE Step 2 Press the Enter button The Zero Tolerance Menu appears with the cursor in front of Zero Tolerance See Fig 4 79 gt ZERO TOLERANCE 0 00 Lise AUTO ZERO OFF AZERO Tol 10 00 FIG 4 79 ZERO TOLERANCE MENU ZERO TOLERANCE Step 3 Step 4 Press the Clear button to clear the current value Used the alphanumeric key pad to enter the new Zero Tolerance value Step 5 Press the Enter button to set the entry HI 3010 Filler Dispenser IBC 40 Service Manual Step 7 Press the right or left arrow buttons to toggle between OFF or ON Press the Enter button to set the entry Press the down arrow button until the cursor is in front of AZERO Tol See Fig 4 81 Step 8 Step 9 FIG 4 81 ZERO TOLERANCE MENU AUTO ZERO TOLERANCE Step 10 Press the Clear button to clear the current value Step 11 Use the alphanumeric key pad to enter the new Auto Zero Tolerance value Step 12 Press the Enter button to set the entry Step 13 Press the down arrow button until the cursor is in front of Auto Zero Time See Fig
133. ZERO arrow to SPAN 2 Add the test weight to the scale and perform the SPAN entry 3 After SPAN GOOD arrow back to ZERO 4 Remove the test weights and set the ZERO reference point 5 Again perform the SPAN operation and continue with the calibration SPAN y 106 The milli volt signal reading did not show a positive increase 1 Use the Multimeter in Diagnostics to verify milli volt levels 2 Compression load cells can be installed upside down Giving negative signal readings 3 Mechanical binding restricts the scales movement 4 Load cell wires disconnected or improperly wired 5 Improper load sharing or mechanical loading on the load cell The Span weight too small 1 100 counts out of 985 000 is very small 100 000 Ib scale would require 11 Ibs 2 Mechanical binding can mask weight readings Yes Contact Technical Support No Proceed with Calibration 107 CHAPTER 7 Troubleshooting H Mechanical Inspection All pipes and conduits flexible Mechanically Isolated from ladders and connecting structures Are the load cells properly mounted Are Check Rods installed to dampen vessel movement Are cables routed properly Housekeeping To Verify Electrical Go to J Keep flexures on the horizontal Vertical flexures should be avoided Do not use flexures to correct for misaligning piping Do n
134. abilities on Formerly Operating Systems 100 C1 Guidelines for Instabilities on formerly operating systems with Smart Diagnostics 101 E Non Retum to Zero 102 F Verify Individual Load Cell Milli Volt Readings 103 F a Verify Individual Load Cell Readings Using Smart Diagnostics 104 G A D Failure Error 105 H Mechanical Inspection 106 J Electrical Inspection 107 K Load Sharing and Load Sensor Checkout 108 M Weight Reading Stops Incrementing 109 N Blank Screen110 O Display Stuck on a Screen 111 R View Input States 112 S Forcing Outputs 113 System Integrity Check and Fault Determination From the Front Panel 114 Diagnostics 114 About Diagnostics 114 Dictionary of Mapping Symbols Index HI 3010 Filler Dispenser IBC Service Manual Checking the Device Data List 114 Diagnostics 120 Voltage amp Weight Displays 120 Stability Test 122 Factory Defaults 122 Ret
135. accuracy of the instrument Increasing the number of decimal points increases the overall accuracy of the instrument PARAMETER DECIMAL POINT RANGE 0 6 DEFAULT 2 39 CHAPTER 4 Configuration Step 1 Press the down arrow button until the cursor is in front of Decimal Point See Fig 4 75 SETUP MENU TOTALIZER ON LIMIT OF MEASURE LB gt Decimal Point C FIG 4 75 SETUP MENU DECIMAL POINT Step 2 Press the right or left arrow buttons to make your selection Step 3 Press the Enter button to set the entry Total Decimal Point Parameter About the Total Decimal Point Parameter The Total Decimal Point Parameter sets the decimal point for the Totalizer The higher the number the farther to the left the decimal moves and the higher the resolution of the scale PARAMETER TOTAL DECIMAL POINT RANGE 0 6 DEFAULT 0 Step 1 Press the down arrow button until the cursor is in front of the Total Decimal Pt See Fig 4 76 SETUP MENU Decimal PONT S gt Tatar Beca PT U Moron Tol 10 00 FIG 4 76 SETUP MENU TOTAL DECIMAL POINT Step 2 Press the right or left arrow buttons to make your selection Step 3 Press the Enter button to set the entry Motion Tolerance Parameter About Motion Tolerance Motion is the amount of allowable deviation between con secutive readings before a weighment is accepted as being complete Setting Motion Tolerance establishes the amount of deviation you can allow in your particul
136. ack 63 Basic I O Mapping Menu 82 Basic Load Cell Theory 134 Basic Mapping 81 Basic Mapping Using Hardy Link 65 Baud Rate 36 Baud Rate Pull Down 54 Baud Rates 4 BC Intermediate Bulk Container 1 Bi Directional Communications 6 Binding 57 Blind Mount 21 Block Transfer Commands 6 Boolean Equations 78 Boolean Mapping 77 Boolean Operations 77 78 Boolean Tables 77 Boolean Variables 78 Booster Power Supply 4 Built in Smart Diagnostics Knowledgebase 2 Built In Totalizers 1 Button Functions 21 C C Guidelines for Instabilities on Formerly Operating Systems 100 C27 C2 Cal Error 85 C2 Cal Type 57 61 C2 Calibration From the Front Panel 57 C2 Calibration From the Web Page 60 C2 Load Points 18 C2 Load Sensor 116 C2 Load Sensor Certification Data 4 C2 Sensitivity 116 C2 Weighing System 3 C2 Calibration 3 C2 Electronic Calibration 1 C2 Load Point Connection 18 C2 Second Generation Calibration 3 Cable Color Code 18 Cable Color Code for Non C2 Load Points 18 Cabling and Interconnecting 17 CAL Failed 85 Cal Type 58 Calibration Completed OK 61 Calibration Menu 57 61 Calibration Page 63 HI 3010 Filler Dispenser IBC Service Manual Calibration Procedures 57 Calibration Sub Menu 60 63 Calibration Techniques 7 Calibrator 115 Capacity 120 Captive Screws 13 Certified Test Weight 62 63 Change IBC Alarm 92 Changing the Ingredient Name 48 Channels 18 Checking the Device Data List 114 Choose Display
137. ad screws that fasten the rear plate to the instrument You do not need to remove any of the screws that fasten the rear panel to the PC Board Use your fingers to grasp the two 2 knurled knobs that are mounted on the rear panels Gently pull the knobs away from the instrument until the PC Board is clear of the instrument slots Store the circuit board in a secure and dry location free of any ESD Step 2 Step 3 Step 4 Step 5 Electrical Installation Cabling and Interconnecting Recommended Installation Procedures e Carefully plan the cable runs and wiring con nections before routing cutting and trim ming cables and wires CAUTION INSTRUMENT POWER AND RELAY WIRES SHOULD BE ROUTED AWAY FROM ALL OTHER SIGNAL CABLES TO AVOID ELECTRICAL INTERFERENCE e All cabling should be neatly bundled tied and dressed e Use a 6 inch service bend to relieve stress on the connectors and to ease servicing the unit Make sure that all plugs are firmly in place e Be sure to secure the power cord with the two 2 captive screw on clips e All connections are made at the rear panel of the Filler Dispenser IBC AC Power Wiring WARNING DO NOT OPERATE WITH INCORRECT LINE VOLTAGE TO DO SO WILL RESULT IN PROPERTY DAMAGE AND OR PERSONAL INJURY MAKE SURE THAT THE POWER SOURCE DOES NOT EXCEED 240 VAC e The AC power should be supplied by a clean primary line directly from the power panel This line shoul
138. and vessel level when complete HI 3010 Filler Dispenser IBC Service Manual M Weight Reading Stops Incrementing Contact Weight Reading is Frozen at Zero or a High Weight Reading The load sensor output signal has exceeded the millivolt limits set in Configuration and or the internal factory setting Verify the signal wires are properly connected a Verify load cell cable color code 1 Load Cell Certificate 2 Installation Manual 3 Cable marking strips b Broken signal wires act as antenna for EMI RFI c Load cell cable shields must be grounded only at the controller to dampen EMI RFI signals The load cell output signal voltage has exceeded 15 mV DC a Use a multimeter to verify mV levels B Verify individual load cell milli volt signals 1 An individual load cell may be over ranged and exhibit high milli volt readings 2 Possible physical damage to the load cell 3 Internal strain gauge bond broke 4 Moisture in the load cell cable or body Weight in the hopper exceeds the configuration Scale Capacity setting A Under configuration verify the Scale Capacity setting B 105 of the scale capacity setting will cause a HI indication C This is used only as a warning and does not effect calibration D Optional communication signals are unaffected by this indication Weight in the hopper exceeds the load cell capacity a Mechanical forces or product acting on the scale overloads the load cells B Use a multimeter
139. anual in the Cabling Section There are also installation instructions in the Quick Installation Guide Unpacking Step 1 Before signing the packing slip inspect the packing for damage of any kind Report any damage to the carrier company immedi ately Check to see that everything in the package matches the bill of lading You should normally have Step 2 Step 3 HI 3010 Panel Mount e 1 HI3010 Filler Dispenser with mating connectors and ordered options installed e 1 Mounting Kit with a mounting bracket gasket and 4 RAF 8 32 captive screws e CD containing User Guide and Service Man uals Step 4 If any items are missing damaged or there are any questions please contact Customer Support at Hardy Instruments 9440 Carroll Park Drive Suite 150 San Diego CA 92121 Phone 858 278 2900 FAX 858 278 6700 Web Site http www hardyinstruments com E Mail hardysupport hardyinst com Record the model number and serial number of the Weight Controller Store in a convenient secure location for reference when contacting Hardy Instruments Customer Service Department or to buy parts or firmware upgrades Step 5 Disassembly and Reassembly Notes and Cautions e Always disconnect the power cord before disassembling WARNING FAILURE TO DISCONNECT THE POWER CORD BEFORE DISASSEMBLING MAY CAUSE PERSONAL INJURY AND OR PROPERTY DAMAGE e Make sure that any disassembly is done in a clean well ventilated p
140. ar fill dispense process The base motion number can be calculated by using the following formula Base Motion Number Total Load Cell Capacity 10 000 x 3 NOTE Motion Tolerance must be greater than or equal to the Graduation Sizes Our recommendation is three 3 graduation sizes PARAMETER MOTION TOLERANCE RANGE 000001 999999 DEFAULT 10 Step 1 Press the down arrow button until the cursor is in front of Motion Tol Tolerance See Fig 4 77 SETUP MENU TOTAL DECIMAL PT U gt FIOTION Tol 10 00 GRAD SIZE 1 FIG 4 77 SETUP MENU MOTION TOLERANCE Step 2 Press the Clear button to clear the current entry Step 3 Use the alphanumeric key pad to enter the new tol erance value Step 4 Press the Enter button to set the entry Zero Tolerance Parameter About the Zero Tolerance Parameter The Zero Tolerance parameter sets the weight units from zero that will be accepted as zero by the instrument You can also turn on Auto Zero tolerance and set the Auto Zero Tol erance parameter and time The Auto Zero Tolerance time setting sets the time it should take to Auto Zero the scale NOTE The amount of weight zeroed off is cumulative The zero command will fail if the current gross weight plus any previously zeroed amount exceeds the zero tolerance About the Auto Zero Tolerance Parameter If ON Auto Zero automatically zeros the empty scale to gross zero in the pre set time before the OK to Fill becomes active
141. arnings and safety procedures referenced or explicitly stated in this man ual to insure the safe operation and repair of this instrument Hardy Instruments sincerely appreciates your business We encourage input about the performance and operation of our products from our customers Should you not understand any information in this manual or experience any problems with this product please contact our Technical Support Depart ment at Phone 858 278 2900 FAX 858 278 6700 E Mail e hardysupport hardyinst com e hi_sales hardyinst com Or visit our web site at http www hardyinstruments com Our web site is full of useful information about our products process weighing and vibration analysis applications You can also update the Filler Dispenser IBC Manual The latest revised manuals are available FREE in the Support Section of our Web Site While you re on the site feel free to visit the other web pages which can provide answers to your ques tions about load points process weighing vibration analysis or other Hardy instruments Be sure to sign up for the Hardy Newsletter to get the latest information on all Hardy prod ucts and services For answers to technical issues and service problems check the Hardy Web Tech on our Hardy Web Site Most problems can be resolved by the Hardy Web Tech 365 days a year 24 hours a day 7 days a week You can still con tact a technician by phone during our operating hours if nec essa
142. ation Adjust Ingredient Instrument Setup Calibration Basic Mapping Advanced Mapping Security FIG 4 110 CONFIGURATION PAGE SELECT INSTRUMENT SETUP 51 CHAPTER 4 Configuration Step 6 To set the Scale Capacity double click in the Scale Capacity field and enter the scale capacity of the Configuration Instrument Setup Filler scale you are using in your process Enter or select the parameters for the fields below Step 7 To set the Grad Size Instrument ID 52 Hardy Filler e Click on the Grad Size pull down menu Operator ID DNM See Fig 4 113 IR o E e Click on the Grad Size you want for your process Scale Capacity 440 0 Grad Size fi gt Decimal Point 2 gt Totalizer oFF on Enter or select the parameters for the fields below Total Decimal Point fo Instrument ID 52 Hardy Filler Number of Averages fi 0 Configuration Instrument Setup Filler 0 ID Motion Tolerance fi 0 0000 ei DM OK to Fill Input Gaz Gon Units of Measure ib OK to Fill Timer 70 Scale Capacity 440 0 Grad Size poe EAI Decimal Point Totalizer J K Total Decimal Point Number of Averages FIG 4 111 INSTRUMENT SETUP FILLER Mator Toleranse OK to Fill Input Step 2 To change the Instrument ID double click in the Instrument ID field and enter the new ID Step 3 To change the Operator ID double click in the FIG 4 113 INSTRUMENT SETUP SELECTING Operator ID field and enter the new ID Remember GRAD
143. ation Type Last Calibration Type Calibrator Operator ID Status Word Stability Test DeviceNet UDP FIG 7 119 Weight and View Input Output Hardy Filler HI 3010 0650 0119 01 2 2 00 0002 53 not cal d unknown 0000 Set Factory Defaults Parameters Read Only Parameters Voltage ReadMWrite Return to Zero Test lt 4 Status Log Peak Force Step 4 OPERATION SMART DIAGNOSTICS WEIGHT AND VOLTAGE PAGE The values expressed here are for illustration purposes only Your values will be different The Weight and Voltage Web page shows all the Weight Voltage and A D values at once So if you want to save time use the Web Browser Smart Diagnostics Weight and Voltage Page for trou bleshooting e The mV reading is a coarser reading than the mV V or Weight readings The mV reading is sufficient to balance the corners of your scale or vessel e These readings allow you to determine if the problem is in the instrument internal or in a load sensor s external The speci fication range for the Weight Controller is 0 15 mV If you are getting a reading out side this range 15 5 mV 3 1 mV V Maxi mum or any negative values the problem is exterior to the Instrument most likely improper wiring If you are getting a read ing between 0 15 mV the reading is nor mal Check the results 133 CHAPTER 7 Troubleshooting If any or all the load sensor readings are 0 00 t
144. ay reap pears Step 4 Press the Enter button if you want to set the Factory Defaults Step 5 A display appears telling you to Please Wait Step 6 When the Defaults are set you briefly see a display that says Function OK See Fig 7 82 The Choose Instrument display automatically appears See Fig 7 83 FIG 7 82 FUNCTION OK DISPLAY HI 3010 Filler Dispenser IBC 124 Service Manual CHoase One gt FILLER DISPENSER IBC DISPENSER FIG 7 83 INSTRUMENT SELECTION DISPLAY Step 7 Press the down arrow button until the cursor is in front of the instrument you want Step 8 Press the Enter button to select the Instrument The defaults are set for that instrument Return to Zero Test The Return to Zero Test is used to determine whether the instrument can still zero a scale based on preset parameters If you pass the Return to Zero Test you are within the sum of the preset Motion and Zero Tolerance settings If you fail you are outside the sum of the preset Motion and Zero Toler ance settings If you Fail the test there may be too much build up on the scale and you need to clean the scale or you have scale problems You should do this test whenever you cannot zero the scale Step 1 Press the up or down arrow buttons until the cursor is in front of Return to Zero See Fig 7 84 FACTORY DEFAULTS gt gt RETURN TO ZERO View INPUT STATES gt FIG 7 84 DIAGNOSTICS DISPLA Y SELECTING RETURN TO ZERO T
145. ble click in the Timezone field Check Table 4 2 Civilian Time Zones GMT on page 40 for the time zone you are in Enter the correct Greenwich Mean Time value Don t forget to enter the positive or negative sign For our example we used the default time zone which is 8 or PST Pacific Standard Time Click on the Save Parameters button to save the set tings The Browser Instrument Setup is Complete Options Configuration Smart Diagnostics SD Card Configuration from the Front Panel NOTE For Installation instructions go to Chapter 3 Installing the Smart Diagnostics Card Step 1 From the Main Menu press the Setup 3 button The Configuration Menu appears Step 2 Press the Down Arrow button until the cursor is in front of Options See Fig 124 CONFIGURATION MENU CALIBRATION gt gt CPTICNS gt U OMAPPING gt FIG 4 124 CONFIGURATION MENU SELECTING OPTIONS Step 3 Press the Enter button The Options Menu appears See Fig 125 CPTIONS Control nat U O gt Profibus l O gt gt Smart Dag Grl gt FIG 4 125 OPTIONS SELECTING SMART Step 4 DIAGNOSTICS CONTROL Press the down arrow button until the cursor is in front of Smart Diag Ctrl See Fig 125 Step 5 Press the Enter button The Smart Diagnostics Card Menu appears See Fig 126 S D CARD MWU gt channd 1 Channel 2 Channel 3 FIG 4 126 SMART DIAGNOSTICS CARD MENU CHANNELS 1 2 3 Step 6 Press t
146. ble containing addressed memory where the states of the input devices and parameter values are stored The state of each input device is trans ferred to the input image table from the input point during the I O scan Local Mapping This is mapping within an HI 3010 Filler Dispenser module primarily mapping internal memory loca tions of parameter values or device states to locations in the local Input Image Table or Output Image Table Network Mapping This is mapping between the master and slave devices in the case of a DeviceNet ControlNet RIO or Profibus network Hardy Control Link network map ping is mapping between nodes on the network NOTE Itis important to understand that you cannot per form mapping functions on one HI 3000 Series Instrument from another HI 3000 Series instru ment You must map the memory locations in each instrument separately More will said about this later Node Number This is the physical address of a device ina network Output Relay Outputs interface indicators motor starters solenoids and other actuators from the HI 3010 Each output has an address associated with it The address describes the physical location that the output device is connected to Output Image Table The data table containing addressed memory where the desired state of the output devices and parameter values are stored The desired state or parameter value of each output is transferred from the output image file to
147. button The Standby Display appears See Fig 4 8 FIG 4 8 STANDBY DISPLA Y Step 5 Press the Setup 3 DEF button once The Configura tion Menu appears with the cursor in front of ADJUST INGREDIENT Default See Fig 4 ADULO SETUP CALIBRANMON FIG 4 9 CONFIGURATION MENU ADJUST INGREDIENT Configuring Ingredients from the Front Panel About Configuring Ingredients You can configure from 1 12 ingredients in the Filler Dis penser Each ingredient can be given an Ingredient Name Ingredient Number 1 thru 12 Set tolerance Discrete or Percent Target Weight and Preact You can also configure the Gate Time Jog On Time and several other parameters All these settings insure that each ingredient is exactly con figured to deliver the exact amount of material for your fill ing or dispensing process Step 1 With the cursor in front of ADJUST INGREDI ENT Press the Enter button The ADJUST INGREDIENT sub menu appears with the cursor in front of Ingredient 1 Default See Fig 4 10 ADJUST INOREDIENT gt INGREDIENT INGREDIENT O INGREDIENT 2 FIG 4 10 ADJUST INGREDIENT SUB MENU INGREDIENT 1 NOTE Ifyou want to move to another ingredient press the up or down arrow buttons until the cursor is in front of the ingredient you want to adjust NOTE Our example goes through configuring Ingredi ent 1 for illustration purposes however setting all the parameters for all 12
148. calibration errors then re cali brate e Span Counts must be larger than the zero counts Step 19 Press the up or down arrow until the cursor is in front of C2 Sensitivity e The C2 Sensitivity is the full scale output sensitivity of C2 load sensor measured at the factory e To change the sensitivity press the Clr Clear button e Use the alphanumeric key pad and enter the sensitivity specifications that comes with new load sensors and enter the full scale output sensitivity of the C2 load sen sors e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Step 20 Press the up or down arrow until the cursor is in front of Scale Capacity e The Scale Capacity is the weight capacity of the scale being used in this Filler Dis penser IBC application e To change the Scale Capacity press the Clr Clear button e Use the alphanumeric key pad to enter a new the full scale capacity e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Step 21 Press the down arrow button until the next three menu items are displayed See Fig 7 56 ST DATA ZERO IDLER 1 00 AZERG TOLER 4 00 AZERO Time 1 005 FIG 7 56 TEST DATA DISPLAY ZERO TOLERANCE AUTO ZERO TOLERANCE AUTO ZERO TIME Step 22 Zero Tolerance Auto Zero Tolerance Auto Zero time can all be changed from
149. command number 0x1000 The WRITEINTEGER command is used to set the value of integer valued parameters Command data 2 bytes PARAMETER NUMBER the number PARAMID of the parameter to write 4 bytes PARAMETER VALUE what to set the parameter to Data returned by the HI 3010 8 bytes echoing the WRITEINTEGER command WRITEFLOAT command number 0x1001 The WRITEFLOAT command is used to set the value of float valued parameters Command data 2 bytes PARAMETER NUMBER the number PARAMID of the parameter to write 4 bytes PARAMETER VALUE what to set the parameter to HI 3010 Filler Dispenser IBC 78 Service Manual Data returned by the HI 3010 8 bytes echoing the WRITE FLOAT command WRITESTRING command number0x 1002 The WRITESTRING command can be used to set the value of any parameter Command data 2 bytes PARAMETER NUMBER the number PARAMID of the parameter to write Variable number of bytes a zero terminated ASCII string giving the value to set the parameter to Data returned by the HI 3010 8 bytes echoing the first 8 bytes of the WRITESTRING command READINTEGER 0x2000 READFLOAT 0x2001 These commands are used to read the value of integer or float parameters Command data 2 bytes PARAMETER NUMBER the number PARAMID of the parameter to read Data returned by the HI 3010 8 bytes The first 4 bytes echo the command and the next 4 contain the value of the param eter Setting up the
150. connecting 17 Recommended Installation Procedures 17 AC Power Wiring 17 DC Power Wiring 17 Load Point Connections 18 C2 Load Point Connection 18 Non C2 Load Point Connection 18 LVDT and Half Bridge Load Cells Sensors 18 Junction Box Wiring 18 Installation of Secure Memory Module SMM 19 Transferring a Secure Memory Module 19 Configuration e 21 About Chapter 4 21 Getting Started 21 Help Dialog 21 About the Help Dialog 21 Configuring the Filler Dispenser from the Front Panel 21 Front Panel Display 21 Button Functions 21 Start B tton 2 2 5 dd ee ed 21 Help Button 21 Manual Button 21 Print Button 22 Up Down Left Right Buttons 22 Enter Button 22 Exit Button 2 2 4202 Tica da dd ce ee N 22 Clear Button 22
151. cor rection factor for Mexico City See Fig 5 9 Step 16 C2 CAL Ref Point 0 00 1 002102 gt Gavity Do C2 Cal ibr ation FIG 5 9 GRAVITY CORRECTION FACTOR MEXICO CITY Step 17 Press the Enter button to save the setting Step 18 Press the down arrow button to move the cursor in front of Do C2 Calibration See Fig 5 10 Step 19 Wait 15 seconds for the scale to settle Step 20 Press the Enter button to complete the Calibration C2 CAL Ref Point 0 00 1 002102 G avity Do C2 Cal ibr ation FIG 5 10 DO C2 CALIBRATION Step 21 A function OK momentarily appears on the screen indicating the calibration was successful e A message that says Function Error means that the calibration was not successful Check Chapter 7 Troubleshooting of this manual for corrective action e Another message may occur which is Secu rity Violation This means that the User does not have the security level required to do a calibration Step 22 Press the Exit button until you return to the Standby display Step 23 C2 calibration is complete C2 Calibration From the Web Page Step 1 On the Filler Dispenser Home Page Click on Con figuration See Fig 5 11 The Configuration page appears See Fig 5 12 FIG 5 11 CONFIGURATION MENU SELECTING SETUP FIG 5 HI 3010 Filler Dispenser IBC 60 Service Manual Configuration Adjust Ingredient Instrument Setup Calibration Basic Mapping Advanced
152. d See Fig 4 102 Configuration Adjust Ingredient Ingredient Number INGREDIENT 1 F T INGREDIENT 1 SID gt INGREDIENT 2 3 INGREDIENT 3 4 INGREDIENT 4 5 INGREDIENT 5 6 INGREDIENT 6 7INGREDIENT 7 8 INGREDIENT 8 9 INGREDIENT 9 10 INGREDIENT 10 1 INGREDIENT11 7 lt gt FIG 4 102 CONFIGURATION PULL DOWN MENU Configuration Adjust Ingredient Instrument ID 52 Hardy Filler Ingredient Number E z Ingredient Name INGREDIENT 7 Number of Fills fi Target Wt 100 0000 Target Proof Limit OFF Switch on Jog Gate Time E Jog on Time 2 0000 Preact fi 0000 Jog off Time 1 0000 Smart Auto Preact E A Jog Count 6 gt Enter Parameters lt p gt FIG 4 103 CONFIGURATION ADJUST INGREDIENT Step 8 You also see Ingredient Number 7 which you selected in the previous web page See Fig 4 103 You can continue with this ingredient number or you can change it by opening the pull down menu again on this page and selecting another Ingredient number Changing the Ingredient Name Click in the Ingredient Name field Click and hold the left button down while moving the cursor over the Ingredient HI 3010 Filler Dispenser IBC 48 Service Manual name so that the Ingredient name is completely high lighted See Fig 4 104 Configuration Adjust Ingredient Instrument ID 52 Hardy Filler Ingredient Number 7 Ingredient Name INGREDIENT 7 Number of Fills 1 Target Wt 100 0000
153. d not supply any other equipment including the feeding unit and should be supplied with a minimum 10 amp breaker See Fig 3 16 Ana 123450 Neu o S a 2 A 5 Diagnostics Power On de ab YN NS le Y Power In AC Outputs Inputs FIG 3 16 POWER WIRING DIAGRAM e Power Input Jl J1 1 Neu Low J1 2 Line HI J1 3 Ground Step 1 The HI 3000 Series instruments are configured with a universal power supply rated from 120 to 240 VAC The instruments can be powered by a 120 or 240 VAC power source and requires no switching or jumper settings Install a 3 wire minimum 14 AWG power line to the 3 pin terminal block connector See Fig 3 16 The power and relay circuit card filters and condi tions AC power However for noisy power lines external conditioning may be required Step 2 Step 3 DC Power Wiring WARNING DO NOT OPERATE WITH INCORRECT LINE VOLTAGE TO DO SO WILL RESULT IN PROPERTY DAMAGE AND OR PERSONAL INJURY MAKE SURE THAT THE POWER SOURCE DOES NOT EXCEED 24 VDC e The DC power should be supplied by a clean primary line directly from the DC power source 135515092 igeddged ded 29929g9924 o LU crm d chars d 15511853 F aooaa ER 80
154. d or the Aux Auxiliary Device Timer The Aux Auxiliary Device Timer turns on a vibrator feeder or other device if the Not OK to Discharge Alarm occurs If you select OFF the Discharge Menu does not display Make sure you set the Zero Tolerance to deter mine when the fill vessel is empty i e completed the dis charge PARAMETER DISCHARGE RANGE ON OFF DEFAULT OFF PARAMETER AUTO DISCHARGE RANGE ON OFF DEFAULT OFF PARAMETER OK TO DISCHARGE RANGE ON OFF DEFAULT OFF PARAMETER PROOF SWITCH RANGE ON OFF DEFAULT OFF PARAMETER SWITCH TIMER RANGE 0 99 DEFAULT 5 SECONDS PARAMETER AUX DEVICE TIMER RANGE 0 99 DEFAULT 10 SECONDS NOTE The description for these parameters is located in the HI 3010 User Guide Step 1 To select Discharge press on the left or right arrow buttons to toggle Discharge ON or OFF See Fig 4 47 33 CHAPTER 4 Configuration SETUP MENU OK zo FILL INPT ON gt gt DISCHARGE OFF gt REFILL gt FIG 4 47 SETUP MENU DISCHARGE PARAMETER Step 2 With Discharge toggled ON Press the Enter button The Discharge Menu appears with the cursor in front of Auto Discharge See Fig 4 48 DISCHARGE MENU gt Huro DISCHARSE OFF gt Up TO DISCHARGE OFF gt 0 A co co 5A LA a x ca a T 1 y FIG 4 48 DISCHARGE MENU AUTO DISCHARGE Step 3 Press the right or left arrow buttons to toggle Auto Discharge ON or OFF Step 4 Press the Enter button
155. dard Instrument Update Rate e 55 updates per second Resolution e Displayed 1 985 000 3 mV V load cells Internal 1 1 048 5761 Excitation Voltage e 5VDC e Drives up to 8 350 ohm load cells Averages e 1 to 250 Sliding User Selectable in Sin gle Unit Increments Input e Up to eight 8 350 ohm Full Wheatstone Bridge Strain Gauge Load Sensors Cells 5 volt excitation on one vessel e Signal Voltage Range 0 120mV V 600 mV Display 4line x 20 character backlit LCD s 5x 7 dot matrix Display Increments Graduations e 1 2 5 10 20 50 100 200 500 user selectable e Corresponding weight is dependent on the decimal point location Standard Electronic AC Relays Wire Size 12 AWG Maximum e Maximum Switch Current 5 Amps Maximum Switch Power 120 Watts e Maximum Switch Voltage 5 Amps O 240 VAC e Single Cycle Surge 85 Amps Peak Standard Electronic DC Relays e Wire Size 12 AWG Maximum Maximum Switch Current 5 Amps e Maximum Switch Voltage 5 Amps 60 VDC e Switch Voltage 5 60 VDC e I second surge 5 Amps Non Linearity s 0 0015 of Full Scale WAVERSAVER e Off e 7 5 Hz s 35Hz e 1 0Hz s 05Hz e 0 25 Hz Calibration Techniques e C2 Second Generation Electronic e Traditional Calibration with test weights Standard Interfaces Ethernet 10 100 Base T embedded server DeviceNet Master Scanner e Serial RS 232 simplex to Printer
156. down menu See Fig 6 4 3 Start Step 6 To select Output Relays from 1 4 double click in 4 Stop the text box and type in the Output Relay number you want In our example we selected Output Relay e Instrument Setup include parameters for 1 See Fig 6 4 setting up the instrument itself and includes the following which is only a par tial list Configuration Mapping Setup 1 C hers for sit of araa sradcis 4 E INSTRUMENT 10 Hardy Filler 1 Auto Zero On besmanoss 2 Tare Value Geer Selecion 3 Zero Tolerance 4 Discharge On vas h e Ingredient Setup include parameters for Z setting up the ingredients to fill or dis aap 3 pense and includes the following which is Mir x only a partial list 1 Max Weight ss 2 Min Weight E oe pg dat ge ara 3 Fill Time a Meine FIG 6 4 LOCAL OUTPUT SELECTING OUTPUT RELAY 1 e Network includes the network outputs for Hardy Control Link ControlNet Devi ceNet Profibus etc which is only a partial list Step 7 Click on the Select button to the right of the Relay 1 text box An address appears in the Current Mappings text box below You will have to scroll 67 CHAPTER 6 Mapping down to see it In our example we selected Output Relay 1 which has an address of HOO 0 An equal sign also appears Current Mappings BOO OreHT 1 HOO 1 HT2 2 HOO 2 HT2 3 HOO 3 HT2 15 HO1 4eeHTO 0 HO1 SeeHTO 1 HOL 1 lt 4H10 2 DIOO HF11 DIO2 sHF10 RS01
157. e The DeviceNet network lets you monitor your plant floor devices from a central location and reconfigure them as your needs change or service them as required You can for example configure the Filler Dispenser modules for differ ent applications PARAMETER DEVICENET BAUD RATE RANGE 125K 250K 500K DEFAULT 125K PARAMETER DEVICENET NODE ADDRESS RANGE 0 64 DEFAULT 0 Step 1 Press the Down arrow until the cursor is in front of DeviceNet See Fig 4 91 SETUP MENU Set A ock gt Devicenet Et her net FIG 4 91 SETUP MENU DEVICENET Step 2 Press the Enter button The DeviceNet Menu appears with cursor in front of Baud Rate See Fig 4 92 FIG 4 92 DEVICENET MENU BAUD RATE Step 3 Press the right or left arrow buttons to select the Baud Rate you want 45 CHAPTER 4 Configuration NOTE Check with your Network Administrator for the Baud Rate if you don t know the correct Baud Rate Step 4 Press the Enter button to set the entry Step 5 Press the Down arrow until the cursor is in front of Node Address See Fig 4 93 105 E ADDRESS 15 FIG 4 93 DEVICENET MENU NODE ADDRESS Step 6 Press the right or left arrow buttons to select the Node Address Step 7 Press the Enter button to set the entry Step 8 Press the Exit button to return to the SETUP MENU Ethernet Parameters About the Ethernet Parameters All Filler Dispensers are designed with a selectable 10 100 base T Eth
158. e Dimensions e 9 3 L x 4 0 W 236 22mm L x 101 60mm W Overall Height with HI 3010 installed as measured from the base to the top of the front plate e 11 77 High 298 96mm H Swivel Material e 304 Stainless Steel Specifications for I O Option Boards Profibus Option Board Power Supply e LBV max 350mA Operating Temperature e 0 70 C 32 158 F 9 CHAPTER 2 Specifications Profibus Services s DP Services ID Number and GSD Support e 1003H with Standard GSD File May change if required Input Size e 0 122 Words Output Size e 0 122 Words Combined Input and Output Size s Not exceed 208 Words ControlNet Option Board Power Supply e 5V max 350mA Operating Temperature e 0 70 C 32 158 F ControlNet Baud Rate e 5 Mbit second Max I O Data Capacity e Input 250 bytes e Output 250 bytes ControlNet Supported Features e Redundant Media e Cyclic Messaging RIO Option Board Power Supply e 5V max 350mA Operating Temperature e 0 70 C 32 158 F RIO Baud Rate e 57 6 115 225 Kbit second Max I O Data Capacity e Input 63 bytes Full Rack e Output 63 bytes Full Rack e 15 Bytes Discrete e 48 Bytes Block RIO Supported Features s Block Transfer Data s IO Mode s 1 4 1 2 3 4 and Full Rack Control of the Rack_Size and Starting_Quarter Combi nations Starting Quarter Valid Rack Sizes First For all Rack Sizes Seco
159. e Down arrow button until the cursor is in front of the Do Trad Cal See Fig 5 21 HI 3010 Filler Dispenser IBC 62 Service Manual TRADITIONAL CAL ZEROLT 12568 gt DolTrac CAL Zero SPANVALUE 0 00 FIG 5 21 DO TRADITIONAL CALIBRATION ZERO Step 8 Press the Enter button to do the Zero Calibration If Function OK appears the Zero Calibration is complete If an ERR number appears go to Chapter 7 Troubleshooting for more information Step 9 Press the Down arrow button until the cursor is in front of Span Value See Fig 5 22 To Set the Span Value TRADITIONAL CAL Do TRAD CAL ZERG gt SPANVALUE 10 00 SPANCT 950553 FIG 5 22 TRADITIONAL CALIBRATION SPAN VALUE e Place a certified test weight on the scale e Use the alphanumeric key pad to enter the value of the test weight If a 10 lb weight is used enter 10 NOTE Ideally the test weight used for the span should be the highest weight that will be measured in the application e Wait 12 seconds or more Step 10 Press the Down arrow button until the cursor is in front of the Do Trad Cal See Fig 5 23 TRADITIONAL CAL SPANVALUE 10 00 SPANET 962553 gt DoTras Cal Span FIG 5 23 TRADITIONAL CALIBRATION SPAN Step 11 Press the Enter button to do the Span Calibration If Function OK appears the Span Calibration is 63 CHAPTER 5 Calibration complete If an ERR number appears go to Chapter 7 Troubleshooting for
160. e Sources And The Provides the Boolean AND or the Analog TIMES Operator between Sources E The Provides the Boolean OR or the Analog PLUS Operator between Sources FIG 6 19 ADDING BOOLEAN OR TO THE ASSIGNMENT STATEMENT Step 8 Click on the Alarms pull down menu See Fig 6 20 Step 9 Click on Slow Gate Shut Alarm Alarms ISS U z Select or Network 7 FIG 6 20 ALARMS SELECTING SLOW GATE SHUT ALARM Step 10 Click on the Select button to the right of the Alarms pull down menu to add the Slow Gate Shut Alarm to the Assignment Statement See Fig 6 21 HI 3010 Filler Dispenser IBC 70 Service Manual Current Mappings HOO 1 HI2 2 HOO 2 HI2 3 HOO 3 HI2 15 HO1 S HIO 1 DIO2 HFIO RSO1 HFIO HOO 0 HI2 1 HO1 4 HI0 3 HOO 2 HI3 13 H13 15 Unmap FIG 6 21 SLOW GATE SHUT HI3 15 ADDED AS THE SECOND SOURCE TO THE ASSIGNMENT STATEMENT Step 11 Click on the Map button to save the mapping The multiple source map appears in the Current Map pings listing See Fig 6 22 Map Unmap FIG 6 22 MULTIPLE SOURCE MAP Step 12 You have now mapped multiple sources to a single destination Simple Network Mapping Mapping to a Network Output If you want to send data to a PLC or other HI 3000 instru ment you need to map the data to a network output Here is the process Step 1 From the Configuration Mapping Setup 1 page click on the Network pull down menu and select DeviceNet I
161. e are Opto isolated solid state relays switching 110 controller will not 240 VAC They will supply the switching not work as a dry voltage contact closure Use an AC meter to physically verify Contact Hardy Technical Support operation 115 CHAPTER 7 Troubleshooting System Integrity Check and Fault Determi nation From the Front Panel To determine if an instrument or cabling problem exists ver ify the basic operation of the system by performing the fol lowing system checks Diagnostics About Diagnostics The Diagnostics menus enable the technician to get a more complete view of how the Filler Dispensing IBC system is working For example you can check to see the last Calibra tion the type of calibration and when the last Calibration was performed You can view the Data List Display for the Serial Number assigned to the instrument or Program Part Number You can also check the last graduation size Units selected Operator ID Analog Options and more information about the configuration of the instrument you are checking You can get information about the Load Sensors such as Out put Sensitivity Hysteresis Sensitivity of each individual Load Sensor Many of the Menu Items will allow you to change them If a Menu Item has an asterisk in front of it then you can change this item The Diagnostic Menus allow you to perform a Self Test which provides the total scale input to the instrument such as mV and Weight mV V and
162. e scale Do not just Check recalibrate or mechanical increase the zero connections tolerance levels are correct Troubleshoot the scale to why the zero point has shifted HI 3010 Filler Dispenser IBC 104 Service Manual F Verify Individual Load Cell Milli Volt Readings Using the load cell certificate verify the milli volt per volt rating Example 3 mV load cells will produce approximately 15 mV at full load That is 5 volts excitation x 3 u A scale capacity of 1 000 Ibs with 100 Ibs of dead load at empty the load point mV reading should equal 1 5 mV 1 No dead load Apply load and re test Using a Multimeter 2 Wiring error Verify color code using the MV load cell certificate readings Open bridge circuit acceptable Disconnect power and verify load point bridge resistance reading with an Ohmmeter Physically lift the Check individual signal leads to read load sensor a output mV each load cell s readings 1 Stressed load cell remove output MV all load and re test j 2 Excessive loading readings For additional acceptable testing go to Check load sensor Record load NEXT sensor mV output level for comparison MV readings acceptable MV readings acceptable Repeat for all load sensors Defective load cell Replace and repeat Test F MV readings acceptable If you were unable to determine the Milli volt readings
163. e taken as Zero HFO130 Auto Zero Tolerance wt near zero that can be zeroed HFO131 Calibration Low Wt wt used for zero of cali bration HFO132 Calibration Span Wt wt used for span of tradi tional calibration HFO133 AutoZero Tolerance Time time allowed for autozeroing HFO134 Tare Limit max wt that can be tared off HTO Hardy Text Output Table HTOO Operator ID max 3 chars HTO Instrument ID max 19 chars HTO2 Custom Text0 max 20 chars HTO3 Custom Text max 20 chars HTO11 Custom Text9 max 20 chars HTO12 Ingredient 1 Name max 19 chars HTO23 Ingredient 12 Name max 19 chars HTI Hardy Text Input Table HTIO Calibrator ID max 3 chars HTI1 Model Number max 20 chars HT Program Part Number max 20 chars HTI3 Firmware Revision Number max 20 chars HII Hardy Integer Input Table HIO Serial Number HII Totalizer0 Cycles HIT 12 Totalizer11 Cycles HDI Hardy Double Input Table HDIO TotalizerO Wt HDI11 Totalizer11 Wt DI DO DFI DFO DSI DSO DII DIO DTI DTO DeviceNet tables DeviceNet tables contain 125 16 bit words DI DO DeviceNet input output addressed as bits DFI DFO DeviceNet input output addressed as floats DSI DSO DeviceNet input output addressed as 16 bit integers DIL DIO DeviceNet input output addressed as 32 bit inte gers DTL DTO DeviceNet input output addressed as text RL RO RFI RFO RSI RSO RII RIO
164. e there isn t any side loading from piping or external forces Install flexures on all piping to insure a free floating vessel Make sure the vessel and load cell mounts are mechanically stable and fixed Large changes in individual load cells indicate a shift in COG or faulty load cells Piping and motors will effect the individual load cell readings Allow for a higher reading on Load Cells that support motors and piping Make sure pneumatic lines are not applying 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 Stable N _ gt Be Return to Me DA f S Configuration Settings Incorrect WAVERSAVER settings can cause unstable weight readings Adjust to the lowest WAVERSAVER setting that gives you a stable reading Higher frequencies with low amplitude vibrations Use WS setting 7 5hz or 3 50hz Low frequency with high amplitude vibrations Use WS setting 1 0hz or higher Incorrect number of decimal places Reading weight increments beyond the equipments applications level See guidelines calculations below Repeatability Divide the total load cell capacity including decimal points by 1 000 Expected Stable Weight Reading Resolution Divide the total load cell capacity including deci
165. eNet Scanner Mapping a Network Input to a Local Output If you want a PLC to send instructions to an HI 3010 you will have to map the local Output to a network input Here is the process NOTE Keep in mind that the network input on the HI 3010 will be the source for the PLC output This enables the PLC to send instructions to the net work input on the HI 3010 and in turn to the HI 3010 output Step 1 From the Configuration Mapping Setup 1 page click on the Local Outputs pull down menu and select Output Relay See Fig 6 27 Relay 2 Sold FIG 6 27 LOCAL OUTPUT SELECTING OUTPUT RELAY 2 Step 2 Double click in the Relay field and type the num ber of the relay you want In our example we selected Relay 2 Step 3 Click on the Select button to select Output Relay 2 as the Destination for the left side of the Assign ment Statement See Fig 6 28 Current Mappings HOO 1 HI2 2 HOO 3 HI2 15 HO1 5 HI0 1 HO1 1 HI0 2 DIOO HFI1 RSO HO0 0 H12 1 HO1 4 H10 3 HOO 2 HI3 13 HI3 15 EIO2 HFI2 DIO2 HFI2 HO0 1 Jump to Sources Page FIG 6 28 OUTPUT RELAY 2 HO0 1 SET AS DESTINATION Step 4 Click on the Jump to Sources Page button The Configuration Mapping 2 page appears Step 5 Click on the Network pull down menu See Fig 6 29 or Networks DeviceNet Boolean In gt or Scratchpad z word 2 Bit fr Select FIG 6 29 NETWORK SELECTING DEVICENET BOOLEAN IN Step 6
166. ears See Fig 7 98 Operation Diagnostics Instrument ID Hardy Filler Model Number HI 3010 Program Part Number 0650 O0cx 01 Firmware revision 1 10 beta Serial number 1 Last Calibration Type TRAD Last Calibration Date unknown Calibrator Operator ID Status Word 0001 AID Conversion Error C2 Data Stability Test Weight and voltage SetFactory Defaults DeviceNet UDP View inputfoutput Return to Zero Test FIG 7 98 OPERATION DIAGNOSTICS Step 2 Click on Set Factory Defaults The Set Factory Defaults page appears See Fig 7 99 Operation Diagnostics Set Factory Defaults High Security Code Return to Factory Defaults 4 gt FIG 7 99 SET FACTORY DEFAULTS WARNING ANY AND ALL DATA WILL BE LOST IF FAC TORY DEFAULTS ARE INSTALLED THIS INCLUDES EVERY PARAMETER THAT WAS CHANGED FOR INGREDIENTS IP ADDRESS EVERYTHING THE INSTRUMENT IS RETURNED TO THE CONDITION IT WAS RIGHT FROM THE FACTORY Step 3 Enter the High Security Code Number Step 4 Click on the Return to Factory Defaults button Step 5 The Confirmation Page appears See Fig 7 100 The page informs you that all Factory default have been set and asks you to select what type of instrument you want this instrument to be Step 6 Click on the pull down menu and select the type of instrument you want this instrument to be Factory Defaults Set Select Application Typefnore selectea 7 Filler Dispenser Back FIG 7 100 FACTO
167. ed holes on the instrument until the screws are finger tight Step 7 Use a slotted head screwdriver and tighten each screw until the instrument is snug and the compres sion gasket is tight against the Enclosure Front Panel DO NOT OVERTIGHTEN Step 8 The Panel Mount installation is complete Installing the HI 3010 in a Swivel Wall Mount About the Swivel Wall Mount The swivel mounts allows the Filler Dispenser to mount on a horizontal or vertical surface The instrument is mounted in the swivel which is fastened to a hard surface The mount not only supports the instrument but also allows the Filler Dis penser to rotate for a better view of the display and more convenient access to the front panel key board The Swivel Mount also serves as a wall mount Simply rotate the swivel mount 90 degrees and attach it to a wall The swivel allows the instrument to rotate several degrees even with cables and rear cover attached Step 1 Use four 4 1 4 x 20 fasteners to fasten the swivel mount to a horizontal surface See Fig 3 5 FIG 3 5 INSTALLING THE SWIVEL MOUNT TO A HORIZONTAL SURFACE Step 2 Place the Filler Dispenser between the Swivel Mount brackets so that the threaded holes in the instrument are aligned with the slots in the Swivel bracket See Fig 3 6 HI 3010 Filler Dispenser IBC 14 Service Manual P ED A C 45 Fr 2 Y FIG 3 6 FILLER D
168. elp Button The Help Button initiates the Help Dialog which displays a Help message for the current Menu Item the Menu Item in front of the cursor that is displayed Manual Button Enables you to enter the manual mode of operation for the following e Tare Scale Press Clear button to tare the instrument e Discharge Press the Start button to start a discharge e Refill Press the Start button to Start a refill e Auxiliary Device Press the Start button to start an Auxiliary device e Fast Fill Dispense Press the Start button to start the Fast Fill Fill Dispense Press the Start button to start slow fill Print Button The Print Button when pressed brings up a series of screens See Fig 4 2 and allows the user to Print the following e Current Fill Dispense e Current Cycle e Totals e Setup Data Press the Print button the following screen appears PRINT KEY MENU gt Print current Disp Print Our r ent Oycle Print Totals FIG 4 2 PRINT SCREEN DEFAULT Note that the cursor is in front of the Print Current Fill Menu that is the default setting The print button will only print the menu with a cursor in front of it To move to another menu press the up or down arrow until the cursor is in front of the menu you want to print Up Down Left Right Buttons FIG 4 3 DIRECTIONAL BUTTONS The Up down arrow buttons move the cursor vertically allowing the user to scroll through each item of a men
169. embly 11 85 Disassembly and Reassembly Notes and Cautions 85 Discharge Alarms 94 Discharge Function 87 Discharge Gate Did Not Close Alarm 94 Discharge Gate Did Not Open Alarm 94 Discharge Gate Proof ON Radio Button 53 Discharge Gate Timer Field 53 Discharge is Complete 94 Discharge OFF Radio Button 53 Discharge ON Radio Button 53 Discharge Parameters 32 Dispensing A Vessel Using a Feeder 2 Dispensing from a Vessel to Another Vessel 2 Display 7 Display Increments Graduations 7 Do C2 Calibration 59 Do C2 Calibration Button 61 Do Cal High Button 63 Do Cal Low Button 63 Do Cal Low Calibration 63 Do Trad Cal 62 Dressed 17 Drives 44 Dual Speed 29 E E Non Return to Zero 102 Electrical Installation 17 Electrical Parts 11 85 Electrical Plug 11 85 ELectrostatic Discharge 11 12 85 Embedded Controllers 44 Embedded Web Server 3 Enclosure Front Panel 13 Enclosure Size Requirements 12 Enter Button 22 Enter Parameters Button 49 50 Environmental Requirements 8 ESD 11 12 17 85 Ethernet 10 100 Base T 7 Ethernet Card 46 Ethernet IP Port 3 Ethernet Parameters 45 EVEN 37 Excitation Monitor 7 Excitation Voltage 7 Exit Button 22 Extranet 1 45 F F Verify Individual Load Cell Milli Volt Readings 103 Factory Defaults 4 122 Fail Display 122 130 FALSE 78 Fanuc 6 Fast Fill Gate 86 FAST GATE DID NOT CLOSE 86 Fast Gate Did Not Close Alarm 86 90 FAST GATE DID NOT OPEN alarm 86 Fast Gate Did Not Op
170. en Alarm 86 90 Fastener Knobs 14 Fill 86 Fill Cycles 25 117 Fill Timer 118 Fill Timer Field 49 Fill Dispense Time Parameter 28 Filler Dispenser Home Page 63 127 Filler Dispenser System 85 Filler Dispenser IBC 1 Filling a Vessel Using a Feeder 2 Float 77 78 Flow Chart 85 Follow Proper Safety Procedures 12 85 FOR FURTHER INFORMATION CONTACT 134 Force Outputs 124 Force Outputs Function 124 Front Panel Display 21 Front Panel NEMA 4 Seal 8 Full Scale Output Sensitivity 116 Function Error 60 Function OK 60 123 Function Selection Display 23 G G A D Failure Error 105 Gain in Weight 25 Gate Proof OFF Radio Button 53 GE 6 General Policies and Information 134 General Troubleshooting Flow Chart Index 95 Getting Started 21 57 Global Industry Standard Communication Network 44 Grad 115 Grad Size Pull Down Menu 51 Graduation Size 115 Graduation Size Parameter 39 Gravity 58 Gravity Correction Factor 58 Gravity Corrector Factors Table 59 H H Mechanical Inspection 106 Hardy C2 Second Generation 57 Hardy Input and Output Tables 77 Hardy Instruments C2 Certified Load Sensors 3 Hardy Link Basic Mapping 74 Hardy Technical Support Technician 114 Hardy Web Site 1 Hardy Web Tech 1 3 Help Button 21 Help Dialog 21 HFIO 78 HFI1 78 HI 215IT Junction Box 128 HI 215JB SS1 or PS1 Series 10 HI 3000 RC 4 High and Low Level 34 High Level Sensor 34 High Security Code Number 127 Higher Level Controll
171. ences in potential and static build up Loadcells Ground straps must be installed to provide a direct discharge path to ground around the loadpoints Cable Routing Separate high voltage sources and cables from low voltage signal cables Stay a minimum of 14 inches from magnetic fields and SCR controls Avoid parallel high voltage and signal cable runs Cable Shielding Ground low voltage cable shields only at the controller end Grounding both cable ends will produce ground currents Verify with an ohm meter the shield is only grounded at the weight controller Disconnect the shield at the controller and check for an pen circuit between ground and shield Reconnect the shield to ground and confirm a proper ground path from the J unction Box to the controller Verify the shield is not connected to ground at the J unction Box Loadcell cable shields only pass through the J unction Boxes and are not connected to ground at any point Weight Controller Common AC ground and Chassis grounds HI 3010 Filler Dispenser IBC 100 Service Manual B2 Guidelines for Instabilities on For merly Operating Systems Mechanical Sta bility and Configuration Settings EIN B2 MS et Mechanical Stability Vessel When inspecting a vessel keep in mind the Center of Gravity COG should be low and centered equally over all the load cells Make sure the load is directly over or under the load point to avoid side loading Insur
172. ense and time Total Number of Cycles e Total Weight of the Fill Dispense HI 3010 Filler Dispenser IBC 36 Service Manual The Printer provides a hard copy of a fill dispense You can also select whether you want the Auto Print function which will automatically print the results after every fill dispense Check you Printer User Guide or Technical Manual to deter mine the parameters for your printer If you don t have the Printer User guide or Technical Manual check with your Network Administrator for the parameter settings PARAMETER BAUD RATE RANGE 300 1200 2400 4800 9600 19200 DEFAULT 9600 PARAMETER PARITY RANGE NONE ODD EVEN DEFAULT NONE PARAMETER DATA BITS RANGE 7 OR 8 DEFAULT 8 PARAMETER AUTO PRINT RANGE ON OF DEFAULT OFF Step 1 Press the down arrow until the cursor is in front of Serial Port See Fig 4 64 50 m 0 T T FIG 4 64 SETUP MENU SERIAL PORT Step 2 Press the Enter button The Serial Port Menu appears with the cursor in front of Print Port See Fig 4 65 FIG 4 65 SERIAL PORT MENU PRINTER PORT SETUP Step 3 Press the Enter button The Printer Port Menu appears See Fig 4 66 37 CHAPTER 4 Configuration PRINTER PORT MENU gt Baud RATE 3600 PARITY NON Data BITS 8 FIG 4 66 PRINTER PORT MENU BAUD RATE Step 4 Press the right or left arrow buttons to select the Baud Rate The Selections are e 300 e 1200 e 2400 e 4800 e 9600 e 1
173. ensor informa tion which is read from the C2 chip do the following a Press the Enter button The Load Sensor Display appears See Fig 7 67 LORD SENSOR gt SERIAL NUMBER 6844501 CAPACITY 25000 Sen 25 18 A V FIG 7 67 LOAD SENSOR DISPLAY SERIAL NUM BER CAPACITY SENSITIVITY MV V b Serial Number This is the serial number of the selected load sen sor c Capacity the maximum weigh ing capacity of the load sensor d Sensitivity Sensitivity specifica tion of the load sensor set at the factory e Press the down arrow until the remainder of the load sensor specifications appear See Fig 7 68 LOAD SENSOR gt Sens 2 00 V V INPUT RES TUD O OUTPUT RES 19000 O FIG 7 68 SENSITIVITY INPUT RESISTANCE OUTPUT RESISTANCE f Input Resistance This is the Certified Input Resistance from the certification done by the fac tory g This is the Certified Output Resistance from the certification done by the factory Step 52 Press the down arrow button until the next three menu items are displayed See Fig 7 69 TEST DATA LORD SENSOR 0 gt IP 192 168 10 99 gt Devicener Apr Nace 3 FIG 7 69 TEST DATA DISPLAY LOAD SENSOR IP ADDRESS DEVICENET ADR Step 53 IP Address Devicenet Address are read only e IP Lists the IP address for this instru ment The address listed in Fig 5 69 is the default IP address of an instrument right from the factory
174. entral Alaska HST Hawaii Standard Anchorage Alaska Honolulu Hawaii 11 NT Nome Nome Alaska 12 IDLW International Date Line West TABLE 4 2 GREENWICH TIME ZONES GMT Step 18 Check Table 4 2 for the time zone you are in Step 19 Press the right or left arrow until the correct time zone appears For example Pacific Standard Time is 8 Step 20 Press the Enter button to set the entry Step 21 Press the Exit button to return to the SETUP MENU DeviceNet Parameters About the DeviceNet Parameters DeviceNet is a low level network designed to connect the Filler Dispenser to higher level controllers such as PCs PLCs or embedded controllers The DeviceNet Network is an open global industry standard communication network HI 3010 Filler Dispenser IBC 44 Service Manual designed to provide an interface through a single cable from a programmable controller or PC directly to all HI 3000 Series products as well as smart devices such as sensors push buttons motor starters simple operator interfaces drives and other weight modules With DeviceNet the user can monitor or control multiple applications from one dis play and allows 3rd party I O to be easily added to any sys tem You no longer have to hard wire each device to an I O module or I O block The network also provides access to the intelligence present in the instruments for superior diag nostics and troubleshooting to help increase system up tim
175. ep 1 Press the down arrow button until the cursor is in front of Refill See Fig 4 57 SETUP MENU DISCHARGE OFF gt gt REFILL gt SERIAL PORT gt FIG 4 57 SETUP MENU REFILL Step 2 Press the Enter button The Refill Menu appears with the cursor in front of Refill See Fig 4 58 REALL MENU gt Pill CN Initial Refil CFF Refill Prf Sw ON FIG 4 58 REFILL MENU REFILL Step 3 Press the right or left arrow buttons to toggle between ON and OFF Step 4 Press the enter button to set the entry Step 5 Press the down arrow button to move the cursor in front of Initial Refill See Fig 4 59 REALL MENU Pef il CN gt Initial Refill OF Refill Prf Sw ON FIG 4 59 REFILL MENU INITIAL REFILL Step 6 Press the right or left arrow button to toggle between OFF and ON Step 7 Press the Enter button to set the entry Step 8 Press the down arrow button to move the cursor in front of Refill Prf Sw See Fig 4 60 REALL MENU Initial Refil CFF gt Pill Prf Sw ON Reill W 1000 00 FIG 4 60 REFILL MENU SETTING REFILL PROOF SWITCH Step 9 Press the right or left arrow buttons to toggle between ON and OFF Step 10 Press the Enter button to set the entry Step 11 Press the down arrow button to move the cursor in front of Refill Sw Timer See Fig 4 61 REALL MENU Initial Refil CFF Refill Prf Sw CN gt Refill Wine 5s FIG 4 61 REFILL MENU SETTING REFILL SWITCH TIMER
176. ernet connection which links your PC to an embedded server in the instrument You can connect to an instrument via the Internet Intranet Extranet or VPN Vir tual Private Network Your computer must have an ethernet card and cable with an RJ45 connector to connect to the instrument Once connected you can transfer data monitor map and configure any of the instruments from your web browser from any location in your plant or enterprise Help Dialogs are also available to assist when performing setup or troubleshooting of an instrument In addition the browser connects you to the Hardy Web Site which connects the user to a full range of customer service and support File down loads from your control room are a snap No more hauling devices to download files to an instrument Should you want to download a file or monitor the instrument from your lap top at the site simply connect a short cable from the lap top to the Ethernet connect at the rear panel of the instrument to transfer files monitor or configure the instrument No matter where you are if you are connected to our instrument you can configure and troubleshoot the HI 3010 Filler Dispenser About IP Addresses An IP address consists of 32 bits It is composed of two parts s The Network Number s The Host Number By convention the address is expressed as four decimal numbers separated by periods such as 200 1 2 3 represent ing the decimal value of each of the four bytes
177. ers 44 History of Totals 1 Home Page 55 130 Hour hh field 54 http www hardyinstruments com 1 Humidity Range 8 Hysteresis 114 l I O Mapping 81 IBC Dispense Alarms 92 Individual Boolean Variable 77 Infra Red IR Port Parameter 42 Infrared IR 7 Ing 1 Button 22 Ingredient 117 Ingredient 1 24 Ingredient Name Field 48 Ingredient Name Parameter 24 Initial Refill 34 Initial Refill OFF Radio Button 53 Input 7 Input Resistance 120 Input States Display 124 Input Table 79 Installation of Secure Memory Module 19 Installing Printed Circuit Boards 15 Installing the HI 3010 Filler Dispenser 12 Installing the HI 3010 in a Panel 12 Installing the HI 3010 in a Swivel Wall Mount 13 Installing the Smart Diagnostics SD Card 16 Instrument Configuration 30 Instrument ID 31 Instrument ID Field 51 Instrument Local I O 8 Instrument Selection Screen 23 HI 3010 Filler Dispenser IBC Service Manual Instrument Setup 52 Instrument Setup from the Browser 50 Instrument Setup Page 50 Internet 45 Internet World Wide Web 1 Internet Wizards 2 Intranet 1 45 IP Address 120 IT Web Page 131 J J Electrical Inspection 107 J9 Terminal Block 18 JB 4 Jog Alarms 88 92 Jog Count 27 118 Jog Count 49 Jog Count Alarm 93 Jog Count Pull Down Menu 49 JOG Cycle 93 Jog Gate Did Not Close Alarm 92 Jog Gate Did Not Open Alarm 92 JOG Hold Display 93 Jog Off Time 27 Jog off Time Field 49 Jog On Time 27 118 Jog on Time Field 49
178. ess the Enter button to map Input to OK to Fill Step 9 Press the Exit button to return to the OK to Fill Menu See Fig 6 48 Notice that Input 1 appears in place of Not Mapped OK to Fill gt ITEM Input 1 gt FIG 6 48 OK TO FILL MENU INPUT 1 MAPPED FIG 6 49 OK TO FILL SOURCE MAPPED Step 10 Press Exit to get back to the Basic I O Mapping Menu Notice that an asterisk has been added to the right arrow indicating that OK to Fill is mapped to something See Fig 6 50 Step 11 To Map other items repeat steps 1 8 for those items you want to map OA gt gt Of to FLL CLEAR ALARN gt FIG 6 50 OK TO FILL MAP INDICATION Step 12 To check what Items are mapped to which Input or what Outputs are mapped to which Item just go to the Basic I O Mapping Menu select the Destination you want to see and press Enter The mapped data is readily available Unmapping Procedures for Front Panel Step 1 To Unmap Items go to the Basic I O Mapping Menu Step 2 Press the up or down arrow buttons until the cursor is in front of the Item you want to unmap In our example we used OK to Fill Step 3 Press the Enter button The OK to Fill Menu appears See Fig 6 51 OK to Fill gt ITEM Input 1 gt FIG 6 51 OK TO FILL MENU INPUT 1 MAPPED Step 4 Press the Enter button The Item Selection Menu appears with the cursor in front of Not Mapped Default See F
179. et the entry Scale Capacity Parameter About the Scale Capacity Parameter If this value is exceeded by 5 a HI indication appears on the front display Communications to and from optional devices are not effected This value is the nominal operating capacity of the scale It is recommended that you use the default parameter PARAMETER SCALE CAP RANGE 000001 999999 DEFAULT 999999 Press the Down arrow button until the cursor is in front of Scale Cap See Fig 4 85 Step 1 SETUP MENU AVERAGES 16 gt Scare CAP 180 WAVERSAVER 1 GH2 FIG 4 85 SETUP MENU SCALE CAPACITY Step 2 Press the Clear button to clear the current entry Step 3 Use the alphanumeric key pad to enter the new Scale Capacity value Step 4 Press the Enter button to set the entry The WAVERSAVER Parameter About the WAVERSAVER Parameter Typically mechanical noise from other machinery in a plant environment is present in forces larger than the weight forces trying to be detected The Filler Dispenser is fitted with WAVERSAVER technology which eliminates the effects of vibratory forces present in all industrial weight control and measurement applications By eliminating the factor of vibratory forces the Filler Dispenser is capable of identifying the actual weight data WAVERSAVERC enables the Filler Dispenser to distinguish between actual weight data and mechanical noise both of which are typically trans ferred to the Filler Dis
180. from starting a gate from opening etc You need to select OK to Fill as the Destination and Input 1 as the source Step 1 Press the Setup 3 DEF button once The Configura tion Menu appears with the cursor in front of ADJUST INGREDIENT Default Step 2 Press the down or up arrow buttons to move the cursor in front of I O Mapping See Fig 6 43 OPTIONS gt gt I O MAPPING gt SECURITY gt FIG 6 43 CONFIGURATION MENU I O MAPPING Step 3 Press the Enter button The Basic I O Mapping Menu appears See Fig 6 44 The List you see is a list of Destinations We need to map the Destination OK to Fill to the Source Input 1 Step 4 Press the down arrow button until the cursor is in front of OK to Fill See Fig 6 44 Stop gt gt OATS PILL gt CLEAR ALARN gt FIG 6 44 BASIC I O MAPPING OK TO FILL SELECTION Step 5 OK to Fill Menu appears See Fig 45 OK to Fill gt ITEM Not Mapped gt FIG 6 45 OK TO FILL MENU ITEM NOT MAPPED Step 6 Press the Enter button The Item Selection Menu appears with a list of sources See Fig 6 46 ITEMSELECTION gt Not Mapped Input 1 Input 2 FIG 6 46 ITEM SELECTION MENU NOT MAPPED SELECTED Step 7 Press the up or down arrow button to until the cur sor is in front of Input 1 See Fig 47 ITEMSELECTION Not Mapped gt Input 1 Input 2 FIG 6 47 ITEM SELECTION MENU INPUT 1 SELECTED Step 8 Pr
181. g the terminal block into the Channel 1 connec tor on the rear panel Non C2 Load Point Connection Cable color Code for Non C2 Load Points e Shield Ground Wire e C2 Not Used e C2 Not Used e EXC Black e SEN Brown e SIG White e SIG Green e SEN Blue EXC Red Step 1 Remove the factory installed jumper from the ter minal block if you have 6 wire load cell cable that includes sense wires from the load cell or junction box Step 2 Connect the cable Recommended load cell cable Hardy Instruments Prt 6020 0001 wires to the J9 terminal block according to the Non C2 cable color chart Step 3 Plug the terminal block into the Channel 1 J9 con nector on the rear panel LVDT and Half Bridge Load Cells Sensors Please contact Hardy Technical Support for installation instructions Junction Box Wiring Shield c2 c2 Exc Sen Sig Sig Se Exc Shield c2 c2 Exc Se Sig Sig Se Exc Shield C2 C2 Exc Se Sig Sig Se Exc O DO Shield CZ 02 Exc Sen Sig Sig Sen Exc Gnd Iso Gnd Rxd Txd o LINK O m oO IL A FIG 3 19 JUNCTION BOX CONNECTIONS Step 4 Connect the cable wires directly to the terminal blocks according to the C2 or Non C2 cable color charts Step 5 Plug the terminal blocks into Channels 1 thru 4 con nectors on the rear panel Write down which load cell is connected to Channel 1 Channel 2 Channel 3
182. ght are read only e bast Fill Proof Switch Proof switch for the fill feeder is either ON or OFF s Fast Fill Proof Timer If the Fast Fill Proof Switch is ON the set time it takes for the switch to safely open or close e Fast Fill Weight If Dual Speed is selected the weight set point in which the fast gate closes Step 46 Press the down arrow button until the next three menu items are displayed See Fig 7 64 TEST DATA INDR gt Auto Fast Abe ON MODE SIMULTANEGUS 1 lo FIG 7 64 TEST DATA INGREDIENT DISPLA Y AUTO FAST ADJUST MODE SLOW FILL PROOF SWITCH Step 47 Auto Fast Adjust Mode Slow Fill Proof Switch are read only e Auto Fast Adjust If Dual Speed is selected it adjusts the Fast Weight value this value is the preact weight from the tar get weight where the fast feed shuts off Preact is the pre activation point where the valve closes to account for in flight mate rial and valve de activation timing e Mode If Dual Speed is selected it and Auto Fast Adjust is ON shows which fill HI 3010 Filler Dispenser IBC 120 Service Manual mode has been selected Simultaneous or Sequential e Slow Fill Proof Switch If Dual Speed is selected and Auto Fast is ON this menu item indicates if the Slow Fill Feeder Switch is On or Off Step 48 Press the down arrow button until the next three menu items are displayed See Fig 7 65 gt TEST DATA gt SLOW PILL PRE TAR 5s PRT DAUD
183. he Swivel Wall Mount 13 About the Tare Limit Parameter 40 About the Total Decimal Point Parameter 39 About the Totalizer Parameter 37 About the WAVERSAVER Parameter 41 About the Zero Tolerance Parameter 39 About Traditional Calibration 61 About Unit of Measure 38 About Wait Timer 28 AC 4 AC Power 17 Accept the Dispense 91 Activated 81 Add 78 ADJUST INGREDIENT 24 81 Allen Bradley Remote l O 2 3 4 Alphanumeric Character LCD 21 Amount of Deviation 39 Amount 4 GHI 23 Analog 2 Analog Equation 78 Analog Mapping 77 Analog tables 78 Analog Variables 78 AND 77 Application Specific Process Weighing Instruments 1 Approvals 8 Arrays of Numeric Entities 75 Artificial Zeroing 40 ASCII String 78 Asterisk 82 Auto Zero Time Field 52 Auto Zero Tolerance Field 52 Auto Discharge 32 Auto Discharge OFF Radio Button 53 Auto Fast Adjust 119 Auto Print 36 Auto Zero Time 116 Auto Zero Tolerance 116 Auto Adjusting Preacts 1 Auto Zero OFF Radio Button 52 Auto Zero ON Radio Button 52 Aux Auxiliary Device Timer 32 Auxiliary Devices 124 Average Reading 122 129 Averages 7 117 Averages Parameter 41 Awaiting Command to Discharge Display 94 B B Guidelines for Instabilities on Formerly Operating Systems Cont d 97 B1 Guidelines for Instabilities on Former Operating Systems Cont d 98 B2 Guidelines for Instabilities on Formerly Operating Systems Mechanical Stability and Configuration Settings 99 B
184. he communications parameters IP Address etc are stored in the Secure Memory Module SMM 31 CHAPTER 4 Configuration Step 1 In the Configuration Menu press the down arrow until the cursor is in front of SETUP See Fig 4 ADULO gt SETUP CALIBRAMON FIG 4 41 CONFIGURATION MENU SETUP Step 2 Press the Enter button The SETUP MENU appears with the cursor in front of Operator ID See Fig 4 42 Operator ID About Operator ID The Operator ID is the ID of the user who is going to operate the Filler Dispenser or service the instrument Select three letters or numbers or any combination of the two that ade quately identifies the user We have provided some examples below for your assistance The Operator ID is used in con nection with the security level of the user SETUP MENO gt OPERATOR ID INSTRURENT 10 gt DK to FILL INPT ON gt FIG 4 42 SETUP MENU OPERATOR ID Step 1 Use the alphanumeric key pad to enter your Opera tor ID or press the Clear button to clear the previous entry and use the alphanumeric key pad to enter you Operator ID Step 2 A Operator ID is three 3 characters long and can consist of alphanumeric characters Some examples of Operator IDs e Joe 312 Ji15 JD7 Step 3 Press the Enter button to set the entry Instrument ID About Instrument ID The Instrument ID parameter is used to provide specific identification for a Filler Dispenser This is extre
185. he left or right arrow buttons to select the Units you want The selections are lbs kg oz g e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Step 10 Step 11 HI 3010 Filler Dispenser IBC Service Manual 116 Press the up or down arrow until the cursor is in front of WAVERSAVER This display shows the last WAVERSAVER selection e Press the left or right arrow buttons to select the WAVERSAVER selection you want e Press the Enter button to set the entry e Press the down arrow to move to the next parameter Press the down arrow button until the next three menu items are displayed See Fig 7 54 TEST DATA gt DORAD SIZE 1 SPAN VALUE 1000 00 Zero CT 21581 FIG 7 54 TEST DATA DISPLA Y GRADUATION Step 12 Step 13 Step 14 Step 15 NOTE SIZE SPAN VALUE ZERO COUNT The Span Value is read only The Graduation Size and Zero counts are for the last calibration only The Grad Graduations and Zero Count can be changed Press the up or down arrow until the cursor is in front of Grad e This display shows the last selected Grad uation size Press the left or right arrow buttons to select the Units you want The selections are 1 2 5 10 20 50 100 200 500 1000 e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Press the u
186. he right arrow button to toggle between ON and OFF In our example we enabled Channel 1 See Fig 127 FIG 4 127 SMART DIAGNOSTICS ENABLING CHANNEL 1 Step 7 To see Channel 4 press the down arrow button until Channel 4 appears See Fig 128 FIG 4 128 SMART DIAGNOSTICS CARD MENU CHANNEL 2 3 4 Step 8 Continue to enable the channels you want for your process Step 9 Press the Enter button to save the entries Step 10 Press the Exit button to return to the Main Menu Smart Diagnostics Card Configuration from the Web Browser Step 1 From the Home Page click on Configuration See Fig 129 The Configuration Page appears See Fig 130 Step 2 Click on Options See Fig 130 The Configuration Options page appears See Fig 131 FIG 4 129 HOME PAGE SELECTING CONFIGURATION Configuration Choose One Adjust Ingredient Instrument Setup Calibration Basic Mapping Advanced Mapping Security FIG 4 130 CONFIGURATION PAGE SELECT OPTIONS Configuration Options Smart diagnostic card configuration View Profibus configuration FIG 4 131 CONFIGURATION OPTIONS SELECTING SMART DIAGNOSTICS CARD CONFIGURATION Step 3 Click on Smart diagnostic card configuration See Fig 64 The Configuration Smart Diagnostics Card appears See Fig 132 HI 3010 Filler Dispenser IBC 56 Service Manual Configuration smart diagnostic card Board ID 0080 Board Revision 0001
187. here is something wrong between the HI 3000 and the load cells The cable s is disconnected or something is wrong with the such that it is not transmitting the read ings to the HI 3000 instrument If you do not get a reading for one or pos sibly two or more load sensors Sensor 3 for example reads 0 00 or the reading is either larger or smaller than it should be and you know that the Load Sensors are connected to the instrument the individual load sensor cable is disconnected from the instrument broken cable or the load sensor is malfunctioning UNIVERSAL JOINT OR Step 5 With this information you can quickly determine what the problem is and where it is located either from the Web Browser Front Panel Step 6 To return to the Operation Smart Diagnostics Page click on the back arrow at the bottom of the page Overview of Typical Load Cell System _____USE SYMMETRIC BEAM LOADED 1 THROUGH SHEAR CENTER TO AVOID TWIST WITH LOAD The typical system consists of one or more load cells points a summing junction box and an HI 3010 control ler See Figure 7 121 JUNCTION BOX Weight Controller Y INTERMEDIATE SUPPORT FRAME FULLY CONSTRAINED LATERALLY WITH STAY RODS NON METALLIC EXPANSION ASSEMBLY OR HOSE k Sy e
188. hts total 80 to 100 of the scale live load capacity Step 1 Press the Setup 3 button The Configuration Menu appears See Fig 5 16 CONFIGURATIONTENG AUYUST INGREDIENT gt SETUP gt CALIBRATION gt FIG 5 17 CONFIGURATION MENU CALIBRATION Step 2 Step 3 NOTE Press the down arrow until the cursor is in front of CALIBRATION See Fig 5 17 Press the Enter button The CALIBRATION Menu appears with the C2 Cal Type See Fig 5 18 If the CALIBRATIN MENU appears with Cal Type TRAD go to Step 5 CALIBRATION Sensor Type 0 3nV V1 gt Cal Type Q gt FIG 5 18 CALIBRATION MENU Step 4 Press the Right or Left arrow buttons to select Tra ditional Calibration See Fig 5 19 CALIBRATION Sensor Type 0 3nV V1 TRAD gt gt Cal Type FIG 5 19 CALIBRATION TRADITIONAL Step 5 Press the Enter Button The Traditional Cal Menu appears with the cursor in front of Zero Value See Fig 5 19 y 70 a m m 70 O 000 X D cx m co ca N ev FIG 5 20 TRADITIONAL CALIBRATION ZERO VALUE Step 6 Traditional Calibration requires a zero point and the physical placement of test weights on the scale To Set the Zero Value e Remove all weight live load from the scale The Zero Value should be 0 00 CAUTION THE SCALE MUST BE EMPTY s Wait 12 seconds or more NOTE Zero Ct is read only and is used to Troubleshoot the instrument Step 7 Press th
189. id bit Set when the rest of the status bits are valid HSI6 Watchdog Word Each bit represents the correspond ing node bit0O Node0 etc sending data Five seconds after the last data packet arrives form any node its bit is set to zero HO Hardy Output Table HOO0 0 Output Relay 1 HOO 1 Output Relay 2 HOO 2 Output Relay 3 HOO 3 Output Relay 4 HO0 7 Software LED HO2 0 Do C2 Calibration HO2 1 Do Traditional Calibration Low Zero weight HO2 2 Do Traditional Calibration High Span weight HO2 3 Clear All Totalizers HO2 4 Clear Totalizer 1 HO2 5 Clear Totalizer 2 HO2 6 Clear Totalizer 3 HO2 7 Clear Totalizer 4 HO2 8 Clear Totalizer 5 HO2 9 Clear Totalizer 6 HO2 10 Clear Totalizer 7 HO2 11 Clear Totalizer 8 HO2 12 Clear Totalizer 9 HO2 13 Clear Totalizer 10 HO2 14 Clear Totalizer 11 HO2 15 Clear Totalizer 12 HO3 0 Send Custom Email 0 HO3 1 Send Custom Email 1 HO3 2 Send Custom Email 2 HO3 3 Send Custom Email 3 HO3 4 Send Custom Email 4 HO3 5 Send Custom Email 5 HO3 6 Send Custom Email 6 HO3 7 Send Custom Email 7 HO3 8 Send Custom Email 8 HO3 9 Send Custom Email 9 HSO Hardy Short Output table A table of 16 bit integers NOTE HSO is a distinct table and does not refer to HO in any way HSOO Cycles Ordered for Active Ingredient 0 continuous HSO1 Ingr 1 Speed O single 1 dual HSO2 Ingr 2 Speed HSO12 Ingr 12 Speed HSO13 Ingr 1 Fills or
190. ie Wo 1 General Introduction to the Hardy Filler Dispenser IBC HI 3010 Service Manual 1 Description 1 Typical Applications 2 Hardy Web Tech 3 Connectivity 3 Setup Wizards 3 Mapped VO 3 WAVERSAVER Ast a At Bah ott ers al 3 C2 Calibrations 2 2 seattle ork Ses SO SE RE 3 On Board Diagnostics 4 Secure Memory Module SMM 4 Relays 4 Serial Port 4 Options 4 JB 4 HI 3000 RC 4 PB 4 AC 4 RIO 4 Smart Diagnostics SD 4 Hardware 5 MB 5 Communication Options 5 EtherNet IP 5 MOD Bus TPC IP 5 OPC 5 Remote I O RIO Interface to the Allen Bradley Network 5 Profibus 6 Specifications
191. ig 52 FIG 6 52 ITEM SELECTION SELECTING NOT MAPPED Step 5 Press the enter button to set the entry HI 3010 Filler Dispenser IBC 82 Service Manual Step 6 Press the Exit button to return to the OK to Fill Menu See Fig 6 53 OK to Fill gt ITEM Not Mapped gt FIG 6 53 OK TO FILL MENUITEM UNMAPPED Step 7 Press on the Exit button to return to the Basic I O Mapping Menu See Fig 6 54 Notice that the asterisk no longer appears This tells you that the item is unmapped BASIC U OMAPPING Stop gt CKtoFill Gear Alarm FIG 6 54 BASIC I O MAPPING OK TO FILL UNMAPPED Step 8 Ifyou want to unmap more items just repeat steps 1 7 83 CHAPTER 6 Mapping Mapping a Hardy Control Link Network to a ControlNet DeviceNet Profibus Network FIG 6 55 HARDY CONTROL LINK NETWORK CONNECTED TO A CONTROLNET DEVICENET PROFIBUS The Hardy HI 3000 Series of controllers are designed to save Step 3 Connect the network cables from the designated HI you money To connect a Hardy Control Link Network to a ControlNet DeviceNet Profibus Network simply purchase one of the Hardy HI 3000 Series Network Interface Option ControlNet Interface Profibus Interface DeviceNet Interface HI 3010 FilleriDispenser With Network Option Card Hardy Control Link Network NETWORK Cards and install it in the instrument that you want to directly work connect to the other network You can map to this in
192. ig 7 33 At this time you can 1 Accept the dispense by pressing the START button 2 Physically remove some of the mate rial until it meets the target window requirements and then press the START button 3 The instrument returns to the Waiting ON display repeats the motion check autotares and or checks the OK to Dispense processes and begins dis pense cycle number 2 See Fig 7 33 BERRIES APT 5 00 20 00 ACCEPTOISPENSE LB PRESSSTART HL D FIG 7 33 ACCEPT DISPENSE DISPLAY e UNDERDISPENSE ALARM press the Clear button to clear the alarm the Accept the Dispense display appears At this time you can 1 Accept the dispense by pressing the START button 2 Physically add some of the material until it meets the target window requirements and then press the START button 3 The instrument returns to the Waiting On Display repeats the motion check autotares and or checks the OK to Dispense processes and begins dis pense cycle number 2 4 The instrument checks to see if the gate of the vessel opens HI 3010 Filler Dispenser IBC 92 Service Manual IBC Dispense Alarms Change IBC Alarm s If there is still no motion An alarm telling you to Change IBC appears See Fig 7 34 GRANULES An 0 00 10800 00 ICHANGEISE LB ALARM HLD FIG 7 34 CHANGE IBC ALARM Jog Alarms Jog Gate Did Not Open Alarm e The instrument checks to see if the gate of the vessel opens If the gate DID NOT ope
193. ill pro cess continues to another procedure See Fig 7 40 FLOUR AMT 224 35 225 00 CYLLES 25 56 TNE 2 05 QU HLD FIG 7 40 JOG DISPLAY COMPLETED ONE JOG SEQUENCE CHECKING WEIGHT 5 You can pause the JOG cycle by push ing the Stop button once at any time during the JOG cycle The JOG Hold display appears See Fig 7 41 C3 cl 70 am Za L ma Tu Ln Tru Ss Coun Se a ke ca Abe mm ca in FIG 3 41 JOG PAUSED 1 0 SECOND INTO THE JOG SEQUENCE 6 Ifthe gain in weight is still NOT within the target window the instru ment automatically continues through the preset JOG sequences until the tar get window is reached and then con tinues on to another procedure Jog Count Alarm e If the JOG sequences are completed and an UNDERFILL condition still exists a JOG count alarm appears telling you that you have used up the JOGs for this sequence See Fig 7 42 FLOUR AMT 224 35 2025 00 iar CONT 1 UU U Luu ALARM Joo HL D FIG 7 42 JOG COUNT ALARM 1 Press the Clear button to clear the alarm 2 The JOG display reappears asking you if you want to start the JOG sequence again See Fig 7 43 FLOUR ANT 224 39 205 00 TO JOG AGAIN PRESS START HL D FIG 7 43 JOG DISPLAY JOG AGAIN 3 If you want the instrument to JOG again press the Start button to repeat the JOG sequence 4 Ifyou DO NOT want the instrument to JOG again press the Stop button The instrume
194. ingredients is exactly the same Step 2 Press the Enter button Ingredient 1 sub menu appears with the cursor in front of Ingredient 1 See Fig 4 11 Default HI 3010 Filler Dispenser IBC 24 Service Manual Ingredient Name Parameter FIG 4 11 INGREDIENT 1 SUB MENU ENTER INGREDIENT NAME PARAMETER INGREDIENT NAME RANGE 19 ALPHANUMERIC CHARACTERS DEFAULT INGREDIENT 1 Step 1 Press the Clear button to clear the existing ingredi ent name See Fig 4 12 FIG 4 12 CLEARING INGREDIENT NAME Step 2 Use the alphanumeric key pad to enter the new Ingredient Name Remember you can only use 19 characters In our example we entered Flour See Fig 4 13 FIG 4 13 INGREDIENT NAME ENTERED FLOUR Step 3 Press the Enter button to select the entry The entry is selected and the cursor moves to the next item in the menu In this case it is the Fill Cycle See Fig 4 14 NOTE Another way to accept the entered parameter is to use the down arrow When you press the down arrow after entering a parameter value the instrument accepts that entry and moves the cur sor to the next item on the menu 25 CHAPTER 4 Configuration Fill Cycles About Fill Dispense Cycles Fill cycles are the number of fill dispense cycles you are going to use for this ingredient In our example we are using the ingredient Flour and we want Flour to cycle 15 times FLOUR gt FILL CYCLES TARGET LIT TARGET PREACT
195. ipment model number and serial number ready System Support Technical Service is provided as follows e New system start up Ensure that the installation is checked and correct instru ments are calibrated and operators trained 1 Service Engineers are trained and qualified to provide on site installa tion calibration and maintenance 2 On site training A Hardy Support Representative can be scheduled to train your operations and maintenance personnel This can be as simple as basic load cell theory or as complete as troubleshooting techniques which allow you to service your equipment Warranty A warranty problem may be handled by returning the prod uct to the factory for repair or replacement under warranty HI 3010 Filler Dispenser IBC 136 Service Manual 135 Appendix A HI 3010 Complete Mapping Symbols DICTIONARY OF MAPPING SYMBOLS Map Dictionary CMDO Specifies input and output locations for the com mand interface e g CMD0 DSI25 DSO20 Unit will look for commands starting at DeviceNet input word 25 and send acknowledgement to output word 20 Please distinguish between digit zero 0 and upper case letter O HI HSI Hardy Input Table Bit y of word x in table is specified as HIx y 16 bit word x in table is specified as HSIx HSIO Digital Inputs Word HI0 0 Digital Input 1 HI0 1 Digital Input 2 HI0 2 Digital Input 3 HI0 3 Digital Input 4 HI0 4 Digital Input 5 HS
196. istrib uted OLE technology DCOM to facilitate clients interfac ing to remote servers Remote I O RIO Interface to the Allen Bradley Network The RIO port allows bi directional communications with Allen Bradley Programmable Logic Controllers PLC and Small Logic Controllers SLC The HI 3010 represents a selectable 1 4 1 2 3 4 or full rack of discrete I O 32 bits in the Logic Controllers output and input image files to the PLC Controller and supports both discrete and block trans fers of data It can support up to 230 4 Kbaud transfer rates Profibus Allows bi directional communications to Profibus Process Fieldbus products including those made by Siemens GE Fanuc and Texas Instruments This interface supports PRO FIBUS DP Decentralized Periphery and processes both Selectable Predetermined and Block transfer commands It supports up to 12 Mbaud transfer rates HI 3010 Filler Dispenser IBC Service Manual 6 7 CHAPTER 2 Specifications CHAPTER 2 SPECIFICATIONS About Chapter 2 Chapter 2 lists the specifications for the HI 3010 Filler Dis penser Specifications are listed for the standard instrument and for instruments fitted with optional equipment The specifications listed are designed to assist in the installation operation and troubleshooting of the instrument Service per sonnel should be familiar with this section before attempting an installation or repair of the instrument Specifications for a Stan
197. ity test The display indicates Testing See Fig 7 111 MESTNA Press Enter to Est FIG 7 111 STABILITY TEST TESTING DISPLAY e The results of the Stability Test are dis played for this scale as PASS See Fig 7 112 This means that the Mean Squared Variation is less than 5 0 and the average reading is between 30237 and 36955 In short the instrument is working fine SYSTEMSTABILITY TEST gt Test Results PASS gt 2 37 Mean Sq Var MeanADCOount 34k FIG 7 112 SYSTEM STABILITY TEST DISPLAY PASS e The test results shown are for all four Channels If you want to see the results for each individual channel press the down or up arrow buttons until the cursor is in front of Test Results PASS Press the Enter but ton to see the test results per channel See Fig 7 113 131 CHAPTER 7 Troubleshooting gt Channel gt Channel Channel Channel Channel Channel Channel Channel FIG 7 113 TEST RESULTS PER CHANNEL FIG 7 115 STABILITY TEST RESULTS CHANNEL 3 FAILED To see the individual results for Channel 1 press the up or down arrow buttons until NOTE Ifthe result for a Channel shows N A it means the cursor is in front of the channel you that this channel is inactive want to view Press the Enter button to see the individual Stability Test results for the selected Channel in our example Channel 1 See Fig 114 STABILITYTEST H3 gt Est Result FAIL STABILITY TEST CH1 el gt Test Resul
198. l reason for the alarm is determined The OK to FILL timer may be set incorrectly for your process See the HI 3010 Service Manual for Instructions on setting the OK to FILL Timer Lost OK to Fill Alarm During the filling process conditions may develop that cause the Filler Dispenser to lose the OK to FILL during Fast Fill or Slow Fill When this occurs an alarm appears that says LOST OK TO FILL See Figs 7 2 amp 7 3 FLOUR AMT 0 00 225 00 LOST G4 TOFILL ALARM FASTFILL ALO FLOUR AMT 0 00 225 00 LOST Db TOFILL IALARM SLOWFILL HLD FIG 7 3 LOST OK TO FILL ALARM SLOW FILL 1 The Operator needs to determine why the system LOST OK to FILL by checking for problems with the elec trical and or mechanical systems 2 Once the problem has been fixed push the Clear button to clear the Alarm Press the Start button the Filler Dispenser resumes filling from where it stopped Press Stop to Halt HI 3010 Filler Dispenser IBC 86 Service Manual Fast Gate Did Not Open Alarm e If the Fast Fill Gate is not open at the time you want to fill the FAST GATE DID NOT OPEN alarm appears on the display See Fig 7 4 FIG 7 4 FAST FILL GATE DID NOT OPEN ALARM 1 Determine why the Fast Fill Gate did not open and correct the problem 2 Press the Clear button to clear the alarm The RESUME FILLING FAST display appears See Fig 7 5 FLOUR ART 0 00 225 00 RESUME FILLING FAST PRESSSTART JOGI ALD
199. l the next three menu items are displayed See Fig 7 57 FIG 7 57 TEST DATA DISPLAY TARE LIMIT MOTION TOLERANCE AVERAGES Step 27 Tare Limit Motion Tolerance Averages can all be changed from this menu Step 28 Press the up or down arrow until the cursor is in front of Tare Limit e The Tare Limit is the maximum net weight value that can be reduced tared to zero e To clear the Tare Limit press the Clr Clear button e Use the alphanumeric key pad and enter the new Tare Limit e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Step 29 Press the up or down arrow until the cursor is in front of Motion Tolerance e The Motion Tolerance is the allowable deviation between consecutive weight readings to confirm filling or dispensing is active e To change the Motion Tolerance press the Clr Clear button e Use the alphanumeric key pad and enter the new Motion Tolerance HI 3010 Filler Dispenser IBC 118 Service Manual e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Step 30 Press the up or down arrow until the cursor is in front of Averages e The Averages is the Number of weight readings used to compute displayed weight e To change the Averages press the Clr Clear button e Use the alphanumeric key pad and enter the new Averages e Press
200. lecting the module by number for Testing NOTE Tou can only ping from the PC you cannot ping from an instrument Step 1 Type PING lt space gt IP address of the instrument you want to test For Example C PING 192 168 110 99 s n our example we used the default address for all HI 3000 Series Instruments The IP address you are testing will be dif ferent Step 2 Press the Enter key on the PC Step 3 The PING utility starts sending out 56 signals and 64 signals should return if the unit is functioning correctly e Ifthe instrument or network are config ured incorrectly and cables are loose or not connected correctly nothing prints out after the first line Do the following 1 Check the Network cables and con nectors to be sure they are tightly fas tened and the correct cables for this application 2 Check the configuration to be sure that the instrument is configured cor rectly See Configuration IP Address in Chapter 6 3 Check the Ethernet card to be sure that is securely seated and that it is functioning correctly e Ifthe unit is configured correctly and the Ethernet card is functioning correctly and the cables are the correct ones for this HI 3010 Filler Dispenser IBC 134 Service Manual application and are securely fastened 64 signals should be returned and the print out will reflect this fact NOTE NOTE The Ping utility continues to send out sig nals pings until you exit the Ping Tool e
201. lick in the Min Weight field and enter the new Minimum target weight tol erance e Double click in the Max Weight field and enter the new Maximum target weight tol erance Step 31 If you choose percentage e Double click in the Min percent field and enter the new Minimum target weight tolerance e Double click in the Max percent field and enter the new Maximum target weight tolerance Step 32 Click on the Speed pull down menu to select Single or Dual Speed See Fig 4 109 HI 3010 Filler Dispenser IBC 50 Service Manual Configuration Adjust Ingredient Instrument ID 52 Hardy Filler Ingredient Number Tolerance Percent Min Max Speed B Ingredient Name Flour Timers Fill Timer 120 Wait timer 2 000000 Weight 1 0000 Min Weight 1 0000 1 0000 Max Weight 1 0000 Single gt lt gt FIG 4 109 SPEED SELECTION Step 33 Click on the Enter Parameters button to set the entries Step 34 If you have more than one ingredient you want to configure go back to the previous page and select a new ingredient and repeat the Ingredient Adjust ment procedures Continue this process until all the ingredients you want to use in this fill have been configured The Browser Ingredient Setup is Complete Instrument Setup from the Browser Step 1 From the Configuration page click on Instrument Setup See Fig 4 110 The Instrument Setup page appears See Fig 4 111 Configur
202. lity Test switches a fixed signal into the analog to digital convertor and calculates the mean squared variation from the average reading using 100 samples The test passes if the mean squared variation is less than 5 0 and the average reading is between 30237 and 36955 Step 1 Press the up or down arrow buttons until the cursor is in front of Stability Test See Fig 7 76 VOLTAGE B WEIGHT gt gt STABILITY TEST gt Factory Deraurrs gt FIG 7 76 DIAGNOSTICS DISPLA Y SELECTING STABILITY TEST Step 2 Press the Enter button The Information display appears SYS STABILITY TEST PRESS ENTER TO START See Fig 7 77 395 STABILITS TEST U i Docec ENTED n Er Press ENTER 72 STAR FIG 7 77 STABILITY TEST DISPLAY Step 3 Press the ENTER button to perform the stability test e Ifthe instrument passes the Stability Test the Pass display appears See Fig 7 78 This means that the Mean Squared Varia tion is less than 5 0 and the average read ing is between 30237 and 36955 In short the instrument is working fine FIG 7 78 SYSTEM STABILITY TEST DISPLAY PASS e Ifthe instrument does not pass the Stabil ity Test the Fail display appears See Fig 7 79 This means that the Mean Squared Variation is greater than 5 0 and or the average reading is not between 30237 and 36955 This test examines the internal electronics and not the load cells input sig FIG 7 79 SYSTEM STABILITY TES
203. lug the power connector and cable Step 2 Remove the Secure Memory Module Step 3 Unplug the load cell connector and cable Step 4 Disconnect all the communication cables connected to the instrument Step 5 Use a phillips head screw driver and remove the two phillips head screws that fasten the back plate to the rear of the instrument chassis See Fig 3 14 HI 3010 Filler Dispenser IBC 16 Service Manual Phillips Screws Screws FIG 3 14 REAR PLATE FASTENERS Step 6 Grasp the two thumb screws and gently pull the rear plate and Main Board out of the instrument Step 7 Use a phillips head screw driver and remove the three phillips screws that fasten the rear plate to the Single Channel Main board Step 8 Remove the two thumb screws that fasten the rear plate to the Single Channel Main board Step 9 Attach the four 4 7 8 standoffs to the Smart Diagnostics Card with the four 4 1 4 phillips screws Tighten the screws until they are snug Do not overtighten See Fig 3 15 Step 10 With the Hardy Logo facing the back of the Main board line up the pins of the Smart Diagnostics card with the connector on the Main board NOTE Make sure that none of the pins are bent before installing Connector Pins pee Board jammy SWARTDAGNOSIOS BWA ees 0595 0502 _ FEV NT OP TON B a a 5353 ERG Install Standoffs Here Install Standoffs Here FIG 3 15 STAND
204. mal Point Parameter 39 About the Total Decimal Point Parameter 39 Motion Tolerance Parameter 39 About Motion Tolerance 39 Zero Tolerance Parameter 39 About the Zero Tolerance Parameter 39 About the Auto Zero Tolerance Parameter 39 Tare Limit Parameter 40 About the Tare Limit Parameter 40 Averages Parameter 41 About the Averages Parameter 41 Scale Capacity Parameter 41 About the Scale Capacity Parameter 41 The WAVERSAVER Parameter 41 About the WAVERSAVER Parameter 41 Set Clock Parameter 42 About Setting the Clock 42 About Timezones Greenwich Mean Time 43 DeviceNet Parameters 44 About the DeviceNet Parameters 44 Ethernet Parameters 45 About the Ethernet Parameters 45 About IP Addresses 45 This Completes the Configuration of the Instrument from the Front Panel 46 Configuring the Filler Dispenser from the
205. mal ponts by 30 000 The amount you can expect to see but not necessarily stable 1011 CHAPTER 7 Troubleshooting C Guidelines for Instabilities on Formerly Operating Systems Use a Multi meter and Check individual load sensors output by Record load sensor physically lifting the signal wires and data for comparison and making a reading of that sensors output stability A load sensor output can be considered stable if the readings only vary 0 01mV Applying weight and releasing the weight should show a Lift the signal wires read and record the Millivolt reading very rapid Millivolt change A slow Millivolt change can indicate a damaged strain guage Repeat for each sensor Inspect the summing junction box for contamination or damage and replace if necessary Yes TEST COMPLETE Remove and replace any load sensor determined to be unstable If you are unable to isolate the problem contact Hardy Technical Support 800 821 5831 Insure the problem is not mechanical Review Section B HI 3010 Filler Dispenser IBC 102 Service Manual C1 Guidelines for Instabilities on formerly operating systems with Smart Diagnostics Record load sensor for comparison and stability Read and record the Millivolt readings Repeat for each sensor No TEST COMPLETE If you are unable to isolate the problem contact Hardy Technical Support 800 821 5831 Check individual load sensors output by
206. mand 1 discharge without waiting for command HSO139 OK to Discharge Enabled O don t wait for OK to Discharge input 1 wait for it HSO140 Auxiliary Device time s max time allowed for Auxiliary Device operation HSO141 Discharge Proof On O don t wait for Discharge Proof Sw 1 wait for it HSO142 Discharge Gate Timer s max time for dis charge proof sw to verify gate operation HI 3010 Weight Controller 136 Service Manual HSO143 Use Auto Zero 0O don t auto zero 1 auto zero when within autozero range of zero HSO144 Refill On O do not attempt refill 1 refill when needed HSO145 Initial Refill On O do not attempt refill 1 refill before operation HSO146 Active Ingredient Number 1 ingr 1 2 ingr 2 12 ingr 12 HSO147 WAVERSAVER setting 0 0ff 1 7 5Hz 2 3 5Hz 3 1 0Hz 4 0 5Hz 5 0 25Hz HSO148 Calibration Type 0 Traditional 1 C2 1 not calibrated HFI Hardy Float Input Table HFIO Gross Weight lb HFI1 Net Weight lb HFI2 Gross Weight HFI3 Net Weight HFI4 Tare Weight lb HFI5 weight Fraction 1 with SD board fraction of wt currently on input 1 HFI6 weight Fraction 2 with SD board fraction of wt currently on input 2 HFI7 weight Fraction 3 with SD board fraction of wt currently on input 3 HFI8 weight Fraction 4 with SD board fraction of wt currently on input 4 HFI9 capacity HFO Hardy Float Output Table HFOO user defined floati
207. mely important when using several Filler Dispensers in a process A unique Instrument ID allows you to identify one instru ment from another The Instrument ID is also useful when setting up the ingredients for a filling dispensing process PARAMETER INSTRUMENT ID RANGE 19 CHARACTERS DEFAULT HARDY FILLER OR HARDY DISPENSER Step 1 Press the down arrow until the cursor is in front of Instrument ID See Fig 4 43 SETUP MENU UPERATOR ID gt INSTRUMENT 10 gt OK to FILL INPT ON gt FIG 4 43 INSTRUMENT ID PARAMETER Step 2 Press the Enter button The Instrument ID Menu appears See Fig 4 44 FIG 4 44 INSTRUMENT ID MENU CHEM 3 FILLER Step 3 Press the Clear button to clear the current entry Step 4 Use the alphanumeric buttons to enter a new Instru ment ID It is important to be as descriptive as you can in 19 characters In our example we identified the instrument as the Chemical 3 Filler This that this is the 3rd Chemical Filler in a process Step 5 Press the Enter button to set the entry Step 6 Press the Exit button to return to the SETUP MENU Step 7 Press the down arrow until the cursor is in front of OK to Fill Inpt See Fig 4 45 OK to Fill Input Parameter About OK to Fill Input Parameter The OK to Fill Input Parameter is user selectable and is one of the alarm settings When the OK to Fill Input Parameter is on the instrument Auto Tares the scale and resets and starts the Fill Di
208. more information Step 12 End of Calibration Traditional Calibration From the Web Page Step 1 On the Filler Dispenser Home Page Click on Configuration See Fig 5 24 The Configura tion page appears See Fig 5 25 FaeriDispenzer Home Page FIG 5 24 CONFIGURATION MENU SELECTING SETUP Configuration Adjust Ingredient Instrument Setup Calibration Basic Mapping Advanced Mapping Security FIG 5 25 CONFIGURATION PAGE Step 2 Click on Calibration The Calibration Sub menu appears See Fig 5 25 Step 3 Select the Sensor type connected to this instru ment Traditional Calibration Traditional Calibration Low Step 0 0000 Reference weight Traditional Calibration High Step fi 0 00 Span Weight FIG 5 26 CALIBRATION SUB MENU Step 4 If the Traditional Calibration Low Step Refer ence is any value other than 0 0000 go to Step 5 otherwise go to Step 10 Step 5 To clear the entry move the cursor over the cur rent Reference Weight which highlights the weight value Step 6 Use your keyboard to type in the new 0 0000 See Fig 5 25 Step 7 Wait 12 seconds or more Step 8 Click on the Do Cal Low button Step 9 A page telling you that the Do Cal Low Calibra tion completed OK See Fig 5 26 Cal completed OK Back FIG 5 27 CAL LOW COMPLETED OK Step 10 Click on Back to return to the Calibration page Step 11 Place a certified test weight on the scale S
209. ms 2 Once the problem has been fixed push the Clear button to clear the Alarm The Filler Dispenser resumes dispensing from where it stopped Fast Gate Did Not Open Alarm e Ifthe Fast Dispense Gate is not open at the time you want to dispense the FAST GATE DID NOT OPEN alarm appears on the display See Fig 7 22 FIG 7 22 FAST DISPENSE GATE DID NOT OPEN ALARM 1 Determine why the Fast Dispense Gate did not open and correct the problem HI 3010 Filler Dispenser IBC 90 Service Manual 2 Press the Clear button to clear the alarm The RESUME DISPENS ING display appears See Fig 7 23 FIG 7 23 RESUME DISPENSING FAST DISPLAY Press the Start button to resume dispense See Fig 7 24 BERRIES AMT 2 057 00 00 CYCLES 123 LB FAST DISPON FIG 7 24 FAST DISPENSE ON Fast Gate Did Not Close Alarm If the Fast Dispense Gate does not close at the end of a cycle the FAST GATE DID NOT CLOSE alarm appears on the dis play See Fig 7 25 FIG 7 25 FAST GATE DID NOT CLOSE 1 Determine why the Fast Dispense Gate did not close and correct the problem 2 Press the Clear button to clear the alarm The RESUME DISPENSE display appears See Fig 7 26 91 CHAPTER 7 Troubleshooting BERRIES BERRIES ANT 0 08 20 00 ArT 20 23 20 00 RESUME DISPENSE LB HL HRP SLOW GATE PRESS START HLD IHIONGT CLOSE HLD FIG 7 26 RESUME DISPENSE DISPLAY FIG 7 29 SLOW GATE DID NOT CLOS
210. n OVERFILL the OVER FILL alarm appears Clear the alarm using the same procedures for the OVERFILL Alarm in the previous section 2 Ifthe out of target window is an UNDER FILL the Jog ON display appears 3 IfJog is off you will get a wait display until the amount is satisfied 89 CHAPTER 7 Troubleshooting Dispense Alarms Over Refill Alarm Ar 0 00 20 00 REFILL TIMEOUT LB ALARM REFILL KLD FIG 7 18 DISPENSE STANDBY DISPLAY FIG 7 16 OVER REFILL ALARM e If the Refill exceeds the Refill High set point or exceeds the capacity of the vessel the OVER REFILL ALARM appears See Fig 7 16 1 2 Correct the Over Refill condition Press the Clear button to clear the alarm The Dispense Standby display appears See Fig 7 17 Refill Timeout Alarm BERRIES HT 0 00 20 00 IREFILL TIMECUT LB ALARM REFILL HALO FIG 7 17 REFILL TIME OUT ALARM e Ifthe time taken to Refill exceeds the Refill Time out parameter which is set during configuration the Refill Time out Alarm appears For setup information check the HI 3010 Service Manual 1 Check to see why the refill took too long If there is an obstruction or excessive material bridging etc cor rect the problem If the Refill Time out was set incor rectly Use your HI 3010 Service Manual and reset the Refill Time out parameter Press the Clear button to clear the alarm The Dispense Standby display appears See Fig 7 18 No
211. n a JOG GATE DID NOT OPEN ALARM appears on the display and the Filler Dispenser is placed in a hold state See Fig 7 35 E min Leon OMT 370 M I AM me CECIU CEI UU LIAC COTO MINOT INOGDOATEDIDNOT 1 Na mi m1 Mal OPENALARA UU 1 HL U FIG 7 35 JOG GATE DID NOT OPEN ALARM 1 Check to see why the gate did not open Correct the problem Press on the Clear button to clear the alarm See Fig 7 36 FLOUR AM 224 99 225 00 TO JOG AGAIN PRESS START HLD FIG 7 36 TO JOG AGAIN PRESS START DISPLAY 93 CHAPTER 7 Troubleshooting 2 The Jog sequence resumes from where the Jog left off when it was paused Jog Gate Did Not Close Alarm e You might experience a JOG GATE DID NOT CLOSE ALARM also If the JOG gate does not close the alarm appears See Fig 7 37 FIG 7 37 JOG GATE DID NOT CLOSE ALARM 1 Check to see why the gate did not close Correct the problem Press on the Clear button to clear the alarm 2 The Jog sequence resumes from where the Jog left off when it was paused See Fig 7 38 3 The Filler Dispenser goes through one JOG sequence that was previously set up See Fig 7 38 amp 7 39 FLOUR AMT Gou 157005 00 CYELES 25 56 THE 0 05 JOGI ON FLOUR AMT P24 35 225 00 CYELES 25 56 TNE 2 85 JOGI ON FIG 7 39 JOG DISPLAY JOG 1 2 0 SECONDS 4 The instrument continuously checks to see if the gain in weight is within the target window If it is the f
212. nd For 1 4 1 2 3 4 Racks Third For 1 4 1 2 Racks Fourth Only for 1 4 Racks Table 1 Quarter Combinations EtherNet IP Option Card Power Supply 5V max 450mA Operating Temperature e 0 70 C 32 158 F Baud Rate e 10 100 Mbit s UO Input e 2048 bytes YO Output e 2048 bytes Application Interface e Parallel Specification Rel 2 EtherNet IP level 2 I O Server CIP Con trolNet amp DeviceNet Functionality s 10 100Mbit MB TCP EtherNet IP IT functions Specifications for Peripherals Systems Components HI 215JB SS1 or PS1 Series Case Dimensions 6 25 H x 6 25 W x 4 50D 158 75mmH x 158 75mmW x 114 3mmD Weight e 5 pounds 2 27 Kilograms Enclosure Ratings SS1 Stainless Steel NEMA 4 amp 4X PS1 Painted Carbon Steel NEMA 4 HI 3010 Filler Dispenser IBC Service Manual 10 11 CHAPTER 3 Installation CHAPTER 3 INSTALLATION About Chapter 3 All information contained in Chapter 3 pertains to unpack ing cabling interconnecting and installing the HI 3010 Filler Dispenser Alternatives to any specifications contained or implied in this section are not recommended It is very important that the user and service personnel be familiar with the procedures contained in this chapter before install ing or operating the HI 3010 Filler Dispenser NOTE Ethernet and DeviceNet installation and setup instructions are located in the HI 3000 Series Operation and Installation M
213. nder stand Mapping we first need to define some of the terms and understand the structure of an Assignment Statement In short mapping is nothing more than assigning data from an address Source to another address Destination to be used by the controller in ways that meet your process requirements Since the HI 3010 does not have any pre defined Addressed I O you are free to Address I O in any fashion that meets your needs Glossary of Mapping Terms Assignment Statement The assignment statement is an order to the computer to change the value stored in the vari able Memory Address on the left hand side of the assign 73 CHAPTER 6 Mapping ment operator i e the sign For example i a b means get the value stored in a and add it to the value stored in b and store the sum value at memory address 1 The left hand side of the operator sign is the address where you want the values on the right hand side of the operator sign to be stored Destination This is the destination memory address to which data will be moved Left Hand Side I O Interface The section of the instrument that communi cates with the outside world Input Contact Inputs interface selector switches push but tons limit switches and other sensors to the HI 3010 Each input has an address associated with it which describes the physical location that the input device is connected to Input Image Table A data ta
214. ng point variable saved in non volatile RAM HFO1 user defined floating point variable saved in non volatile RAM HFO2 user defined floating point variable saved in non volatile RAM HFO3 user defined floating point variable saved in non volatile RAM HFO4 user defined floating point variable saved in non volatile RAM HFOS user defined floating point variable saved in non volatile RAM HFO6 user defined floating point variable saved in non volatile RAM HFO7 user defined floating point variable saved in non volatile RAM HFO8 Active Target Weight HFOS9 Ingr 1 Target Wt HFO10 Ingr 2 Target Wt HFO20 Ingr 12 Target Wt HFO21 Ingr 1 Preact Wt HFO32 Ingr 12 Preact Wt HFO33 Ingr 1 Max Wt Tolerance in wt above target wt HFO44 Ingr 12 Max Wt HFO45 Ingr 1 Min Wt Tolerance in wt below target wt 137 Appendix A HI 3010 Complete Mapping Symbols HFO56 Ingr 12 Min Wt HFOS7 Ingr 1 Max Tolerance in above target wt HFO68 Ingr 12 Max HFO69 Ingr 1 Min Tolerance in below target wt HFO80 Ingr 12 Min HFO81 Ingr 1 Jog On Time s HFO92 Ingr 12 Jog On Time s HFOSS Ingr 1 Jog Off Time s HFO 104 Ingr 12 Jog Off Time s HFO105 Ingr 1 Wait Time s HFO116 Ingr 12 Wait Time s HFO117 Ingr 1 Fast Target Wt wt below target wt where dual unit switches to slow feed HFO128 Ingr 12 Fast Target Wt HFO129 Zero Tolerance wt near zero that can b
215. nt Out See Fig 6 23 or Network DeviceNet Int Out z or E mail 7 or Word E Select FIG 6 23 NETWORK SELECTING DEVICENET INT OUT Step 2 Double click in the Word text box and type in the number 2 Step 3 Click on the Select button to set the Destination The DeviceNet Int Out address appears on the left side of the Assignment Statement See Fig 6 24 71 CHAPTER 6 Mapping Current Mappings HOO 1 HI2 2 HO0 3 H12 15 HO1 5 H10 1 HO1 1 H10 2 DIOO HFI1 DIOZ RSO1 HFIO HOO O HI2 1 HO1 4 HI0 3 HO0 2 H13 13 H13 15 EIO2 HFI2 Dl02 Jump to Sources Page FIG 6 24 DEVICENET INT OUT DIO2 SET AS DESTINATION Step 4 Click on the Jump to Sources Page button The Configuration Mapping 2 page appears Data Gross Wt Select FIG 6 25 PROCESS DATA SELECTING GROSS WEIGHT Step 5 Click on the Process Data pull down menu See Fig 6 25 Step 6 Click on Gross Wt See Fig 6 25 Step 7 Click on the Select button to enter Gross Wt as the source of the Assignment Statement Step 8 The Gross Wt address appears on the right side of the Assignment Statement See Fig 6 26 Current Mappings HOO 1 HI2 2 HOO 3 HI2 15 HO1 5 H10 1 HO1 1 HI0 2 RSO1 HFIO HO0 0 H12 1 HO1 4 HIO 3 HOO 2 HI3 13 HI DIO2 HFI2 Unmap FIG 6 26 ASSIGNMENT STATEMENT MAPPING GROSS WEIGHT HF12 TO DEVICENET INT OUT DIO2 Step 9 The Gross Weight is now available to the PLC via the Devic
216. nt goes to the Fill ON menu if there are more cycles to com plete or the Standby Menu if the JOG was on the last cycle Discharge Alarms Not OK to Discharge Alarm e If the instrument determines that it is NOT OK to Discharge a Not OK to discharge alarm appears See Fig 7 44 FLOUR ART 225 00 225 00 INGOT GK TO DISEHARGE RLAR HLD FIG 7 44 NOT OK TO DISCHARGE ALARM 1 Check to see what is causing the Not OK to discharge alarm to appear 2 Correct the problem 3 Press the Clear button to clear the alarm The Awaiting Command to Discharge display appears Discharge Gate Did Not Open Alarm e Ifthe instrument determines that the dis charge gate did not open the DIS CHARGE GATE DID NOT OPEN alarm appears See Fig 7 45 HI 3010 Filler Dispenser IBC 94 Service Manual FLOUR AMT 225 00 225 00 IDISCHARGE GATE PIN NT A EN HI m AAA nn Lo FIG 7 45 DISCHARGE GATE DID NOT OPEN ALARM 1 Check to see what is preventing the discharge gate from opening 2 Correct the problem 3 Press the Clear button to clear the alarm The Awaiting Command to Discharge display appears Clogged Gate Alarm s Tf during the discharge the discharge gate becomes clogged and the Auxiliary is turned OFF the CLOGGED GATE ALARM appears See Fig 7 46 FLOUR AMT iee 00 2e5 00 CLOGGED GATE ALARTE ALO FIG 7 46 CLOGGED DISCHARGE GATE ALARM e Ifthe Auxiliary is turned ON the clogged gate alarm appea
217. o letters of the variable e HO Hardy Output Image Table e DO DeviceNet Output Image Table e RO RIO Output Image Table e CO ControlNet Output Image Table or Profibus Output Image Table NOTE You won t use ControlNet and Profibus at the same time so they can both use the same tables If the items in the table are only permitted on the right hand side of an Assignment Statement we call it an input image table e HI Hardy Input Image Table e DI DeviceNet Input Image Table RI RIO Input Image Table e CIl ControlNet Input Image Table or Pro fibus Output Image Table For example the digital inputs on the Filler Dispenser are found in an input image table as are the items in the Devi ceNet input image table The HI 3010 scans through the I O image tables 55 times a second and reads any values that are contained in the tables If there is nothing stored in the tables the controller does nothing with it If there are state values or other values stored in the tables the firmware processes the data and outputs it to an output device or the screen Local Mapping Example Local Mapping Output You hardwired a Valve Actuator to Output Relay 1 When the Filling process gets an OK to Fill the Filler changes the Fast Fill value which is stored in the Input Image Table from 0 to 1 which means close the output relay to begin a fast fill You need to map the Fast Fill to Output Relay 1 75 CHAPTER 6 Mapping
218. ocedures were not performed Apply weight to the vessel a Does the weight increase and decrease in the correct direction with the weight B Is the weight reading repeatable C The weight value will not be correct until a proper calibration is completed Verify color code input is excitation Output is signal Shielding a Grounded only at the controller b Continuous shield connection from the load cell cable to the instrument Single point EMI RFI drain c Terminated but not grounded at the summing box Sense lines Installed A Jumpers or sense lines in the J 1 connector B Sense lines must be installed for C2 calibration Using a multimeter verify readings 109 CHAPTER 7 Troubleshooting K Load Sharing and Load Sensor Checkout 1 Does the mV signal increase in a positive direction 2 If you receive a negative result check if load cell is mounted correctly a The arrow goes with the direction of the force b If there isn t an arrow you must manually verify the correct direction A negative reading indicates the load cell is upside down c Load cells in tension will not reflect a negative reading if installed upside down If upside down only the Verify the proper force applied by the cable would be included in the voltage level has been weight readings supplied If you are still receiving a negative signal verify the Load cell wire color code Verify a positive reading from each load cell using a m
219. og Mapping lt 77 Mixed Mapping 78 Special Command Mapping 78 Command Interface 79 Parameter Numbers Code Explanations and Valid Ranges 79 Mapping From the Front Panel 81 Unmapping Procedures for Front Panel 82 Mapping a Hardy Control Link Network to a ControlNet DeviceNet Profibus Network 83 iv Y Table of Contents Chapter 7 Troubleshooting lt lt lt lt o 85 About Chapter 7 85 Disassembly and Reassembly Notes and Cautions 85 Error Messages 85 List of Alarms 85 Not OK to FILL Alarm 85 Lost OK to Fill Alarm 86 Fast Gate Did Not Open Alarm 86 Fast Gate Did Not Close Alarm 86 Slow Gate Did Not Open Alarm 87 Slow Gate Did Not Close Alarm 87 Underfill Overfill Alarm 88 Dispense Alarms 88 Over Refill Alarm 88 Refill Timeout Alarm 89 Not OK to Dispense Alarm
220. oose Dis FIG 7 72 DIAGNOSTICS DISPLA Y SELECTING play screen VOLTAGE amp WEIGHT Step 7 Press the up or down arrow buttons until the cursor is in front of mV V and Weight Step 3 To see the Voltage and Weight Press the enter but Step 8 Press the Enter button The mV V and Weight Dis ton The Choose Display screen appears See Fig play appears See Fig 7 75 7 13 s UV LB CHOOSE DISPLAS 2 UC 6 0 03 7 ce JAR gt A AND VEIA gt R V AND WEIGHT gt FIG 7 75 MILLIVOLT VOLT AND WEIGHT READ FIG 7 73 DIAGNOSTICS DISPLAY CHOOSE DIS ING PLAY SCREEN e This reading is a higher resolution reading Step 4 Press on the up or down arrow buttons to select the to a 10th of a microvolt Use this reading display you want to see to determine if the load cell is working Step 5 With the cursor in front of mV and Weight Press correctly the Enter button The mV and Weight display e You can also use this reading to determine appears See Fig 7 74 which load sensor is malfunctioning by looking at each load sensor to determine any problems e g creep in the millivolt reading Multiply the mV V reading by the sense voltage to get a mV reading with 3 decimals points e Converting mV V to mV use this formula 5 x mV V lt mY 1221 CHAPTER 7 Troubleshooting Step 9 Press the Exit button to return to the Choose Dis play Step 10 Press the Exit button to return to the Diagnostics Display Stability Test The Stabi
221. ot use hose flexures to make right angle bends Non flexed piping should have an unsupported horizontal run using a ratio of 36 times its diameter Pipe flexure lengths should be a ratio of 6 times it s diameter Feed and discharge piping flexed Are the flex joints on the correct side of the valve a You weigh the output valve not the input valve b Does the weigh scale see all the product to be weighed C If the product applies a force to a valve or pipe so that pipe or valve must be included in the weigh vessel d Proper positioning of the flexures are key E Your vessel must seem to float Floors or structures do not interact Local traffic does not interact Protected from forklifts and adjacent processing equipment Level solid mounting base The load cell is mounted right side up All load cell bolts installed using anti seize compounds Mechanically aligned to compensate for expansion and contraction Protects the load cells from overload and impact forces Limits the movement of the vessel Rods must be loose and not interacting with the vessel Separate conduit for low and high voltage cables Do not bundle low voltage with high voltage cables Maintain at least 3 inches of separation Maintain 14 separation from magnetic fields and 440 VAC Cables are in conduit or tied up and protected from damage Product tools and production aids are off the vessel No workers are physically on the scale Must
222. p or down arrow until the cursor is in front of Span Value The Span Value is the value entered for the last calibration only Press the up or down arrow until the cursor is in front of Zero Count e Changing the Zero Count can nullify your calibration e The Zero Count is the stored A D counts on the last calibration zero e To clear the Zero Count press the Clr Clear button Zero counts must be less than Span counts e Press the Enter button to set the entry 117 CHAPTER 7 Troubleshooting e Press the down arrow to move to the next parameter you want to view or change e Ifyou get an error during calibration change Zero Count to 500 000 to clear the calibration error then recalibrate Step 16 Press the down arrow button until the next three menu items are displayed See Fig 7 55 FIG 7 55 TEST DATA DISPLAY SPAN COUNT C2 SENSITIVITY SCALE CAPACITY Step 17 Span Count C2 Sensitivity Scale Capacity can all be changed Step 18 Press the up or down arrow until the cursor is in front of Span Count e Changing the Span Count can nullify your calibration e The Span Count are the A D counts on the last C2 full scale or Traditional Span calibration e To clear the Span Count press the Clr Clear button e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change e Change the Span Count to a large number to clear
223. penser by the load cell signal WAVERSAVER can be configured to ignore noise with fre quencies as low as 0 25 Hz One of four higher additional cut off frequencies may be selected to provide a faster instru ment response time The function is user selectable and can be turned off PARAMETER WAVERSAVER RANGE 25 HZ 50 HZ 1 0 HZ 3 50 HZ 7 50 HZ OFF DEFAULT 1 00 HZ Step 1 Press the Down arrow button until the cursor is in front of WAVERSAVER See Fig 4 86 SETUP MENU SCALE CAP 100 gt WAVERSAVER 1 0GHz IR PORT DFF FIG 4 86 SETUP MENU WAVERSAVER Step 2 Press the right or left arrow buttons to select the set ting or turn WAVERSAVER off Step 3 Press the Enter button to set the entry Set Clock Parameter About Setting the Clock You set the Hour Minutes Month Day and Year parameters here The settings are important when printing out the fill dispense data These settings are the time stamps for the alarms and fills dispenses The Timezone setting is used to date the e mails that are sent from the instrument in Green wich Mean Time GMT PARAMETER HOURS RANGE hh 01 24 DEFAULT NONE PARAMETER MINUTES RANGE mm 01 60 DEFAULT NONE PARAMETER MONTH RANGE Jan thru Dec DEFAULT NONE HI 3010 Filler Dispenser IBC 42 Service Manual PARAMETER DAY RANGE dd 01 31 DEFAULT NONE PARAMETER YEAR RANGE yyyy 2001 2002 2003 DEFAULT NONE PARAMETER TIMEZONE RANGE 12 TO
224. ply 78 mV and Weight 121 mV and Weight Display 121 mV Reading 127 mV V 127 mV V and Weight 121 mV V and Weight Display 121 N N Blank Screen 110 Underdispense Overdispense Alarms 91 Neatly Bundled 17 Negate 78 NEMA 4 amp 4X 12 NEMA 4X 4 No C2 Sensor 85 Non C2 Load Point Connection 18 NONE 37 Non Linearity 7 Normally Open 125 NOT 77 Not OK to Discharge Alarm 94 Not OK to Dispense Alarm 89 Not OK to FILL Alarm 85 Number of Cycles 1 number of graduations 39 Number of Sensors 119 O O Display Stuck on a Screen 111 ODD 37 Offset 78 OK to Discharge 32 OK to Discharge OFF Radio Button 53 OK to Fill Input Parameter 32 OK to Fill Timer Field 52 OK to Fill Times Out 86 OLE Technology DCOM 5 On Board Diagnostics 4 On board Help Files 3 Online Tech Support Knowledge Base 3 Operating Temperature Operating Temperature Range 8 Operation Diagnostics Weight 8 Voltage Page 131 Operator ID 31 Operator ID Field 51 Options 4 Options Configuration 55 Options Menu 55 OR 77 Original Point of Removal 11 85 Output Alarms 1 Output Relay 41 125 Output Relay Forced Closed 125 Output Table 75 Outputs 81 82 OVER FILL 87 Over Refill Alarm 88 Overall Depth 12 OVERDISPENSE ALARM 91 OVERFILL ALARM 88 Overview of Typical Load Cell System 132 P Panel Cutout Specifications 12 Panel Mount 21 Panel Mount Model HI 3010 PM 8 Panhead Screw 16 Parallel Resistor 134 Parallel Shunt Resistor 1
225. provide a faster instrument response time The default factory configuration is 0 50 Hz vibration fre quency immunity C2 Calibration C2 Second Generation Calibration enables a scale system to be calibrated electronically without using certified test weights which equals the systems load capacity A C2 weighing system consists of up to eight load sensors a junc tion box interconnect cable and an instrument with C2 capa bilities such as the Filler Dispenser IBC All Hardy Instruments C2 certified load sensors contain digital infor mation detailing its unique performance characteristics The Hardy Filler Dispenser IBC reads the performance charac teristics of each individual load sensor and detects the quan tity of load sensors in the system Calibration is performed by simply adding a reference point from the front panel or via the Web Server The reference can be zero no weight on the scale or alternatively a known weight on the scale The instrument is capable of performing traditional calibration such as with the use of certified test weights NOTE WAVERSAVER and C2 are registered trade marks of Hardy Instruments Inc On Board Diagnostics The HI 3010 has a built in diagnostics utility which enables the operator to rapidly troubleshoot a weighing system from the front panel of the controller or via the Web Server Sim ply press the Test button and scroll through several tests that will furnish the current state
226. ransport and network layer protocol of the Internet and is commonly linked with all Ethernet installa tions and the business world TCP IP provides a set of ser vices that any two devices can use to share data Because Ethernet technology and standard protocol suites such as TCP IP have been published for public use standardized software tools and physical media have been mass produced and are readily available offering you the benefits of known technology and accessibility The UDP IP User Datagram Protocol is also used in conjunction with the Ethernet net work UDP IP provides fast efficient data transport required for real time data exchange MOD Bus TPC IP TCP IP is the common transport protocol of the Internet and is actually a set of layered protocols providing a reliable data transport mechanism between machines Ethernet has become the de facto standard of corporate enterprise systems and it has also become the de facto standard for factory net working Ethernet has matured to the point that the cost of implementing this network solution has been dropping to where its cost is commensurate with those of today s field buses Using Ethernet TCP IP in the factory allows true inte gration with the corporate Intranet and MES systems that support your factory OPC OLE for Process Control OPC enables an HI 3000 module to communicate with any device that supports OLE COM The architecture is designed to utilize the Microsoft d
227. re that the assemblies and sub assemblies are well supported and insulated when doing any repairs on the Filler Dispenser e Place small fasteners connectors and elec trical parts in closed containers so as not to lose parts during reassembly s Read all the disassembly instructions before any disassembly begins Be sure that you are familiar with the procedures If any of the instructions for disassembly are unclear contact Hardy Instruments Technical Support Department for addi tional information and assistance e Do not disconnect any electrical plug con nector or terminal unless an identification tag is present or one is attached Always note where the connector or plug was attached to the electrical component or wiring harness e Always install complete hardware groups Screws Washers Lock Washers Spacers Etc back to the original point of removal e Always replace broken or damaged mod ules or hardware immediately e Always check to be sure that no loose parts are sitting on printed circuit boards or electrical connectors or wires when dis assembling or reassembling e Always protect printed circuit boards from electrostatic discharge ESD Always use approved ESD wrist straps and anti static pads e Always perform a final inspection after completing any reassembly to be sure that all fasteners are tight all connectors are secure and there are no loose parts on any of the printed circuit boards in the Filler
228. roperly con trolled static environment e Always make sure that the assemblies and sub assemblies are well supported and insulated when doing any repairs on the instrument e Place small fasteners connectors and elec trical parts in closed containers so as not to lose parts during reassembly e Read all the disassembly instructions before any disassembly begins Be sure that you are familiar with the procedures If any of the instructions for disassembly are unclear contact Hardy Instruments Technical Support Department for addi tional information and assistance e Do not disconnect any electrical plug con nector or terminal unless an identification tag is present or one is attached Always note where the connector or plug was attached to the electrical component or wiring harness e Always install complete hardware groups Screws Washers Lock Washers Spacers Etc back to the original point of removal e Always replace broken or damaged mod ules or hardware immediately e Always check to be sure that no loose parts are sitting on printed circuit boards or electrical connectors or wires when dis assembling or reassembling e Always protect printed circuit boards from electrostatic discharge ESD Always use approved ESD wrist straps and anti static pads e Always perform a final inspection after completing any reassembly to be sure that all fasteners are tight all connectors are secure and there are no loose parts
229. rrow button until the cursor is in front of Switch timer See Fig 4 52 DISCHARGE MENU PROOF SUITCH DFF gt gt SITO TIRER Ss Aux DEVICE TAR 1Os FIG 4 52 DISCHARGE MENU SWITCH TIMER Step 15 Press the right or left arrow buttons to increase or decrease the time Step 16 Press the Enter button to set the entry Step 17 Press the down arrow button until the cursor is in front of Aux Device Tmr Auxiliary Device Timer See Fig 4 53 DISCHARGE MENU PROOF SUITCH OFF gt OAITOH HER 55 gt Aux Device TAR igs FIG 4 53 DISCHARGE MENU AUXILIARY DEVICE TIMER About the Auxiliary Device Timer An example of an Auxiliary Device is a vibrator for a feeder to correct bridging that can occur with some materials when being discharged from a vessel The timer setting sets how long the Auxiliary Device should remain on until the bridg ing condition corrects itself An Auxiliary Device can be any device you want to enable The timer is set based on your process requirements Step 18 Press the right or left arrow buttons to increase or decrease the time you want the Auxiliary Device to operate Step 19 Press the Enter button to set the entry Step 20 Press the Exit button to return to the SETUP MENU Refill Parameters About the Filler Refill Parameters The Refill pertains to the vessel that is putting material into the filler vessel This vessel must have enough material to complete one whole fill cycle of
230. rs if the auxiliary time elapses and the discharge weight equals zero within the zero tolerance setting The CLOGGED GATE ALARM appears See Fig 7 46 Step 1 When the discharge is complete the instrument closes the discharge gate and returns to the Fill On display or the Standby Display depending on the filling cycle Discharge Gate Did Not Close Alarm e Ifthe Discharge gate does not close a DISCHARGE GATE DID NOT CLOSE ALARM appears See Fig 7 47 95 CHAPTER 7 Troubleshooting FLOUR DISCHARGE GATE DIONGT CLOSE ALARDI HL U FIG 7 47 DISCHARGE GATE DID NOT CLOSE ALARM 1 Check to see what is preventing the discharge gate from closing 2 Correct the problem 3 Press the Clear button to clear the alarm 4 The instrument returns to the Fill On display or the Standby Display depending on the filling cycle HI 3010 Filler Dispenser IBC 96 Service Manual General Troubleshooting Flow Chart Index Drifting or unstable weight readings Electrical Mechanical and Configuration reviews Instabilities on Formerly Operating System Weight indication will not return to zero Verify individual load sensor operation Trad Cal A D Failure Error Mechanical Inspection be Electrical Inspection Load Sensor Installation Weight Display Stops Incrementing Blank Display Display Stuck on a Screen View Input States Forcing Outputs Le 97
231. ry Description The Hardy Instruments Filler Dispenser IBC controller is part of a complete line of application specific process weigh ing and condition monitoring instruments The Filler Dis penser IBC instrument is available as an HI 3010 a stand alone controller with a display 4 lines 20 characters and key pad or an HI 3010R blind remote stand alone controller swivel mounted with no display A remote 6 digit 7 segment LED display is available as an option for the HI 3010R The Filler Dispenser controller has built in totalizers that keep you up to date as to the following e History of Totals for each of the twelve 12 internally stored material configura tions include 1 Number of Cycles 2 Amount of material in a cycle The HI 3010 Filler Dispenser IBC is designed with output alarms for example e Over Fills Under Fills e Feed Time outs e Out of Tolerance e Not OK to Fill e Too Many Jogs e Discharge gate is not responding e Change an Immediate Bulk container The HI 3010 Filler Dispenser IBC is field configurable for filling dispensing and IBC Intermediate Bulk Container applications This instrument is a stand alone controller with fast and slow speeds and auto adjusting preacts for precise rapid process control Displays keep the user up to date as to the number of cycles and amount of material in the cycle In addition the instrument maintains a history of the totals for each of the twelve internall
232. s 378928 L Doon Q 9 ES Eg pa Sla R ao 0 aig o_O Boo Bel 1 loo RD fire Se jf fered fa sees ela pi OU 7 mE aR R NR NAR R NR NA R RUR NAR O FIG 1 5 SMART DIAGNOSTICS CARD 5 CHAPTER 1 Overview Hardware If you are retrofitting Smart Diagnostics to an existing sys tem you should receive e Smart Diagnostics Card e Rear Plate with three additional ports e Fasteners to connect the rear plate to the Main Board and to the rear of the chassis e Rear Panel for Smart Diagnostics card See Fig 2 e Installation and Operation Manual e 4 standoffs NOTE Smart Diagnostics does not require a junction box FIG 1 6 SMART DIAGNOSTICS REAR PANEL MB Stainless steel wall mount swivel bracket stand for wall or desktop mounting Communication Options NOTE For Installation Configuration and Setup please refer to the HI 3000 Operation and Installation Manual Cabling and Networks Sections EtherNet IP EtherNet IP short for Ethernet Industrial Protocol is an open industrial networking standard that takes advantage of commercial off the shelf Ethernet communication chips and media Ethernet technology enables the user to access device level data from the Internet The Ethernet IP network ing standard supports both implicit messaging real time I O messaging and explicit messaging message exchange EtherNet IP is an open network that takes advantage of commercial technology that already exists TCP IP is the t
233. sly configured Filler the Filler changes into a Dispenser and vice versa Make sure that you HI 3010 Filler Dispenser IBC 20 Service Manual 21 CHAPTER 4 Configuration CHAPTER 4 CONFIGURATION About Chapter 4 Chapter 4 contains step by step instructions for configuring the Hardy Instruments HI 3010 Filler Dispenser IBC The procedures include complete instructions for configuring the Filler Dispenser from the Front Panel DeviceNet and Web Browser We highly recommend reading the procedures before configuring the Filler Dispenser For information on network setup optional cards and Email see the HI 3000 Series Operation and Installation Manual Being familiar with the operating procedures insures that the Filler Dispenser will provide trouble free service For the best performance of the HI 3010 Filler Dispenser any instructions that are not contained in this manual either implicit or explicit are not recommended It is important to note that the HI 3000 Series standard products do not require any jumper or dip switch settings Some of the communica tion option cards do have jumper settings however Getting Started Before configuring the Hardy HI 3010 Filler Dispenser check to make sure the following procedures have been per formed e Panel Mount and Blind Mount units properly installed See chapter 3 Installation e Power and Load Point cables properly installed e Communication cables properly installed e
234. spense timer If for any reason the instrument can not detect the OK to Fill input before the OK to Fill timer times out the Not OK to Fill Alarm appears PARAMETER OK TO FILL INPUT PARAMETER RANGE ON OFF DEFAULT ON SETUP MENU INSTRUMENT ID gt gt OK TD Fie INPT uN gt DISCHARGE OFF gt FIG 4 45 OK TO FILL INPUT PARAMETER Step 1 Press the right or left arrow buttons to toggle between ON and OFF Step 2 If you have turned the OK to Fill ON press the Enter button The OK TO FILL MENU appears See Fig 4 46 FIG 4 46 OK TO FILL MENU SETTING OK TO FILL TIMER PARAMETER OK TO FILL TIMER RANGE 0 999 DEFAULT 10 SECONDS Step 3 Press the right or left arrow buttons to increase or decrease the OK to Fill Time In our example we set the timer for 10 seconds Step 4 Press the Enter button to set the entry Step 5 Press the Exit button to return to the SETUP MENU NOTE Ifyou toggle the Ok to Fill to OFF the OK to Fill Menu will not appear HI 3010 Filler Dispenser IBC 32 Service Manual Step 6 Press the down arrow until the cursor is in front of Discharge See Fig 4 47 Discharge Parameters About the Discharge Parameters If your process requires you to discharge from the filled ves sel you need to turn on the Discharge function If you turn the Discharge ON the Discharge Menu will display and you can select between Auto Discharge OK to Discharge Proof Switch Alarm Switch Timer an
235. splayed on the Web page You can configure from 1 12 Ingredients from the Browser Each ingredient can be given an Ingredient Name Set Tolerance Discrete or Percent Target Weight and Pre act You can also configure the Gate Time Jog On Time and several other parameters All these settings insure that each ingredient is exactly configured to deliver the exact amount of material for your filling process The parameter ranges are the same when setting the instrument from the Front Panel Step 1 Click on Adjust Ingredient The Configuration Adjust Ingredient Page appears See Fig 4 99 Configuration Adjust Ingredient INGREDIENT 1 lt Ingredient Number Edit Ingredient lt p gt FIG 4 99 CONFIGURATION ADJUST INGREDIENT WEB PAGE Step 2 Click on the Ingredient Number pull down menu See Fig 4 100 Move the cursor over the Ingredient number you want to adjust When the cursor hovers above an ingredient the ingredient is highlighted With the cursor over the Ingredient number click on the selection Click on the Edit Ingredient Button The second page of the Adjust Ingredient web pages appears Step 3 Step 4 Step 5 Configuration Adjust Ingredient Ingredient Number Edit Ingredient TINGREDIENT 1 z TINGREDIENT1 amp 2 INGREDIENT 2 3 INGREDIENT 3 4INGREDIENT 4 5 INGREDIENT 5 6 INGREDIENT 6 INGREDIENT B INGREDIENT 8 INGREDIENT 9 10 INGREDIENT 10 11 INGREDIENT 11_ 4 gt
236. strument from all the other instruments on the Hardy Control Link Network rather than buy a separate network card for each instrument See Fig 6 55 Step 1 Step 2 Determine into which Instrument you want to install the Network option card Install the network card See the HI 3000 Installa tion and Operation manual Cabling and Installation Section 3000 Series Instrument and begin mapping to that instrument from either the Hardy Control Link Net work or the ControlNet DeviceNet Profibus Net HI 3010 Filler Dispenser IBC 84 Service Manual 85 CHAPTER 7 Troubleshooting CHAPTER 7 TROUBLESHOOTING About Chapter 7 Chapter 7 consists of all the procedures for troubleshooting the electrical mechanical and firmware elements of the HI 3010 Filler Dispenser in the event of a malfunction Included in Chapter 7 is a comprehensive flow chart to provide a road map for troubleshooting an entire Filler Dispenser system including load cells and cabling For help with networking card options security and Email see the HI 3000 Series Operation and Installation Manual Disassembly and Reassembly Notes and Cautions e Always disconnect the power cord before disassembling WARNING FAILURE TO DISCONNECT THE POWER CORD BEFORE DISASSEMBLING MAY CAUSE PERSONAL INJURY AND OR PROPERTY DAMAGE e Make sure that any disassembly is done in a clean well ventilated properly con trolled static environment e Always make su
237. t e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Step 36 Press the down arrow button until the next three menu items are displayed See Fig 7 59 gt 167 PREACT 0 30 SMART PREALT ON TRGT WIN UT Oct FIG 7 59 TEST DATA INGREDIENT DISPLAY TAR GET PREACT SMART PREACT TARGET WIN DOW WT Step 37 Target Preact Smart Preact and Target Window Weight are read only e The Target Preact is the value below which a target gate will close e Smart Preact is a self adjusting or auto matic preact and the user can turn this function ON or OFF e The Target Window Wt is the Target Window tolerance above the Target Win dow expressed in Weight Step 38 Press the down arrow button until the next three menu items are displayed See Fig 7 60 TEST DATA INOR gt TRGT UN UT 0 00 TROT UN 1 00 TROT LN 1 00 FIG 7 60 TEST DATA INGREDIENT DISPLAY TAR GET WINDOW WT TARGET WINDOW WT Ye TARGET WINDOW WT Step 39 Target Window Weight Target Window Weight Target Window Weight are read only e The Target Window Wt is the Target Window tolerance below the Target Win dow expressed in Weight e The Target Window Wt is the Target Window tolerance above the Target Win dow expressed in Percentage e The Target Window Wt is the Target Window tolerance below the Target Win do
238. t put and Input Image Tables is stored in volatile memory This means when you power off you lose the data The Addressing I O Mapping is saved in non volatile memory and is not lost when you power off A Definition of Mapping Mapping Addressing I O is the same as using an Assign ment Statement The Destination is located on the left hand side of the equals sign and is a memory address vari able The Source is the data located on the right hand side of the equals sign at a memory address So when you refer to the right hand side of the Assignment Statement you are referring to the data only and not the address even though the address is listed e Memory Address Variable Data Val ues states HI 3010 Filler Dispenser IBC 74 Service Manual The equals sign assigns the data on the right side of the Assignment Statement to the Memory Address on the left side of the Assignment Statement This is exactly what you are doing when you map a source to a destination The things that can be mapped are organized into Input Image Tables and Output Image Tables which are arrays of variables i e memory locations of a certain size based on the type assigned to the variable with addresses where data is stored A table is called an output image table if the items in the table are permitted to be on the left hand side of an Assign ment Statement The Output variables are also further identi fied by the first tw
239. t OK to Dispense Alarm e Tfitis NOT OK TO DISPENSE an alarm appears in the display See Fig 7 19 FIG 7 19 NOT OK TO DISPENSE 1 The Operator needs to determine why 1tis NOT OK TO DISPENSE by checking for problems with the elec trical and or mechanical systems 2 Once the problem has been fixed push the Clear button to clear the Alarm The Filler Dispenser begins dispensing NOTE The OK to DISPENSE Timer has a preset time to determine if it is OK to Dispense If the OK to Dispense times out it means that the preset time is too short for the process and the NOT OK to DISPENSE Alarm appears with no real alarm condition You may need to reset the timer if it appears that no electrical or mechanical reason for the alarm is determined The OK to DIS PENSE timer may be set incorrectly for your pro cess See the HI 3010 Service Manual for Instructions on setting the OK to DISPENSE Timer Lost OK to Dispense Alarm e During the dispensing process conditions may develop that cause the Filler Dis penser to lose the OK to DISPENSE dur ing Fast Dispense or Slow Dispense When this occurs an alarm appears that says LOST OK TO DISPENSE See Figs 7 20 amp 7 21 FIG 7 20 LOST OK TO DISPENSE ALARM FAST DISPENSE FIG 7 21 LOST OK TO DISPENSE ALARM SLOW DISPENSE 1 The Operator needs to determine why the system LOST OK to DISPENSE by checking for problems with the electrical and or mechanical syste
240. t or right arrow buttons to toggle between ON and OFF If you want to a written record of the states during a fill or dispense toggle the State Logging function ON See Fig 7 96 NOTE Itis a good idea to turn off Auto print If Auto Print is turned ON you will get the fill informa tion plus the Logged States and it can get confus ing DIAONOSTICO VIEW INPUT STATES gt FORCE OUTPUTS gt gt STATE LOGGING Un FIG 7 96 DIAGNOSTICS DISPLAY STATE LOG GING ON Each time a state change occurs the State Logging function will print out the Time in hours minutes and seconds of the change state and the name of the state Step 4 Press the Enter button to set the entry Step 3 127 CHAPTER7 Troubleshooting Step 5 Press the Exit button until you return to the Standby Display Using Solid State Relays with Light Loads Optional Set Relays About Solid State Relays With Light Loads There have been installations where solid state relays have been used and failed to shut off a solenoid or relay when de energized The actual problem comes from the internal snub bing network in parallel with the Silicon Controlled Rectifier SCR which does the actual switching This network pre sents an impedance of 30K ohms which means with 120 volts across it will pass 4mA of AC current HOT SOLID STATE RELAY 15000 ohm NEEDED RELAY SHUNT COIL NEUTRAL FIG 7 97 SCR SWITCHING LOAD CIRCUIT 1 The SCR itself presen
241. t readings to the instrument If you do not get a reading for one or pos sibly two or more load sensors Channel 3 for example reads 0 00 mV V or the milli volt Volt reading is either larger or smaller than it should be and you know that the Load Sensors are connected to the instru ment the individual load sensor cable is disconnected from the instrument or the load sensor is malfunctioning or the cable is broken With this information you can quickly determine what the problem is and where it is located either from the Front Panel or Web Browser If the Millivolt Volt readings are not fine enough to determine the problem select the Weight readings Step 11 Press the Exit button to return to the Totals Display See Fig 7 107 Step 12 To read the Weight reading for finer troubleshoot ing press the down arrow until the cursor is in front of the Weight lb kg gr oz reading total for the scale See Fig 7 107 VOLTAGE amp VEIGHT ALL ALL gt ALL 17 20 nV 3 970 mI V 72 001b FIG 7 107 SCALE WITH TOTALS WEIGHT LB SELECTED Step 13 Press the Enter button The Scale Weight for the individual Scale Load Sensor display appears See Fig 7 108 16 021b 16 031 b 16 021 b 16 001 D Channel Channel Channel gt Channel FIG 7 108 INDIVIDUAL WEIGHT DISPLAY s Ifyou do not get a reading from one of the load sensors either the cable to the load sensor is disconnected or the load sensor is malf
242. ta Bits pH Save Parameters FIG 4 118 INSTRUMENT SETUP REFILL AND J gt DISCHARGE PAGE Refill Parameters FIG 4 119 INSTRUMENT SETUP PRINTER PORT Step 1 To turn ON Refill click in the Refill ON radio but ton To turn OFF Refill click in the Refill OFF radio Serial Port Parameters button Step 2 To turn ON Initial Refill click in the Initial Refill Step 1 To select the Serial Port device ON radio button To turn OFF Initial Refill click in the Initial Refill OFF radio button e Click on the Serial port pull down menu See Fig 4 120 e Click on the Serial Port device you want for your process For our example we selected the Printer Port Step 2 To turn ON Auto Print click on the pull down menu and click on ON To turn OFF Auto Print click on the pull down menu and click on OFF Step 3 To select the Baud Rate e Click on the Baud Rate pull down menu See Fig 4 120 e Click on the Baud Rate you want for your process Configuration Instrument Setup Filler Enter parameters for the fields below Printer Port Auto Print OFF E Baud Rate 300 El Parity 1200 Data Bits Save Parameters FIG 4 120 INSTRUMENT SETUP SERIAL PORT Step 4 To select the Parity e Click on the Parity pull down menu See Fig 4 121 e Click on the Parity you want for your pro cess Configuration Instrument Setup Filler Enter parameters for the fields below Printer Port Auto Print OFF Baud
243. tep 12 To enter the Span Weight click in the Span Weight field See Fig 5 25 Step 13 To clear the entry move the cursor over the current Span Weight which highlights the weight value Step 14 Use you keyboard to type in the new value In our example we entered 10 00 See Fig 5 25 Step 15 Wait 12 seconds or more Step 16 Click on the Do Cal High button Step 17 A page telling you that the Do Cal High Calibration completed OK See Fig 5 28 Cal completed OK Back FIG 5 28 CAL HIGH COMPLETED OK Step 18 Click on Home to return to the Filler Dispenser Home page Step 19 Traditional calibration is complete HI 3010 Filler Dispenser IBC Service Manual 64 65 CHAPTER 6 Mapping CHAPTER 6 MAPPING About Mapping Mapping is a simple process where you connect an input Source to an output Destination The HI 3010 has four output Relays and five Input Contacts You can also map parameter values to and from these outputs and inputs The benefit of Mapping is that it requires no programming NOTE The HI 3000 Series Operation and Installation Manual provides additional mapping help NOTE Data is handled based on the method used writ ing data to the unit If data is written using the Command Interface See Below the data is inter preted based on the displayed units However if data is directly mapped into the unit the unit assumes lbs pounds and converts the entered data to the displayed
244. the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Step 31 Press the down arrow button until the next three menu items are displayed See Fig 7 58 gt TEST DATA INGR gt INGREDIENT 1 FILL CYCLES CU TARGET LT 3 00 FIG 7 58 TEST DATA INGREDIENT DISPLAY INGREDIENT FILL CYCLES TARGET WEIGHT Step 32 Ingredient Fill Cycles and Target Weight can be changed from this menu Step 33 Press the up or down arrow until the cursor is in front of Ingredient e To select the ingredient press the right or left buttons until the ingredient you want to view or change appears e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Step 34 Press the up or down arrow until the cursor is in front of Fill Cycles e The Fill Cycles are the number of fills to complete one cycle e Press the right or left buttons to increase the number of fills per cycle e Press the Enter button to set the entry e Press the down arrow to move to the next parameter you want to view or change Step 35 Press the up or down arrow until the cursor is in front of Target Weight 119 CHAPTER 7 Troubleshooting e The Target Weight is the weight you want for each fill e To change the Target Weight press the Clr Clear button e Use the alphanumeric key pad and enter the new Target Weigh
245. the HI 3010 See Fig 6 3 Configuration Choose One Adjust Ingredient Instrument Setup Calibration Hardy Control Link Mapping Setup Security Email N FIG 6 2 CONFIGURATION PAGE SELECTING MAPPING SETUP HI 3010 Filler Dispenser IBC 66 Service Manual 1 Hardy Control Link Text Out 2 Hardy Control Link Int Out 3 DeviceNet Text Out 4 DeviceNet Int Out as Bromo T 2 5 S i tw gt PEE 1 e E Mail includes E Mail Outputs such as bnr 1 Send E Mail 2 Custom Text e Calibration includes calibration parame n ters 1 Zero Weight 2 Span Weight ES e Scratchpad which are empty registers you FIG 6 3 CONFIGURATION MAPPING SETUP 1 can do whatever you want with SELECTING A DESTINATION l NOTE The lists above do not include all the parameters Step 3 Let s take a moment to take a look at this page For a list of all the parameters and their addresses please see Appendix A e Local Outputs include the 4 Output Relays Step 4 Back to our example We want to select Output e Control includes parameters that control Relay 1 as our destination Click on the Local Out the filling or dispensing which includes puts pull down menu See Fig 6 4 the following which is only a partial list Step 5 Click on Output Relay After you click on Output Relay it is selected and a Number and a Select but 1 OK to Fill ton appear to the right of the Local Outputs pull 2 OK to Discharge
246. the jog cycles again The Jog parameters include the Jog On Time the amount of time you want the jog to run for each jog count The Jog Count which is the number of times you want the instrument to go through the jog cycle The Jog Off Time is the time you want the jog to be off while the instru ment calculates the change in weight to see if the jog increased the weight so that the fill dispense is within the Target Window To shut OFF the Jog function set the Jog On Time to 0 NOTE The Jog settings should be made in conjunction with the Fast and Slow Fill timers It is recom mended that the AutoPreact be turned on so that the system can self adjust until you no longer need a jog during each cycle If the instrument goes through the jog sequence for each cycle you will need to adjust the Fill Dispense Timers and or the Preact PARAMETER JOG ON TIME RANGE 00 0 99 9 DEFAULT 2 50 PARAMETER JOG COUNT RANGE 0 9 DEFAULT 5 PARAMETER JOG OFF TIME RANGE 00 0 99 9 DEFAULT 1 00 ADOUST INGREDIENT TARGET WINBOY ur gt gt 05 gt FILL TIMER us FIG 4 27 ADJUST INGREDIENT 1 JOG Step 1 Press the Enter button The Jog Menu appears with the cursor in front of Jog On Time See Fig 4 28 JOG MENU gt Usa UN Time 1005 ucG COUNT 5 JOG UEP Time 1 Ue FIG 4 28 JOG MENU DEFAULT SETTINGS Step 2 Press the Clear button to clear the previous entry Step 3 Use the alphanumeric key pad to enter the new Jog
247. the output point during the I O scan Source This is the memory address of the data you want to move to the destination Right Hand Side Rules for Hardy Control Link Mapping Some rules for Hardy Link Mapping e Input Contacts 5 total can only be a Source e Output Relays can be a Source and a Des tination Local Input Inputs interface with selector switches push buttons limit switches and other sensors connected to the HI 3010 When the firmware is initiated it assigns the physical input contact to a memory address Remember Inputs can only be a Source when mapping See Source definition in the Glos sary of Mapping Terms t Data Table npu 76543210 0 Output Image Y a 1 Input Image S Input Device Y 2 4 E OY gt O Address 1 3 FIG 6 37 INPUT FUNCTION e Bach input has an address associated with 1t e The address describes the physical loca tion that the input device is connected to e The address also describes the Input Image Table location where the STATE of the input device is stored e The state of each input is transferred to the Input Image File from the input point dur ing the I O scan every 1 55th of a second See Fig 6 37 e When you are mapping an Input to some other Destination you are assigning the value in the Input Image Table for that Input to an Address in the Output Image Table e For example OK TO FI
248. tion See Fig Channel 3 7 117 The Operation Choose One page appears See Fig 7 118 bet Step 3 Le H R DJI Deen Ro EL Jos A A Weight Contraer Home Page L NOTE E K aa rere FIG 7 117 HOME PAGE SELECTING OPERATION 2 lt HI 3010 Filler Dispenser IBC Service Manual 132 Click on Weight and Voltage See Fig 7 119 The Operation Diagnostics Weight amp Voltage page appears with all four 4 channels Inputs with the Sense Voltages Millivolts Millivolts Volt A D counts and Gross Weight displayed See Fig 7 120 To differentiate between a unit with regular diag nostics and Smart Diagnostics SD option card the regular diagnostics has only one input Smart Diagnostics has 4 inputs Operation Diagnostics Weight and Voltage Sense Voltage 4 8 4 8 4 8 4 9 Step 2 Click on Diagnostics See Fig 7 118 The Opera ine M i ld tion Diagnostics Page appears with the four 4 Input 1 0 051963 44 0 9221 5196308 scales listed See Fig 7 119 Input 2 0 043631 37 0 7582 4362951 Input 3 0 025372 19 0 3991 2537249 Input 4 0 125863 11 5 2 3761 12588637 Operation Choose One Diaqnostics Monitor FIG 7 120 OPERATION SMART DIAGNOSTICS NOTE Totalizers NOTE FIG 7 118 OPERATION CHOOSE ONE SELECT ING DIAGNOSTICS Operation Diagnostics Instrument ID Model Number Program Part Number Firmware Revision Serial Number Last Calibr
249. to set the entry Step 5 Press the down arrow until the cursor is in front of OK to Discharge See Fig 4 49 DISCHARDE MENO AUTO DISCHARGE OFF gt gt UR TO DISCHARGE ON gt PROOF SUITCH OFF gt FIG 4 49 DISCHARGE MENU OK TO DISCHARGE Step 6 Press the right or left arrow buttons to toggle the OK to Discharge ON or OFF If you toggle the OK to Discharge ON press the Enter button The OK to Discharge Menu appears See Fig 4 50 Step 7 FIG 4 50 OK TO DISCHARGE MENU Step 8 Press the right or left arrow buttons to increase or decrease the OK to Discharge time Step 9 Press the Enter button to set the entry Step 10 Press the Exit button to return to the Discharge Menu Step 11 Press the down button until the cursor is in front of Proof Switch See Fig 4 51 DISCHARGE MENU AUTO LISCHARGE GOFF gt Up TO DISCHARGE DIFF gt gt Henne SuUITCH OFF gt FIG 4 51 DISCHARGE MENU PROOF SWITCH About Proof Switch When you turn ON the Proof Switch it senses the state of a physical actuator or a proximity sensor for example to determine if a gate is open or closed If the gate is closed when it should be open or vice versa an alarm is displayed that says NO DISCHARGE PROOF ALARM depending on how your system is configured Step 12 Press the right or left arrow buttons to toggle the Proof Switch OFF or ON Step 13 Press the Enter button to set the entry Step 14 Press the down a
250. ts PASS gt Mean ADC Count Mean Sq Var 2 37 MeanADCCount 34k FIG 7 116 STABILITY TEST RESULTS CHANNEL 3 MEAN ADC COUNT IS OUT FIG 7 114 TEST RESULTS FOR CHANNEL 1 e The Stability Test display a Mean ADC count is outside the range of 30237 and e Ifthe channel does not pass the Stability 36955 Now you know which channel is Test the FAIL display appears This means not reading correctly Do the following that the Mean Squared Variation is greater than 5 0 and or the average reading is not 1 Disconnect the power cord and recon between 30237 and 36955 This test exam nect the power cord to restart the ines the internal electronics and not the instrument load cells input signal 1 Repeat the Stability test e The test results shown are for all four 2 Ifa channel Fails the Stability Test Channels If you want to see which chan again contact Hardy Instruments Inc nel s failed the test press the down or up Technical Support for assistance arrow buttons until the cursor is in front of Test Results FAIL Press the Enter button Step 4 Press the Exit button to return to the Diagnostics to see the test results per channel See Fig display 7 116 In our example channel 3 failed e To see the results of the failed channel use Using Smart Diagnostics From the Web the up or down arrow buttons until the cur Browser sor is in front of Channel 3 Press the Enter button to see the individual results for Step 1 From the Home Page click on Opera
251. ts no leakage current Some solid state relay manu factures specify 20mA minimum load This is based on the presumption a relay or solenoid will drop out with only 4mA through it which is not always true That may not be true When switching a light load with a solid state relay across the line you must look at the rated drop out current of the load and if it is less than 4mA it may not turn off The solution is to put a loading resistor in parallel with the light load to be sure leakage cur rent is sufficiently shunted away from the coil 2 Assume a load like a relay with a coil of 15 000 ohms and of 5 of nominal drop out When the solid state relay is off there will still be 1 3 of the line voltages across the relay so it will not drop out For the relay to have 5 of the line across it it and a parallel shunt resistor must be 20 times less resistance than the 30K snubbing net work or 1 5K ohms Use less than a 1 67K ohm parallel resistor and now total load is below 1 5K ohm or 80mA System Integrity Check and Fault Determi nation From the Web Browser Diagnostics Diagnostics is used to troubleshoot the Filler Dispenser A complete Troubleshooting Guide is available in the Service Manual What is important for Operational purposes is to be able to see the information about this instrument See Fig 7 98 Setting Default Settings is also useful to operators Step 1 Click on Diagnostics The Diagnostics Page app
252. turn to the Diagnostics display Force Outputs WARNING FORCING THE OUTPUT RELAY MAY CAUSE DAMAGE OR PERSONAL INJURY MAKE ABSOLUTELY SURE THAT YOU KNOW WHAT THE RELAY IS CONNECTED TO BEFORE ACTIVATING IF INSECTARY DO A PHYSICAL CHECK TO DETERMINE WHAT THE SELECTED RELAY IS CON NECTED TO BEFORE ACTIVATING The Force Outputs function individually activates each of the 4 Output relays in the instrument Useful in pre startup to determine that all the relays are connected to the correct aux iliary devices Step 1 Press the up or down arrow buttons until the cursor is in front of Force Outputs See Fig 7 90 VIEW INPUT STATES gt gt Force OUTPUTS gt STATE LOGGING OFF FIG 7 90 DIAGNOSTICS DISPLA Y FORCE OUT PUTS Step 2 Press the Enter button A WARNING display appears See Fig 7 91 FIG 7 91 WARNING FOR FORCE OUTPUTS Step 3 If you are not sure if this is what you want to do or got here by mistake press the Exit button If you are absolutely sure that this is what you want to do press the Start button The Output Relay dis play appears with the cursor in front of Output Relay 1 See Fig 7 92 Step 4 PRESS ENTER TO FORCE gt DuTPut RELAY gt OUTPUT RELAY p gt OUTPUT RELAY 3 gt FIG 7 92 OUTPUT RELAY DISPLAY SELECTING OUTPUT RELAY 1 Step 5 To select another Output Relay press the up or down arrow buttons until the cursor is in front of the Output Relay you
253. u The Left Right arrow buttons move the cursor horizontally left and right The Left arrow button has an added backspace function For example if there are AlphaNumeric characters that appear in the display as you press the left arrow button 1t erases the characters The Right arrow button moves the cursor to the right in the display and does not erase a alpha numeric entry The Left Right arrow buttons also move the cursor through a pick list See Fig 4 3 HI 3010 Filler Dispenser IBC 22 Service Manual Enter Button The Enter Button enters the alphanumeric value entered for a menu item in the display The Enter Button also enters the selections from a pick list See Fig 4 4 SeLect UNIT LEFT amp RIGHT Burton THEN PRESS ENTER Lp Poungs gt KG HILOSRAMS Oz Ounces 5 DRS FIG 4 4 LIST SELECTION ENTER BUTTON For example when selecting units from a pick list use the left and right arrows to move the cursor in front of the unit you want and press the Enter button Exit Button The Exit Button disregards the current value entry restores the previous value and moves the cursor to the last menu Clear Button The Clear Button clears the total alphanumeric entry and repositions the cursor for the first entry Ing 1 Button Enables you to change the preprogrammed ingredient 1 12 while in the Standby Mode Also enters the integer 1 in the display 2 ABC Button Enters the integer 2 in the
254. u to determine if the problem is in the instrument internal or in a load sensor s external The speci fication range for the instrument is 0 15 mV If you are getting a reading outside this range 15 5 mV 3 1 mV V Maximum or any negative values the problem is exterior to the Instrument most likely improper wiring If you are getting a read ing between 0 15 mV the reading is nor mal Step 5 To view the total Millivolt readings for all the load sensors that are connected to the scale press the up or down arrow buttons until the cursor is in front Voltage amp Weight Press the Enter button The total millivolt reading for the scale appears See Fig 103 Step 6 VOLTAGE amp VACHT gt AL 2 0M gt AL 30nW V gt AL 72 0Ib gt FIG 7 103 TOTAL MILLIVOLT READING NOTE The values listed here are for illustration pur poses only Your readings will be different Step 7 To view individual millivolt readings for individual load cells 129 CHAPTER 7 Troubleshooting Press the Down or Up Arrow button until the cursor is in front of ALL mV See Fig 103 Press The Enter button The individual Channel millivolt readings appear See Fig 104 FIG 7 104 INDIVIDUAL CHANNEL DISPLAY MIL LIVOLTS If all the load sensor readings are 0 00 mV there is something wrong between the HI 3000 and the load sensors The cable s is disconnected or something is wrong It is not transmitting the Millivolt
255. ulti meter Record the mV reading and compare each corner for proper load Ap power to the sharing pl controller only if supply a Proper load sharing should see only a difference of 5 mV voltage is correct b Larger differences due to motors and piping should not exceed 4 mV If there aren t any motors valves or piping to explain the mV difference adjust the corners and balance the MV readings Use shims or if equipped adjusting bolts on the load cell Mounting Hardware Drawing a load cell map will help determine the correct leg to adjust and in which direction Three Load Cells Balance Like a Three Legged Chair 1 Using a spirit level verify the vessel is vertically and horizontally correct 2 Verify if any height change effects the attitude of adjacent vessels or piping 3 Adjust each leg to dynamically match mV outputs 4 Verify the mV readings and physical level when complete Four Load Cells or More Present a Challenge Use a multi meter Determine the sum of the load cell signals and Your target mV setting for each load cell Read the output of individual load cells Adjust the load cell with the lowest reading to dynamically match the target mV readings obtained in step 1 Read the mV readings from each load cell to verify proper correction Monitor system for proper operation Check out complete Repeat steps 3 and 4 to achieve a proper load sharing vessel Verify the mV readings
256. unctioning s Ifone of the load sensors is reading higher or lower than the other load sensors in your system and you know that you cali brated the instrument and cornered the scale there is something wrong with the load sensor s Ifone of the load sensors is reading higher or lower than the other load sensors and you do not know if the scale has recently been calibrated re calibrate the scale then check the Voltages and Weights again Stability Test The Stability Test switches a fixed signal into the analog to digital convertor and calculates the mean squared variation from the average reading using 100 samples The test passes if the mean squared variation is less than 5 0 and the average reading is between 30237 and 36955 NOTE Before performing the Stability Test check to see if all the Channels have been enabled from the Web Browser Step 1 Press the up or down arrow buttons until the cursor is in front of Stability Test See Fig 7 109 SMARTDIAGNOSTICS Volt age amp W ight gt gt Stability Test gt Fact or y Def ault s gt FIG 7 109 DIAGNOSTICS DISPLAY SELECTING STABILITY TEST HI 3010 Filler Dispenser IBC 130 Service Manual Step 2 Press the Enter button The Information display appears SYSTEM STABILITY TEST PRESS ENTER TO START See Fig 7 110 SYSTEMSTABILITY TEST Pr ess ENTERt ot est FIG 7 110 STABILITY TEST DISPLAY Step 3 Press the ENTER button to perform the stabil
257. urn to Zero Test 123 View Input States 124 Force Outputs 124 State Logging 125 Using Solid State Relays with Light Loads Optional Set Relays 126 About Solid State Relays With Light Loads 126 System Integrity Check and Fault Determination From the Web Browser t s y SeSeo E Se a SE See Ee ee E 126 Diagnostics 126 Smart Diagnostics 127 Using Smart Diagnostics From the Front Panel 127 Stability Test 129 Using Smart Diagnostics From the Web Browser 130 Overview of Typical Load Cell System 132 Troubleshooting The Network Connections and Configuration with the Ping Tool 133 Selecting the module by number for Testing 133 Exiting the Root Directory 133 About Solid State Relays With Light Loads 133 SCR SWITCHING LOAD CIRCUIT 133 General Policies and Information gt 134 FOR FURTHER INFORMATION CONTACT 134 Ordering Replacement Parts 134 System Support 134 Warranty 13
258. ut complete Contact Technical Service 1 800 821 5831 CHAPTER 7 Troubleshooting R View Input States Enter Diagnostics STABILITY TEST Activate the test and review the results The Input States display shows whether or not the instrument has any inputs activated This provides a way of testing the inputs before actually starting the process These are dry contact closures Allowing 110 VAC in the input will damage the unit Contact Hardy Technical Support for repair Verify contact is being made between the connector common to the input desired Use a jumper to physically make the connection and verify operation S Forcing Outputs Enter Diagnostics STABILITY TEST Activate the test and review the results The relay will activate Therefore activating any machinery attached Repeat for each output HI 3010 Filler Dispenser IBC 114 Service Manual The Force Output function individually activates each of the 4 Output relays in the instrument Useful in pre startup to determine that all the relays are connected to the correct auxiliary devices WARNING Forcing the output relay may cause damage or personal injury Make absolutely sure you know what the relay is connected to before activating If you are unsure do a physical check to determine what the selected relay is connected to BEFORE activating Verify voltage is being provided The Thes
259. ut in the Output Image Table See Fig 6 42 Red Arrows Now that you have set up the local mapping for Node 1 and Node 2 and Node 1 is communicat ing with Node 2 you can map the Input Contact at Node 1 directly to the Output Relay at Node 2 See Fig 6 42 Black Arrow 77 CHAPTER 6 Mapping HI 3010 Node 1 Input 0 From Sensor Output Image 1 2 3 Table 4 Input Image Table Input Contact 1 Hardy Boolean Out HI 3010 Node 2 Input Image Hardy Boolean In Output 1 O 109 Actuator 2 Output Image i Table Output Relay 3 Mapping an Input to an Output Relay on Another HI 3010 FIG 6 42 HARDY CONTROL LINK NETWORK MAPPING Boolean Mapping A Boolean variable is a variable that can have the value 0 FALSE or 1 TRUE In the HI 3010 Filler Dispenser there are 3 boolean operations supported e AND The symbol for AND in a Bool ean Assignment Statement is e OR The symbol for OR in a Boolean Assignment Statement is e NOT the symbol for NOT in a Boolean Assignment Statement is The Boolean image tables are arrays of short 2 byte inte gers An individual Boolean variable in the image table is located by its word offset and its bit offset Boolean image tables are given 2 letter names as follows e DI isthe DeviceNet input image table e DO 15
260. uto Zero ON radio button To turn OFF Use Auto Zero Tolerance click in the Use Auto Zero OFF radio button Step 18 To set the Auto Zero Tolerance double click in the Auto Zero Tolerance field and enter a new Auto Zero Tolerance parameter Step 19 To set the Auto Zero Time double click in the Auto Zero Time field and enter a new Auto Zero Time parameter Step 20 To set the Tare Limit double click in the Tare Limit field and enter a new Tare Limit parameter Step 21 To set WAVERSAVER e Click on the WAVERSAVER pull down menu See Fig 4 117 e Click on the WAVERSAVER setting you want for your process Step 11 To set the Motion Tolerance double click in the Motion Tolerance field and enter the new Motion Tolerance parameter 53 CHAPTER 4 Configuration Discharge Parameters Configuration Instrument Setup Filler Step 1 To turn ON Discharge click in the Discharge ON radio button To turn OFF Discharge click in the Discharge OFF radio button Enter or select the parameters for the fields below Zaio o mma Te ee ee Ger OOR Step 2 To turn ON Auto Discharge click in the Auto Dis oferance charge ON radio button To turn OFF Auto Dis ae 10 000 Seni Tolerance 10900 charge click in the Auto Discharge OFF radio Tare Limit 999999 00 WAVERSAVERO 1 00 Hz 2 button ier Step 3 To turn ON OK to Discharge click in the OK to OFF ON Aux Device Timer Discharge ON radio button To turn OFF OK to
261. w expressed in Percentage Step 40 Press the down arrow button until the next three menu items are displayed See Fig 7 61 FIG 7 61 TEST DATA INGREDIENT DISPLAY JOG ON TIME JOG COUNT JOG OFF TIME Step 41 Jog On time Jog Count Jog Off Time are read only e Jog on Time This is the amount of time the feeder will operate in seconds e The Jog Count This is the number of jogs allowed before an alarm is set e Jog Off Time This is the amount of time after a Jog before the net weight is checked Step 42 Press the down arrow button until the next three menu items are displayed See Fig 7 62 TEST DATA INGR gt Fin Timer ieuss WAIT Timer engs Speen DUAL FIG 7 62 TEST DATA INGREDIENT DISPLAY FILL TIMER WAIT TIMER SPEED Step 43 Fill Timer Wait Timer Speed are read only Fill Timer The time in seconds it takes to complete a fill before an alarm is set e Wait Timer The time in seconds after a fill the instrument waits before net weight is read e Speed The speed selected for this Ingre dient either Single or dual Step 44 Press the down arrow button until the next three menu items are displayed See Fig 7 63 gt Fast Fiul Pre Sumeh DFF FAST FILL PRE TIAR 55 FAST FILL UT 10 80 FIG 7 63 TEST DATA INGREDIENT DISPLAY FAST FILL PROOF SWITCH FAST FILL PROOF TIMER FAST FILL WEIGHT Step 45 Fast Fill Proof Switch Fast Fill Proof Time Fast Fill Wei
262. weight you can accept in your process The Target Window can be set as weight or percent age PARAMETER TARGET WINDOW WT RANGE MIN WT 000000 999 999 MAX WT 000000 999 999 DEFAULT 1 0 PARAMETER TARGET WINDOW RANGE MIN 0 00 99 9 MAX 0 00 99 9 DEFAULT 2 Step 1 The cursor should be in front of Target Window If 1t is not use the up and down arrow buttons to move the cursor in front of Target Window See Fig 4 22 Step 2 Press the left or right button to select Weight WT or Percentage See Figs 4 22 amp 4 23 ADJUST INGREDIENT 1 TARGET LIT DD DU TARGET PREACT gt gt TARGET WINDOW lun gt FIG 4 22 INGREDIENT SETUP MENU SELECTING TARGET WINDOW WEIGHT 27 CHAPTER 4 Configuration TARGET LI 180 00 TARGET PREALT gt gt TARGET WINDOU 96 gt FIG 4 23 INGREDIENT SETUP MENU SELECTING TARGET WINDOW PERCENTAGE Step 3 Press the Enter button to access the parameter val ues Press the Clear button to clear the entry Use the alphanumeric key pad to enter the new Max toler ance value either in weight or percentage Press the Enter button to set the entry Press the down arrow button so the cursor is in front of Target Max See Fig 4 24 Step 4 Step 5 Step 6 FIG 4 24 TARGET WINDOW WEIGHT Step 7 Press the Clear button to clear the entry Use the alphanumeric key pad to enter the new Max toler ance value either in weight or percentage
263. y stored material configurations Output alarms warn the operator of overfills feed time outs out of zero tolerance not OK to fill too many jogs if the discharge gate is not responding or when to change an inter mediate bulk container The Filler Dispenser IBC contains Hardy Instrument s core features e WAVERSAVER Eliminates the effects of vibration on the scale e 2 Electronic Calibration Calibration without test weights e SMM Secure Memory Module Mem ory for manual transfer of configuration data to another HI 3010 instrument s All of Hardy s 3000 Series instrumentation is loaded with standard features like a selectable 10 100 BaseT Ethernet port and an embedded web server to link performance diag nostics and setup data to and from your local Intranet Extranet VPN or via the Internet World Wide Web A stan dard Devicenet interface allows multiple applications to be viewed and controlled from one display and allows 3rd party TO to be easily added to the system Mapped I O saves you wiring costs by distributing the I O where you need it at the process or in the control room The controllers act as Mas ters over Ethernet IP and Devicenet communications while optional interfaces for Allen Bradley Remote I O Profibus and Analog provide communications to PLC and DCS sys tems Hard copy records can be printed via a standard 232 simplex printer port to an external printer NOTE PLC isa registered

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