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HI 2151/30WC Weight Controller Operation and Installation Manual

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1. za Displays Milli Volt 4 C2 ny calls Displays readings automatically non OK or ERROR established during of load cells Calibration enter Ya enter wee EXIT y S Z enter 151 an OK or ERROR Y gt enter gt or ERROR E gt y enter 3 I 152 LS ALL Y enter 181 N nter ff Y OK or ERROR enter XXXKXX gt OK or ERROR v enter lt gt lt py 19 154 gt Y ial ge E Le OK or ERROR enter __ enter _ XX enter 153 Ls4 lt gt 539 enter P exit ee Y Return to weight readings NOTE Systems using the Integrated Technician features relating to the isolation or measure ment of the instrument junction box cable the junction box and individual load sen sors or the measurement of weight or voltage of the individual load sensors require an HI 215T series junction box 8 6 Chapter 8 Troubleshooting ARROW keys will move you between menu selections
2. o E s o a f of o iL Pun n IE s 2o Teal o o o e u 2 C wo pu 3 o qu FIG 4 11 PEAK HOLD MODE DIP SWITCH LOCATION When the switch is ON it enables communication to more than one controller on the same line To use the Multidrop function the Hardy Link software option must be installed Multidrop is only available when using the RS 422 485 serial port setting 1 Serial Port Lockout When the switch is ON the following com mands cannot be executed over the serial interface Format Set Setpoints 2 When the Serial switch is OFF it enables these commands OFF is the default position 1 When the switch is ON there is no access to the Option Menu 2 When the switch is OFF the full Option menu is available 1 When the switch is ON there is no access to the Set Point Menu 2 When the switch is OFF the Set Point Menu is available Not Used 1 When the switch is ON the Tare Mode Zero and Ib kg keys are locked out or not available 2151 30WC MANUAL Configuring the Power amp Relay Board Dip Switches S2 See Fig 4 12 4 10 2 When the switch is OFF Tare Mode Zero and lb kg keys are t
3. y m ur Ds y ENTER key will advance or display LIT Press EXIT to return to the last menu level 1 SHFTEST ewe gt Displays System Information ur Arrow to Continue error ENTER IT SEC enter gt 5321 INVAL enter EXCMON enter ONLINE gt BASE R gt READ gt TEST R A enter enter enter enter v v ON XXXX enter XXXX enter ERROR or OFF UR 6000 exit EXCMON Verifies Excitation current for all cables and load sensors connected to the system ONLINE BASE R READ R TEST R Allows the continuous Reflects the Reflects the A simple excitation Monitor to resistance values present resistance resistance he enabled and calculated at values For comparison for disabled power up for C2 comparison of 60 0 60 systems or during values calculated system test the Cal or during power up Soft Cal zero for C2 systems reference point for and during the non C2 systems Hard Cal or Soft Cal zero reference point for Non C2 systems yY Vv DVMTST Excitation Monitor Note C2 Will calculate values at power up and enable the continuous excitation monilor ate Non 02 Will automatically calculate these values during the zero reference operation of Hard or Soft calibration and enable the continuous excitation monitor
4. ejje 2 Made In U S A 1 2 88 5 5 O 8 E Modulo 48 ROTG Ea TE 88 5 pauuuuuuejooooooooo0 I LrLii i Load Cells LJ Remote Functions L 2 J5 Relays 6 J3 Serial EI 1 J4 OptRelays a 53 Config J6 Power Input p Q 9509 7888 55 C Hot Neu NEU HOT GND FIG 3 8 POWER WIRING DIAGRAM 2151 30WC MANUAL Output Setpoint Relay Wiring Optional Relays or TTL Level Outputs e Power Input J6 J6 1 Low Neu J6 2 HI Hot J6 3 Ground zb Step 5 For the Wall Mount WS version route the 14 AWG Mini mum wires through the lower right side of the cut out facing the front of the instrument to TB1 which is mounted at the lower right hand corner of the back plane e HI 2151 30WC WS Power Connection TB1 1 Hot HI TB1 2 Neu Low TB1 3 Gnd Ground 2 Standard SPDT Form C Relays Wire Size 12 AWG Maximum J5 Relays Connector Pin INO Normally Open Relay 1 Pin 2C ARM Relay 1 Pin 3NC Normally Closed Relay 1 Pin 4NO Normally Open Relay 2 Pin 5C ARM Relay 2 Pin 6NC Normally Closed Relay 2 For Wall Mount Version WS Route the wiring through the lower left side of the cutout When facing the front of the instru ment to the J5 center connector of the lower Printed Circuit Card This option supp
5. 4 ENTER key will advance or display Der 78 Press EXIT to return to the last menu level SELF TEST eme Displays System Information ur avrov to Continue error ENTER IT SEC I enter 5321 INVAL enter NEN NEED EXCMON DVMTST Isolates the controller from the weigh hridge at J1 Load cell Return to output connector Isolates the controller ZERO from the Load Sensors at A INTREF gt REFBOX ll Junction hox L enter SYSTST Lj ener enter IT Junction Box Weight Controller internal fixed internal fixed resistor reading exit resistor reading enter If C2 View of load cells NUM LS y If non C2 enter the Return to of load cells weight readings pi T LS1 Y enter XXXXXX Displays the individual and Y Y me gt total load cell weight BT Bu readings Uses the number XXXXXX enter of decimal points selected under contiguration T enter Je 153 de XXXXXX enter P 8 7 2151 30WC MANUAL 8 8 General Troubleshooting Flow Chart Index Drifting or unstable weight readings Electrical Mechanical and Configuration reviews Weight indication will not return to zero Verify individual load sen
6. Voltage Zero Current Spa FIG 4 6 ANALOG OUTPUT BOARD Some receivers require either a positive high pulse or a negative low when printing Select the jumper that meets the receiver input signal requirements The switch is marked W1 W2 in the top center of the board Positive Pulse W1 Negative Pulse W2 Default z z N N Positive Negative Pulse Pulse FIG 4 7 BCD CARD JUMPER SETTING FOR POSITVE PULSE FIG 4 8 BCD JUMPER SETTING FOR NEGATIVE PULSE Calibration Configuration Procedures When Security Code is not Available Dip Switch Location See Fig 4 9 Auto Zero Tolerancing Configuration Procedures About Auto Zero Tolerancing NOTE Chapter 4 Configuration When the security code is not available the config dip CAL switch S3 on the rear panel can be toggled to enter the CAL menu See Chapter 5 Section 5 2 sub paragraph 9 for setup instructions When you press the CAL button at the front panel and the CAL switch S3 is not toggled the display will read ERR 8 Simply perform the following procedures to enter the Calibration Menu Opdon2 s C C Tene Paninin EAE po000000 H FIG 4 9 CAL TOGGLE SWITCH LOCATION Step Change the position of the toggle switch 2 For Calibra tion procedures See Chap
7. Monitor the display for YES STABLE NO econnect signa cables one at a Problem could be the instrument Contact Hardy Customer Support 800 821 5831 Monitor the display for stability If installing any cable causes unstable readings GOTO REVIEW TROUBLE SHOOTING B SECTION B B1 1 B1 7 B Guidelines for Instabilities on Formerly Operating Systems Cont d Check for Electrical Stability Yes Y Chapter 8 Troubleshooting Check for Mechanical Stability OK Yes Y Check Configuration settings for Stability OK Yes GOTO A Re run T Diagnostics 2151 30WC MANUAL B1 Guidelines for Instabilities on Formerly 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 differences in potential and static build up
8. uw ES INTERMEDIATE SUPPORT FRAME FULLY CONSTRAINED LATERALLY WITH STAY RODS VESSEL SUPPORTBRACKET HEAR MAXIMUM CENTER OF GRAVITY FOR INHERENT VESSEL STABILITY c N EX D T Ne BIN ACTIVATOR N N N NON METALLIC EXPANSION ASSEMBLY OR HOSE FIG 8 1 TYPICAL LOAD CELL SYSTEM a Load Cell Sensor Point is a strain gauge based force transducer which generates an electrical signal proportional to the load applied to the scale Load cells points can be used any place a person needs NOTE No Keypad Operation Remote Functions Non operational Chapter 8 Troubleshooting to measure pressure 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 2151 30WC and depending upon how much weight is applied to the scale generates a millivolt output proportional to the weight 0 10mv DC for 2mv V load cells points or 0 15mv DC for 3mv V load cells points b IT Junction Box Prt HI 215IT SS1 Stainless Steel HI 215IT PS1 Painted HI 215IT FG1 Fiber Glass is a system control box used to sum the incoming and outgoing signals of from one to four load sensors or load cells The Junction Box distributes the excitation voltages to each load sensor load cell and transfers each loa
9. 6 16 Setting the Reference Point 6 17 Using the Return RETURN Function 6 17 End of the Soft Calibration Process 6 17 Soft Calibration Self Test Process 6 17 Performing the Self Test 6 17 INTEGRATED TECHNICIAN ITO 6 18 Setting Resistance Baseline for Excitation Monitor 6 18 Quick C20 Calibration Procedures 6 18 About Quick C2 Calibration 6 18 Procedures to Restore Calibration Parameters 6 19 Before Clearing Memory 6 19 Clear Controller Memory 6 19 Restoring Calibration When Changing Decimal Points 6 20 Restoring Decimal Points 6 20 Chapter 7 Operation Description of Front Panel See Fig 7 1 7 1 Process Weighing Function Buttons 7 1 Operator Displays 7 2 Instrument Operation Overview 7 2 Option Menus and Option Parameters 7 3 Option Boards 7 3 General Information 7 3 Set Points
10. 7 21 To print the Total Value 7 21 To clear the Total 7 22 To exit the Total Mode 7 22 Allen Bradley Remote I O Option B8 7 22 Profibus Interface Option B12 7 22 Disassembly Reassembly Notes and Cautions 8 1 Trouble Shooting Using Integrated Technician 8 2 General Troubleshooting Flow Chart Index 8 8 A Guidelines for Instabilities on Formerly Operating Systems 8 9 Guidelines for Instabilities on Formerly Operating System Cont d 8 10 B Guidelines for Instabilities on Formerly Operating Systems Cont d 8 11 B1 Guidelines for Instabilities on Formerly Operating Systems Cont d 8 12 B1 Guidelines for Instabilities on Formerly Operating Systems Cont d 8 13 C Guidelines for Instabilities on Formerly Operating Systems 8 14 Non Return to ZERO 8 15 Verify Individual Load Cell Milli volt Readings 8 16 G Error 18 During Hard Calibration 8 17 Mechanical Inspection 8 18 J Electrical Inspection 8 19 Load Sharing and Load Sensor Checkout
11. 2151 30WC Weight Controller Operation and Installation Manual Sud Hardy Instruments Document Number 0596 0224 Rev H Table of Contents Table of Contents Chapter 1 Overview About Hardy Manuals 1 1 Description 1 1 WAVERSAVER 1 2 C209 Calibr tion 22 4 a ee ae ee 1 2 IT 1 2 Excitation Monitor 1 3 Digital Volt Meter DVM 1 3 Return to Zero Test 1 3 Weighing System Tests 1 3 Secure Memory Module SMM 1 3 Set PointRelays 1 4 Serial Port ete eee ee De eo at eet 1 4 Hardy Link LAN 1 4 Remote Functions 1 4 Auto Zero Tracking 1 4 Output Device Options 1 5 Analog Output 1 1 5 Binary Coded Decimal BCD Output B2 1 5 Binary Coded Decimal BCD Output B5 1 5 BCD Single Termination Card 1 5 BCD Quad Termination 7 1 5 Remote RIO Interface t
12. 252 Installing the HI 2151 30WC in a Panel 3 3 Panel Cutout Specifications 3 3 Installing the HI 2151 30WC Panel Mount 3 3 Installing the HI 2151 30 Remote Mount Model 3 5 Install the Front Panel 3 5 Installation of the Instrument Enclosure 3 6 Installing the HI 2151 30WC BR Blind Remote Model 3 7 Installing the HI 2151 30 Wall Mount Model 3 7 Electrical Installation 3 8 Cabling and Interconnecting 3 8 Recommended Installation Procedures 3 8 Input Power Wiring 3 9 Output Setpoint Relay Wiring 3 10 Optional Relays or TTL Level Outputs 3 10 J3 Serial Port Wiring 3 11 Remote Functions Wiring 3 12 Load Cell Point Connections J1 3 12 About Load Cell Wiring 3 12 C2 Load Cell Connections 71 See Fig 3 9 3 13 ii Table of Contents Chapter 4 Configura tion Chapter 5 Setup Non C2 Load Cell Connections 71 See Fig 3 10 3 14 Output Option Board Ins
13. 8 20 M HI Error 8 21 N Blank Screen 8 22 Excitation Monitor 8 23 Stuck on HARDY Screen 8 24 System Integrity Check and Fault Determination 8 25 Self Test 8 25 Interpreting Diagnostic Error Messages 8 30 Overview of Typical Load Cell System 8 30 No Keypad Operation 8 31 Remote Functions Non operational 8 31 Using Solid State Relays with Light Loads Optional Set Relays 8 32 About Solid State Relays With Light Loads 8 32 IT Test Menu Breakdown 8 33 Excitation Monitor Current Setup Menu 8 34 Digital Volt Meter D V M 8 34 Return to Zero Test 8 35 Weighing System Test 8 36 Error Messages and Definitions 8 37 LO 8 37 HI 8 37 ERREXC 8 37 Error Messages 8 37 Table of Contents Index System data survey sheet Glossary of Terms Se
14. 6 2 BRATION MILLIVOLTS WEIGHT SCALE 6 3 FRONT PANEL DISPLAY WITH NUMBERS 6 4 FRONT PANEL DISPLAY WITH TEXT 6 4 FRONT PANEL STATUS LEDS DISPLAYED 6 5 CHAPTER 7 OPERA FRONT PANEL PROCESS WEIGHING FUNCTION BUTTONS 7 1 TION OPTION MENU TREE 7 3 LOW AND HIGH PREACT TRIP LIMITS 7 5 WIRING DIAGRAM SERIAL COMMUNICATIONS 7 8 2151 30WC MANUAL II Chapter 1 Overview CHAPTER 1 OVERVIEW NOTE About Hardy Manuals Description This manual provides users and service personnel with specifications and procedures for installation setup configuration operation com munication maintenance and troubleshooting for the Hardy Instru ments HI 2151 30WC Weight Controller The HI 2151 30WC is fitted with WAVERSAVER C29 Calibration and the INTE GRATED TECHNICIAN IT diagnostic tools IT WAVERSAVERS and c28 are Registered Trademarks of Hardy Instru ments Inc To ensure the safe operation before using the weight controller users and maintenance personnel should read and understand all cautions warnings and safety procedures stated or referenced in this manual To get the maximum service life from this product follow the instructions described in this manual Hardy Instruments appreciates your business Sho
15. 7 4 About Set Points 7 4 Set Point Limits 7 4 Dead Band Limits 7 4 Three General Rules for Setpoints 7 5 Preact Limits See Fig 7 3 7 5 Entering Set Points 7 5 About the Set Point Menu 7 5 Entering Set Point Procedures 7 6 Entering Dead Band Tolerance Procedures 7 6 Entering Preact Values Procedures 7 6 Serial Communications 6 0 7 7 Bi directional Communications 7 7 RS 232C 7 7 Operation 7 7 RS 422 485 7 7 Operation 7 7 Description of 422 485 Transmission Modes Available 7 7 RS 485 7 7 RS 422 7 7 Additional Non standard Transmission Mode 7 8 RS 422 485 Wiring and Electrical Specifications 7 8 RS 422 485 Configuration Wiring 7 8 RS 422 485 Electrical Specifications 7 9 Instrument Serial Communications 7 9 Abou
16. 8 8 8 8 8 8 ERREXC TEST 1 Chapter 8 Troubleshooting Self test can be entered only from the net gross or rate of change operating modes To initiate self test press the Test Clr button 3 Press the Enter button The name of each test is displayed for about 2 seconds after which the result is displayed for another 2 seconds The self test program automatically steps through each test and continues through any failed tests until all are completed When the self test program has completed all tests the instrument returns to the keyboard test which can be ended by pressing the 0 Speed up the self test by holding down the UP arrow key Pause the self test display by pressing the down arrow key To resume the self test press the up T arrow key To exit the self test at any time Write down the test results and compare them to the System Data Survey Sheet Determine if any differences are due to system modi fications and update the Survey Sheet 4 5 exit button 6 press the exit key 7 8 Following are the sequential tests conducted by the self test pro gram FAILURE SOLUTIONS None Indicates beginning of self test Version of EPROM installed Display Test All segments and words on display turned on Indicates that the measured current is out of tolerance by 10 None Main card not seated properly in display board Contamination on connector pins LED dis
17. C20 5 9 coco oo i kt H PN co ot _ x 9 o m s 5 6 5 o jo of mo o 1250 5 BH o 511 of E 5 gt 5 11 o o lo RI30 218 2 5 o o J B 2 J1 ms Ue R5 C19 RI6 RI9 iS FIG 3 12 ANALOG OUTPUT BOARD Both current and voltage outputs are available simultaneously For Jumper Configurations See Chapter 4 Wire Size 22 AWG Min To 12 AWG Max Option Connector Wiring J1 1 V J1 2 V J1 3 No Connection J1 4 No Connection J1 5 I J1 6 1 The BCD option board See Fig 3 13 is installed in option slot 2 only and will provide parallel output of the sensed gross net or tare weight wi Fr LI E NOT 39 O 2 poooooooooooo OOOOOOOOOO ot Pag ia glo w 5 0 Ojo go o o wn jo ej s ol lo 000000 0000000000 9 all 5 U 5 T o o o o nass oj o 0000000 o 0000000000 5 9 9 B3B o o jo of lo m noooooo nooooooooo oj o u MA 5 5 us o E o 0 0 o 0000000 o 0000000000 Se 99 U3 5 9 9 ie B esl ooo 99 D ol lo ol 2 noooooo 0000000000
18. Stop Bits Length Format MISCELLANEOUS INFORMATION Format Control Address Configured with Hardy Link 2151 30WC MANUAL 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 April 1999 Dynamic Instruments All Rights Reserved Printed in the U S A
19. dd L oo ero m Eija Doody 00000000 cua BE 206 04 cn 05500000000 Eg BU a 050000 000 7 mm O 1600000000000 000090 0000000000000 O BG 30 1003 x IN us m o 20 1001 O mua nus kit NEA PES S Ol E 0 aia 9 _ opg 00000000000000000 wa 4o 3 29029000000000000005012 EE 0000000000000 S 0200000000 299 005 00 cum B BS 583 mmm E 00 es Eis DDODUUOUOUOUUD 0000000000000 CIBER c 2 Ol Po E LEE mae olo O Gan 00000 0000005 CORE oo Bio oS Baie cs E apse MS S LE e ngoooo Ello las 5 3 om E 000000005 000000000 olo E E aoe eo E mme 9189 29 x 0000000000 nen looks olog 00000000000000000 we 00000000000000000 000000 LI 5000509 O Sete Uu eo Oo o ear I oo 200000000 Dip Switch Location Jumper Location FIG 4 1 MAIN BOARD JUMPER AND DIP SWITCH LOCATIONS 4 1 2151 30WC MANUAL Setting th
20. error ENTER IT SEC enter 5321 INVAL enter vw EXCMON enter J gt ONLINE gt BASE R o gt READ R TEST t Verifies Excitation n v Y i ON enter enter Resistance e ERROR OFF OR exit 6000 exit exit DVMTST mene NUMLS DVMTNV lt lt gt DVM enter penter EP P 151 151 Y One Y Four 152 Decimal 15 ALL gt EXIT 152 Decimal 15 ALL Place Places gt Ls3 LS4 Ls3 Ls4 it v exit mene NUMIS gt gt enter enter Y Y LST LST Y OK Y MV 152 or LS ALL 152 Readings LS ALL DEMA ERROR A at CAL L 3 Ls4 L 3 Ls4 Y SYSTST enter ps INTREF REFBOX gt NUMLS enter ie enter enter exit exit Y enter 151 Return to y ENTER weight 152 Displays Corner LS ALL readin Weight gs if C2 view of Load Cells 13 154 If non C2 enter the of load cells NOTE Systems using the Integrated Technician features relating to the isolation or measure ment of the instrument junction box cable the junction box and individual load sen sors or the measurement of weight or voltage of the individual load sensors require an HI 215T series junction box 8 3 2151 30WC MANUAL ARROW keys will move you between menu selections
21. 2 3 Blind Remote Mount 2151 30WC BR 2 4 Portable Display HI 2151 30XX E4 use with HI 2151 30WC BR 2 4 ITG Junction Box HI 215IT SS or PS Series 2 4 IT Junction HI 215IT FG Series 2 5 Approvals 2 5 Seria Communications 2 5 Bi Directional Communications 2 5 Optional Equipment 2 6 Analog Output CBl 2 6 Binary Coded Decimal BCD B2 2 6 Binary Coded Decimal BCD B5 2 7 BCD Single Termination Board B6 2 7 BCD Quad Termination Board B7 2 7 Allen Bradley Remote I O Interface 8 2 1 Binary Coded Decimal BCD 9 2 8 Profibus I O Interface B12 2 8 Peak Hold CCI 3 22 2 ee a Se l 2 8 Rate of Change ROC 2 2 8 Totaliz r C3 2 9 zo ne ee ee ee Ee ee ee 2 9 Six TTL Level Outputs D1 2 9 Six External Solid State Set Point Relays D2 amp D3 2 9 Chapter 3 Installation Unpacking s 3 4 9 She eee E a d le PERSE 3 1 Mechanical Installation
22. Chapter 6 Calibration Step 3 To select one of the sizes use the up arrow T or down arrow keys to scroll through the selections Step 4 The graduation size is recalculated each time the instrument is calibrated for span Step 5 Press Enter to accept the selection The Zero Tolerance OTOL sub menu appears on the display This sets a weight limit for an operator adjusting the weight of an empty scale using the upper left ZERO push button This value is the zero tracking window and reflects an amount of weight differential of an empty scale Normally a Zero Tolerance amount equal to 2 of the total load cell capacity is acceptable The default zero tolerance is 10 units of measure 10 is displayed The maximum Zero Tolerance num ber that can be entered is 32766 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 Step Press the Enter button The default display will appear 10 or the previous set value 10 Step 2 Press the Test Clr button to clear the current value Step 3 Use the numeric keys to enter the new value Step 4 Press the Enter button to accept the new value Zero Tolerance sub menu O TOT appears on the display This parameter sets a weight limit that applies when the Auto Zero Tracking feature 0 TRK or a communication command adjusts an empty scale When 0 TRK is enabled the display
23. Dimensions of the enclosure cutout 3 3 Dip Switch Locations See Fig 4 10 4 7 8 Dip Switch Setting 4 8 Dip Switches S2 4 9 Disassembling the rear panel and setting jumpers 4 4 Disassembly and Reassembly Notes and Cautions 8 1 Display 2 1 Display Increments Graduations 2 1 DO NOT CUT THE CABLE 6 16 Document Number 0596 0173 3 20 Dynamic Data Exchange DDE B14 1 6 Dynamic Data Exchange DDE I O Server B14 3 22 E E2 3 9 Earth Ground Cable Shield 7 8 Echo 5 10 Electrical Check Procedures 6 2 Electrical Installation 3 8 Electrostatic Discharge ESD 3 3 End Calibration 6 14 Enter 5 4 Entering Dead Band Tolerance Procedures 7 6 Entering Preact Values Procedures 7 6 Entering Set Point Procedures 7 6 Entering Set Points 7 5 Environmental Requirements 2 2 ERR 8 4 7 Error Messages and Definitions 8 37 Excitation Monitor 1 3 2 2 Excitation Monitor Current Setup Menu 8 34 Excitation Voltage 2 1 External Setpoint Relays Card D2 1 6 External Setpoint Relays Card D3 1 7 F Firmware 3 10 Formats the serial data output 5 9 Fourteen Segment Display 6 4 Frequency 2 2 Front Panel Dimensions 2 3 Front Panel Setup Procedures 4 5 full analog output 5 12 full scale mV V output 6 15 full weight capacity 6 3 G gasket 3 5 Gross Mode 1 2 H Hard Calibration HD CAL 6 11 to 6 15 Hardy Link LAN 1 4 Hardy Link Local Area Network LAN 1 4 Hardy Link software option 4 9 Hexadecimal number 7 17
24. Loadcells Ground straps must be installed to provide a direct discharge path to ground around the loadpoints Cable Routing Seperate 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 open circuit between ground and shield Reconnect the shield to ground and confirm a proper ground path from the I T Junction box to the controller Verify the shield is not connect to ground at the I T Junction Box Loadcell cable shields only pass thru the I T Junction Boxes and are not connected to ground at that point Weight Controller Common AC ground and Chassis grounds p Pop GOTO T Chapter 8 Troubleshooting B1 Guidelines for Instabilities on Formerly Operating Systems Cont d Mechanical Stability Vessel B2 When inspecting a vessel keep in mind the Center of Gravity COG should be low and centered equally over all the load cells Insure the load is directly over or under the load point to avoid side loading Insure there isn t any
25. Model Code Breakdown Chapter 1 Overview The same as the D2 option except that the length of the cable provided is six inches This is designed to mount in the HI 2151 30WC WS D3 wall mount enclosure This is a factory configuration only The HI 21251 30WC is approved for National Institute of Standards and Technology NIST applications formally called the National Bureau of Standards NBS It is certified under the National Type Evaluation Program NTEP for up to 10 000 counts when the NIST mode is activated This option is required when products are to be directly sold based on weight readings of the scale This kit includes special screws for sealing the instrument a label plate NEMA 4 gas ket and a NIST label The HI 2151 30X X E4 option is used for local set up calibration and display of the blind remote version instrument modelHI 2151 30WC BR The Intrinsic Barrier Assembly Option is used with the Model HI 2151 30WC The option provides safety for Class I II and Division I Applications Only the front face panel is rated for Class I and II Divi sion II areas The remaining portion of the HI 2151 30WC controller must be installed in a NEMA4 enclosure for an intrinsically safe area See 2151 30 FM drawings 0584 0034 for information Contact Hardy Technical Support for questions Phone 1 800 821 5831 Web Address www hardyinstruments com The model code number can be found on a label that is attached
26. a o o o 9 5 5 UM o D XE 0000000 0000000000 go o oj le ol lo oj p o o jo o 9 noooooo 9 nooooooooo ss Un 05 ollo Be FIG 3 13 PARALLEL BCD BOARD Connector Requirements Chapter 3 Installation The board connector is a 40 pin right angle connector termi nating to either a 37 pin D subminiature assembly option B 2 a 40 pin connector with a 60 inch cable option B 5 or a 40 pin connector with a 24 cable option B 9 used with a Wall Mount Model The B 5 option provides flexibility of terminating BCD signal lines to the terminal board options B 6 and B 7 The pin designations for the BCD output are noted in Cable Pinouts List Parallel BCD Board Connector to BCD Con nector All data outputs have a drive capability of 15 LSTTL loads 6 mA total and use positive true logic PRINT READY has a drive capability of 10 LSTTL loads 4mA This option board is electrically and optically isolated from the main board Cable Pinouts Parallel BCD Board Connector to DB Connector BCD BOARD DB CONNECTOR SIGNAL VALUE 1 1 GND 3 2 BCD digit 1 bit 0 1x 10 5 3 BCD digit 1 bit 1 2x 10 7 4 BCD digit 1 bit 2 4x 10 9 5 BCD digit 1 bit 3 8 x 10 11 6 BCD digit 2 bit 0 1 x 10 13 7 BCD digit 2 bit 1 2 x 10 15 8 BCD digit 2 bit 2 4 x 10 17 9 BCD digit 2 bit 3 8 x 10 19 10 BCD digit 3 bit 0 1x 10 BCD BOAR
27. available 000000 969966 FIG 4 12 POWER amp RELAY BOARD DIP SWITCH LOCATION When the switch is ON incoming checksums are ignored When the switch is OFF incoming checksums are read 952 2 When the switch is ON the Peak Hold signal read is aver aged When the switch is OFF the Peak Hold signal is instanta neous 52 3 When the switch is ON the instrument is in the NBS mode of operation Resolution is limited to 1 10 000 counts When the switch is OFF the resolution is 1 985 000 82 4 This switch must be toggled position changed to enter NBS calibration from the front panel CAL button 82 5 Turns Off gt character on print output serial port 82 6 Puts unit in Blind Remote Mode 92 7 is not used 82 8 is used for resetting Calibration amp Configuration to the Fac tory Defaults CHAPTER 5 SETUP Keypad Functions See Fig 5 1 Zero Mode NOTE Tare Chapter 5 Setup Chapter 5 covers firmware settings to prepare the controller for calibra tion and operation User and service personnel should be familiar with the information in this chapter before going through the
28. enables the weight controller to distinguish the actual weight data from the mechanical noise that comes in on the load cell signal WAVERSAVER can be configured from the front panel to ignore noise with frequencies as low as 0 25 Hz Users can select one of four higher additional cut off frequencies to provide a faster instru ment response time The default factory configuration is 0 50 Hz vibra tion frequency immunity C2 Calibration C2 second generation electronic calibration can calibrate a scale sys tem without using certified test weights A C2 weighing system con sists of up to eight load sensors a junction box interconnect cable and an instrument with C2 capabilities such as the HI 2151 30WC Each Hardy Instruments C2 certified load sensor sends a distinct digital sig nal that the HI 2151 30WC uses to calculate weight and count the num ber of sensors in the system To factor in any known weight on the scale the user enters a reference value from the front panel A zero reference value indicates there is no weight on the scale The instrument is also capable of performing traditional calibration such as with the use of certified test weights INTEGRATED TECHNICIAN is a built in diagnostics utility that continuously monitors the system and allows the operator to rapidly troubleshoot problems from the front panel Adding an optional an IT junction box extends the diagnostics capability to any load sensor 1 2 Exci
29. gt The factory default setting is OFF exit to weight readings NOTE 8 4 Systems using the Integrated Technician features relating to the isolation or measure ment of the instrument junction box cable the junction box and individual load sen sors or the measurement of weight or voltage of the individual load sensors require an HI 215T series junction box fo TEST Button A Y Chapter 8 Troubleshooting ARROW keys will move you between menu selections ENTER key will advance or display Press EXIT to return to the last menu level SELF TEST Down Arrow to Ston Displays System Information enter Up Arrow to Continue error ENTER IT SEC enter 3 5321 INVAL enter v EXCMON exit ext DUWIST numis gt x gt DVM MV v If C2 view of load cells If non C2 enter the Y TORTOR ONIS Displays MiliVolts en Displays Milli Volts volt with a single decimal with a single decimal place place enter enter R3 a The ARROW keys will a UC move you between menu Pa Y ES Y selections 151 X Return to The ENTER key
30. CONTACT Chapter 8 Troubleshooting Definition Illegal analog weight span Analog span weight minus analog zero weight must be larger than 246 of the calibrated span The number of load points found did not match the number entered No load points found Load point capacities or sensitivities do not match Check Sum Error on 1 or more load points Too many significant digits after the decimal point to be displayed One or more C2 load cell connections are reversed Bad command sequence Serial Port only 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 Customer support is provided as follows 1 New system start up Ensure that the installation is checked and correct instruments are calibrated and operators trained 2 Service Engineers are trained and qualified to provide on site installation calibration and maintenance 3 Oncsite 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 A warranty problem may be handled by returning the product to the factory for repair or replacement under warranty Before r
31. HI 215IT Series Junction Boxes 3 22 HI 215T series junction box 8 4 Highest gross 4 8 host computer control 7 7 Humidity Range 2 2 individual set point 1 4 in flight compensation value 7 5 Input 2 1 Input Power Wiring 3 9 Install the Front Panel 3 5 Installation Details 3 23 Installation of the Instrument Enclosure 3 6 Installation of the Secure Memory Module 3 24 Installing the HI 2151 30 Remote Mount Model 3 5 Installing the HI 2151 30 Wall Mount Model 3 7 Installing the HI 2151 30WC in a Panel 3 3 Installing the Blind Remote Model 3 7 INTEGRATED TECHNICIAN IT 6 18 INTEGRATED TECHNICIAN IT8 1 1 IT 6 1 2 IT Junction Box 8 31 IT junction box 1 3 IT amp Junction Box HI 215IT FG Series 2 5 IT Junction Box HI 215IT SS or PS Series 2 4 J J3 Serial Port Wiring 3 11 jumper error 5 6 Jumper Location See Fig 4 7 4 6 Jumper Settings See Fig 4 8 4 7 jumpers and dip switches 4 1 K Key Pad 2 1 Keypad Functions See Fig 5 1 5 1 L Linear Correction 6 14 live load 6 13 Load Cell Count 6 12 Load cell point 3 12 Load Cell Point Connections J1 3 12 Load Cell Sensor Point 8 30 Load Check 6 6 Logic Controllers 1 5 logical choice 7 2 M material impacting 6 10 Maximum Zero Tolerance 2 1 Mechanical Check Procedures 6 1 Mechanical Installation 3 2 mechanical noise 1 2 Miscellaneous Options 1 7 Mode 5 1 mode key 5 1 Model Code Breakdown 1 7 MONITOR subcommand 7 17 Motion Toleran
32. Ideally the test weight used for the dead load should be the typical weight that will be measured in the application Step 6 Wait 12 seconds Step 7 Press the Enter button to set the span The Linear Correction LINCOR Sub Menu appears Press the Test Clr button two times The Return RETURN Sub Menu appears The RETURN Display allows the user to change any setting s entered in the Hard Calibration Sub Menu Step Push the up arrow T which takes you back to the Zero Sub Menu Step2 Press the up T arrow until you reach the sub menu you want to change and press enter Step 3 Follow the procedures for each Sub Menu you want to change Step 4 If you want to accept the Hard Calibration parameters entered press the Enter button The End Calibration END CAL message is displayed Step 5 Press the Enter button This seals all calibration settings and exits the Hard Calibration Menu Step Place a test weight on the scale Step 2 Check the displayed weight value Step 3 Remove the test weight from the scale If the displayed value is zero the hard calibration is complete If some value other than zero is displayed check for mechanical problems most likely binding in the system See Chapter 8 Flow Chart H for details Correct the problems and perform the Hard Calibra tion Process again To correct mistakes during calibration or to return to a previous calibration parame ter press the down arrow lt to bypa
33. Mechanical binding restricts the scales 4 Remove the test weights and set movement the ZERO reference point 4 Load cell wires disconnected or improperly 5 Again perform the SPAN wired operation and continue with the 5 Improper load sharing or mechanical loading calibration on the load cell The SPAN weight to 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 ERROR 18 YES NO Contact Hardy Instruments Proceed with Customer Service Calibration 800 821 5831 8 17 2151 30WC MANUAL 8 H Mechanical Inspection pee ee All pipes and conduits flexible Keep flexures on the horizontal Vertical flexures should be avoided Do not use flexures to correct for misaligned piping Do not use hose flexures to make right angle bends Non flexed piping should have an unsupported horizontal run using a ratio of 36 times it s 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 You weigh the output valve not the input valve Does the weigh scale see all the product to be weighed If the product applies a force to a valve or pipe that pipe or valve must be included in the weigh vessel Proper positioning of the flexures are key Your vessel must seem to float Mechanicall
34. NOTE Set PointRelays Serial Port Hardy Link LAN Remote Functions Auto Zero Tracking NOTE NOTE The SMM is limited to 1 000 000 lift time write functions A write is performed after any parameter change to the calibration zero and tare functions You cannot transfer the SMM from the HI 2151 30WC to the HI 2151 20WC The HI 2151 30WC is fitted with two standard internal selectable and mechanical form C SPDT relays Six optional external solid state relays are available and are field configurable as form A or B types Both types have individual set point preact and deadband parameters Each can be programmed to respond to the standard Net or Gross modes of operation or the optional ROC Totalizer or Peak Hold modes These relays can be used to open or close valves or gates or to turn motors mixers vibration equipment heaters coolers etc on or off One standard serial port can be configured to receive commands and transmit weight data to a serial device such as a printer output or bi directional port By resetting jumpers within the instrument it can be configured for RS 232 A1 RS 422 A2 or RS 485 A3 Baud rates are user selectable at 600 1200 2400 4800 9600 or 19 200 The Hardy Link Local Area Network LAN assigns an address to each instrument and provides the firmware necessary to handle in coming and out going communications Rear panel input of a level or momentary grounding that can be
35. Weight Controller System Configuration includes only hardware adjustments such as Jumper and Dip Switch settings We recommend that maintenance personnel be familiar with this chapter before config uring the weight controller Alternative configuration procedures are not recommended The RS 232 RS422 485 Bi directional serial ports are configured by setting jumpers dip switches and are also setup from the front panel The setup instructions are located in Chapter 5 System Setup Bi direc tional Serial Ports The jumpers and dip switches are located on the Main board See Fig 4 1 o N S A33 69vy0 SC S0 YSTIONLNOD me BE TATEM T INWA 332015 ss Pj Ug 30 OF vin c B s c 010000 0000000 p mae 20Q3 i 99
36. appropriate socket position J4 or J5 on the main board Guide the connector pins straight into the socket Step 8 Push down on the option board to seat the option connector pins into the socket on the main board Visually verify that all of the pins are properly seated into the mating connector Step 9 With the option board resting on top of the four standoffs fas tened to the main board install the four screws lock washers and flat washers Step 10 Gently slide the rear panel back into the extrusion Step 11 Replace the four pan head machine screws that fasten the rear panel to the extrusion Step 12 Connect the power cord Analog Output Option card can be mounted in option slot posi tions one or two 2151 30WC MANUAL 3 16 BCD Option Board Installation Procedures B2 B5 B9 This option has one output connector and uses pins and 2 for and voltage outputs and pins 5 and 6 for and current outputs One current and voltage range is selected by configuring the two jumpers on jumper block W of the analog board 2 00000000 je A 5 094 Lo 26 5 B uw 00000000 3 g g Oe Lo j5 lloc o of cout
37. ciently shunted away from the coil 2 Assume a load like a relay with a coil of 15 000 ohms and of 596 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 Chapter 8 Troubleshooting XXXXX 4 TY 51 XXXXX 4 51 9 JO WNS XXXXX F 1 xog ON Tiv 51 em XXXXX XXXXX 51 51 XXXXX es LSI 1 2S1 X Ty H3 O XXXXX 4 IST TY S1 2010 sds vysS1HH3 o XXXXX Jo 4 J8ju3 2129 YON 951 514 o o s1 d1 20 40 3 Xog r 8S NON 81 THHHHHE zcS1HH3 J g 51 XOSJ3M 51 skeidsiq 151444 09 40 187 THHEHHE LSI AS
38. if using the IT Junction Box 2151 30WC MANUAL Fourteen Segment Display Combination Status Indicator Bar Graph LEDs NOTE 6 4 Step3 Allow the controller to warm up for about 15 minutes before doing the calibration procedures The display is a six digit fourteen segment display with selectable dec imal placement The display can show positive values up to 999999 and negative values down to 99999 The LED display shows operational status messages as well as actual numeric values See Figs 6 3 amp 6 4 HI 2151 80WC WAVERSAVER IT 8 8 8 8 8 Test Clr Tare Val Status I e lb kg CR EX Set Pt Option FIG 6 3 FRONT PANEL DISPLA Y WITH NUMBERS HI 2191 904C WAVERSAVER G2 IT TARE PRINT DEL GE A Set Pt Option FIG 6 4 FRONT PANEL DISPLAY WITH TEXT e There are 30 discrete LEDs above the fourteen segment display that function as status indicators and a bar graph display See Fig 6 5 The status indicators use every other led whereas the bar graph uses all thirty when displayed Chapter 6 Calibration INSTRUMENTS t e WAVERSAVER G2 IT Hl 2151 90WC MODE TARE PRINT 099 FIG 6 5 FRONT PANEL STATUS LEDS DISPLAYED e To switch between status and bar graph display press the Status Bar button In the status mode LEDs will light t
39. jo 0187 Buunp en eA einjdea IIM ZO uogeioxe uo UN pue dnuewod uo GNALI IIW zo uoneyoxa3 8 33 2151 30WC MANUAL Excitation Monitor Current Setup Menu 4 Digital Volt Meter D V M Press the Test Clr button SLFTST appears 2 Use the up or down arrows to toggle between SLFTST and Inte grated Technician Security Code Number IT SEC Press the Enter button with IT SEC displayed Use the numeric key pad to enter 5321 Press the Enter button Use the up or down arrows to select one of the following Excita tion Monitor EXCMON Digital Volt Meter Test DVMTST Return to Zero Test RTNTOO System Test SYSTST or Self Test SLFTST Select the Excitation Monitor EXCMON Press the Enter button The On Line ONLINE Sub Menu appears Use the up or down arrows to select one of the following a ONLINE Press the Enter button Use the up or down arrows to toggle between ON and OFF After a selection is made press the Enter button to turn the online monitor ON or OFF The BASE R display appears The Excitation monitor must be ON to enable on line diagnostics Press the Enter button the BASE sub menu appears BASE Displays the resistance reading taken at power up for C2 load points or the reading taken at zero of hard or soft cali bration for no C2 load sensor Press the Enter button The READ R display appears READ R Reads
40. of C2 cells found Press the Enter button 2 2 Use the up or down arrows to toggle between the test voltage TEST E and to read the base voltage BASE E a Voltage Test TEST E Press the Enter button Use the up or down arrows to select LS1 LS2 LS3 L24 or LS ALL To test press the Enter button The controller reads the volt age of the load sensor s and compares that value to the stored value The display may read LS OK or ERRLS for each load sensor if used with the IT Junction Box ALL OK or ERRALL If you get an error statement go to the trouble shooting flow chart Section K to resolve the problem Press the Exit button to go to view the Base Voltage BASE B b View Base Voltage BASE E Use the up or down arrows to select LS1 LS2 LS3 L24 or LS ALL To view the base voltage reading press the Enter button The controller displays the base millivolt value taken at zero calibration Press the Exit button to return to the TEST E Sub Menu Press the Exit button The SYSTST System Test appears Go to step 8 6 4 5 2151 30WC MANUAL NOTE Weighing System Test The IT Junction Box must be used to display individual load sensors Press the Test Clr button SLFTST appears l 2 Use the up or down arrows to toggle between SLFTST and Inte grated Technician Security Code Number IT SEC 3 Use the numeric key pad to enter 5321 Use the up or down arrows to select one of the following Excita tio
41. the value to meet the requirements in step 3 Go to step 4 and repeat steps 4 5 amp 6 to enter new values until the value meets the requirements in Step 3 Press the Enter button to accept the new value AVRAGE sub menu appears Weight can accumulate up to the value entered for the Auto Zero Tolerance and the instrument will automatically display a 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 1 Step 2 This setting is to aid in ignoring the effects of material impact If material is not entering or exiting the scale evenly neces sary weight fluctuations can be seen Averages also contribute 50 ms each to the overall time to calculate the scale weight Applications requiring very quick weight readings should reduce this setting to it s minimum If the weight is unstable due to material impacting increase the averages This sets the number of weight readings that will be used to compute the displayed weight The average is a sliding average so that a new average is available for display at every reading This sets the number of weight readings which will be used to compute the displayed weight The average is a sliding average so that a new average is available for display at every reading The default number of readings per average is 10 Press the Enter button Use the numeric keys to enter the new value in the range of 1 to 200 If you enter a number greater than 200 or a negative
42. 09 06 78 49mm 1 52 High e All cutout surfaces must be deburred before installation of the controller WARNING DO NOT MOUNT THE HI 2151 30WC CONTROLLER NEAR HIGH MAG NETIC FIELD OR HIGH VAC POWER SOURCE TO DO SO WILL EFFECT THE PERFORMANCE OF THE CONTROLLER AND MAY RESULT IN PROPERTY DAMAGE Installing the HI Step l Ensure that all Electrostatic Discharge ESD precautions 2151 30WC Panel have been taken before installation Mount Step2 The controller comes with a NEMA 4 rated compression gas ket Make sure the gasket is properly seated in the bezel before installation 3 3 2151 30WC MANUAL Step 3 Gently slide the controller into the cutout in the enclosure Be sure to secure the controller with both hands when installing 5 75 PANEL CUTOUT 3 09 FIG 3 2 PANEL CUTOUT DIMENSIONS Step 4 Slide the controller into the panel cutout until the NEMA 4 amp 4X gasket is flush against the front panel of the enclosure See Fig 3 3 CAUTION ONCE THE GASKET IS COMPRESSED IT SHOULD NOT BE USED AGAIN WHENEVER THE CONTROLLER IS REMOVED FROM THE PANEL RE INSTALL WITH A NEW GASKET HARDY PRT 0524 0011 Step 5 Install the four mounting bars Slide each of the mounting bars into the slots at the rear of the controller One end of the mounting bar is recessed Make sure you install the bars from this end Check to be sure the mounting bars are flush against the inside surface o
43. 1 and or 2 When using only 1 board position 1 is preferred due to option cover compatibility BCD 1 only 1 RIO 1 only 1 or 2 PROFIBUS 1 only or 2 You can install either the RIO or the Profibus option but you cannot install both at the same time The set point value is the target weight or level It may be set in either net gross ROC Total or Peak hold weight units When entering this value the corresponding LED flag will appear on the display The operator may toggle this flag to the desired mode by pressing the MODE button Refer to the Set point Limits section following installa tion for a description of set point limits Only works when the ROC Total or Peak options are installed in the controller The dead band value can be set as a positive or negative value It is used to prevent relay chatter once the set point is reached Three General Rules for Setpoints Preact Limits See Fig 7 3 Entering Set Points NOTE About the Set Point Menu Chapter 7 Operation For example if a set point value was 1000 pounds and the dead band was set to 5 pounds the relay would close at a 1000 pounds but not open until the weight dropped to 995 pounds This would be used if a set point is a high trip limit A positive dead band would be used for a low trip limit Examples are shown for Low and High Trip Limits See Fig 7 3 Using a set point of 1 000 pounds and a dead band of 800 pounds will ca
44. 2 Remove Factory installed jumpers for C2 wire load cell con nection e Donotrun load cell cable in parallel with or in same con duit with power wiring relay cables or any other high energy cables e Recommend load cell cable Hardy Instruments Prt 6020 0001 T Summing Card Prt 0535 0465 Non C2 Load Cell Step 1 Attach load cell cable shield under screw near J1 on back of Connections J1 weight controller see ig 0 Step 2 Factory installed jumpers to remain in place for 4 wire load cell connection Step 3 Do not run load cell cable in parallel with or in same conduit with power wiring relay cables or any other high energy cables Step 4 Eight conductor load cell cable required when Cable runs greater than 50 feet With Soft Calibration e With INTEGRATED TECHNICIAN IT 2151 30WC MANUAL NOTE NOTE NOTE Output Option Board Installation Procedures WARNING CAUTION Optional WEIGHT 0535 0465 REV 5 Q CONTROLLER 9 9 8 8 8 8 Ofri oO n2 ors oO AUXILLARY 8 JUNCTION INSTRUMENT LP1 LP2 LPS 1 4 BOX a 4 6 us Se o ec oJ amp o ec o J e exc LSR TO AUXILLARY io
45. 2 1 Input 2 1 Display 2 1 Display Increments Graduations 2 1 Key Pad 2 1 Standard Setpoint Relays 2 1 Non Linearity 2 1 Maximum Zero Tolerance 2 1 WAVERSAVER 2 1 Excitation Monitor 2 2 Digital Voltmeter 2 2 Power and Utility Requirements 2 2 2151 30WC MANUAL Voltage 2 2 2 2 2 2 Common Mode Voltage Range 2 2 Common Mode Rejection 2 2 Environmental Requirements 2 2 Operating Temperature Range 2 2 Storage Temperature Range 2 2 Temperature Coefficien 2 2 Humidity Range 2 2 Physical Characteristics 2 2 Panel Mount Model 2151 30WC 2 2 Wall Mount Model HI 2151 30WC WS 2 3 Remote Mount Model HI 2151 30WC RM
46. 200 00 add a zero 0 by pressing the 0 button Now the value is correct If the Span Value should be 200 00 and the current display shows 2000 00 press Test Clr button and enter 200 00 Press the Enter button twice First the Full Scale Count Sub Menu FS CNT appears then the current value is displayed Press the Test Clr button enter the correct FSCNT then press the Enter button or press the Enter button to accept the current value The RETURN display appears Press the Enter button twice First the END CAL display appears then the Secured Memory Module is updated and the system returns to the weight display Chapter 7 Operation CHAPTER 7 OPERATION Chapter 7 covers operation of the HI 2151 30WC weight controller Follow the procedures in this chapter to ensure maximum quality per formance Description of Front Panel See Fig 7 1 Zero Mode Tare 8 8 8 8 8 re Gy eG Tare Val Status C Test Clr FIG 7 1 FRONT PANEL PROCESS WEIGHING FUNCTION BUTTONS Process Weighing ITEM LABEL BRIEF DESCRIPTION Function Buttons ZERO ZERO Sets current count as new gross zero reference point The ZERO button will only zero up to the zero tolerance value entered in the calibration menu See Chapter 6 The user can zero the instrument as many times as desired as long as the total does not exceed the value entered as the zero t
47. 2151 30WC MANUAL NOTE Data Formats 7 10 Data Formats Binary Representation Data Formats Weight Data Format The 2151 30WC weight controller contain intelligent front ends to a distributed sys tem therefore network speed is not usually critical Relays dip switches and LED data along with weight data have their own special format for transmission These formats are described in the following two sections 1 Relay dipswitch and LED numbers represented by the binary bit position In the case of a relay 0 disables the relay and a 1 enables the relay Binary bit position 765 43 21 0 Relay binary bit position 1 7 6 82 134 5 Example To enable relays 4 and 8 the following would be the binary repre sentation 0010001 0 This would be 22 hex hence the command to enable relays 4 and 8 would be E 22 Weights are transmitted according to the following rules e Positive numbers Maximum of 6 numeric decimal point e Negative numbers Maximum of 5 numeric minus sign decimal point Examples Transmitted Correct Received Reason 123 45 Y 123 45 5 numerics minus sign decimal point B above 1234 56 Y 1234 56 6 numerics decimal point A above Serial Commands Serial Commands Data Transmission Format Chapter 7 Operation Transmitted Correct Received Reason 12345 Y 12345 5 numerics minus sign B above 123456 N 12345 6 would be tr
48. 350 ohm load cells points 6 2 Chapter 6 Calibration e The expected output from each load cell point depends on the mV V rating of the load cell point and weight e For example a 2 mV V load cell point will respond with a maximum of 10 mVDC at full weight capacity of the sys tem which includes the weight of the vessel and the weight of the product as measured by the load cell point e the load cell point weight capacity is rated at 1000 pounds the load cell point output will be 10 mVdc at 1000 pounds 7 5 mVdc at 750 pounds 5 mVdc at 500 pounds and so on e zero reference point will vary from system to system depending on the Dead Load of the vessel Dead Load is the weight of the vessel and appurtenances only with no product loaded In our example we will assume the dead load to be 500 Ibs See Fig 6 2 MAXIMUM LOAD CAPACI MILLIVOLTS DC e DEAD LOAD 5001 ZERO REFERENCE PONT 7 250 500 750 1000 WEIGHT IN POUNDS FIG 6 2 MILLIVOLTS WEIGHT SCALE Based on the example the operating range for this scale is 5 10 mVdc with a 500 pound weight range Understand that after zeroing the instrument the 0 reading on the instrument refers to the zero reference point and not absolute 0 mVdc or absolute weight NOTE Load cell point measurements are checked with a digital volt meter at the summing junction box or the J1 connector on the rear panel of the HI 2151 30WC or use Inte grated Technician
49. 5 Analog Card Adjustment 4 5 Voltage 4 5 Current 4 5 Parallel BCD Board Print Configuration Procedures 2 5 B9 4 6 About the BCD Board Print Output Signal 4 6 Jumper Location See Fig 4 7 4 6 Jumper Settings See Fig 4 8 4 7 Calibration Configuration Procedures When Security Code is not Available 4 7 Dip Switch Location See Fig 4 9 4 7 Auto Zero Tolerancing Configuration Procedures 4 8 About Auto Zero Tolerancing 4 8 Dip Switch Location See Fig 4 10 4 8 Dip Switch Setting 4 8 Configuring Peak Hold Mode 4 8 About Configuring Peak Hold 4 8 Configuring Multidrop S3 1 4 9 Configuring Serial 53 3 4 9 Configuring Option 53 4 4 9 Configuring Set Point S3 5 4 9 Set Point 53 6 4 9 Configuring Lock 3 7 4 10 Configuring the Power amp Relay Board Dip Switches S2 See Fig 4 12 4 10 Keypad Functions
50. 6 9 Setting The Auto Zero Tolerance AO 6 9 Setting the Number of Readings Averaged AVRAGE 6 10 Setting the Scale Capacity SC 6 10 WAVERSAVER WVRSVR 6 11 This ends the Calibration Setup Process 6 11 Calibration Procedures 6 11 C2 Second Generation Calibration Procedures 6 12 End of C2 Calibration 6 13 Hard Calibration Procedures HDCAL 6 13 Selecting the Hard Calibration Sub Menu 6 13 Setting the Zero Calibration Value 6 13 Setting the Span Calibration Value 6 14 The Return RETURN Display 6 14 Checking for Mechanical Problems 6 14 Hard Calibration Self Test Procedures Traditional Method Using Test Weights 6 15 Perform the Hard Calibration Self Test 6 15 Soft Calibration Procedures for Single Load Cell Point Systems 6 15 About Soft Calibration 6 15 Selecting the Soft Calibration Sub Menu 6 16 Setting Sensitivity Values 6 16 Table of Contents Setting the Scale Range RANGE
51. CMD DATA MODE CR EOT HAR ADDRE MD SS D 7 D 1 1 CHK2 10 X G D 7 D 1 LborKg CRLF CHK 1 cHK2 Lb or Kg follow data In the case where return data is appropriate for the command an A is returned by the instrument in the form of START INSTRUMENT A BYTECHECKSUM CHAR ADDRESS CMD SUB CMD CR EOT CHK 1 CHK 2 gt 10 A CRLF CHK 1 CHK 2 EOT In the case of an error the message returned would be START CHAR 2 BYTE CHECKSUM INSTR CHECKSU ADDRESS CMD CMD SUB CR EOT CHK 1 CHK 2 10 N 9 9 CRLF CHK 1 CHK 2 EOT where 99 is the error number See Chapter 8 Troubleshooting Error Codes and Definitions for a breakdown of error codes The example uses decimal and mnemonic abbreviation format for clarity however the actual data would be in ASCII format 1 X Xmit When this command is issued without a sub command the type of data specified in the format command will be transmitted to the port issuing the request When this command is issued with a subcommand only the subcommand data will be transmitted Only one subcommand per command is allowed 2 Transmit data specified in SUB CMD as follows SUB CMD Meaning none A G N T DE P Default to data setup by the format command Accumulated total Gross Net Tare Deadband Preact 2151 30WC MANUAL 7 14 5 Set point DI Dipswitch L LED Statu
52. Chapter 6 Calibration The example settings provided below depict a typical system and are for illustration only your setting requirements may vary Step Make sure the controller is in Gross Mode Step 2 Press the Cal button Security Code SEC CD is displayed Step 3 Press the Enter button A flashing zero 0 appears Step 4 Enter the security code number 5321 Step 5 Press Enter The word UNIT appears Note the three leds Zero Track Motion and CTR Zero start to flash on the left side of the status display Step Press the Enter button LB appears Step 2 select pounds LB press the enter button Step 3 select kilograms press either the up or down arrow button until GR is displayed Press the enter button Step 4 unit of measure is selected and will be the basis for all set points Step 5 DECPNT appears on the display The displayed unit of measure can be changed during normal operation However all internal calculations use the unit of measure selected during calibration This parameter sets the number of decimal places to use in weight val ues Total weight may be set to a different number of decimal places Step l To determine the highest recommended decimal point divide the total load cell capacity by 10 000 and use the number of decimal places in your answer as a reference For example 10 000 EU scale divided by 10 000 1 no decimal point is recommended 100 EU load ce
53. Communications Bi directional Communications RS 232C Operation RS 422 485 Operation Description of 422 485 Transmission Modes Available RS 485 RS 422 Chapter 7 Operation Step 8 If the option for 8 relays is active enter set point parameters for relay 3 8 at this time Step 9 When the last set point parameter is entered press Exit button to return to the weight display and resume normal operations The standard serial ports are user selectable RS 232C and RS 422 485 which may be configured as a printer output port or as a bi directional communication port Transmission speed is selectable from 600 to 19 2K baud and may be configured for a continuous data output mode The port allows host computer control using ASCII character com mands and RS 422 485 ports support multiple weight controllers via a multidrop configuration One RS 232C allows serial communication from one weight controller to one peripheral device The RS 232C is user selectable as a print out put only port or as a bi directional control port through the Menu and jumper settings on the main board See Chapter 4 for configuration information The operation consists of properly executing commands over the serial port The RS 422 485 meet RS 422 or RS 485 requirements providing drive over long distances With the Hardy Link two way multidrop commu nication can take place between any of the Hardy Instruments series 2100 controllers and a h
54. Electrical Flow charts for additional tips B1 HI ERROR YES NO Y Y Customer Service Weighing 800 821 5831 Process 8 21 2151 30WC MANUAL N Blank Screen Weight Controller s front display is blank Measure A C Power 5 vdc at J6 No OK Yes Measure the excitation voltage at J1 No Yes Y Contact Hardy Instruments Customer Service 800 821 5831 Check for proper power at J6 and the source connection Check the circuit breaker at the source Check the power fuse located inside the case OK Disconnect all the connectors from the back panel except power Replace the 1 2 amp slo blow fuse i and apply power Measure the Excitation voltage at J1 5 vdc Does the fuse blows again Yes Y 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 v Monitor system for proper operation Check out complete YES Y Y Contact Hardy Instruments Customer Service 800 821 5831 NO Chapter 8 Troubleshooting O Excitation Monitor Excitation Monitor Continuously monitors the system excitation current Checking for open or shorted load sensors or damaged or broken excitation wire s This includes the
55. HI Document 0570 0016 01 for single controllers or 0575 0016 02 for multiple controllers Please photocopy as many copies of the form s as you need The down arrow pauses the test and the up arrow scrolls through the tests one at a time To review the test results Slot 1 for example Press the down arrow to pause the Self Test Press the up arrow one time and the value for Slot 1 appears for example none Write none down in the results column for Slot 1 on the Self Test Calibration form The user can continue to push the up arrow 6 17 2151 30WC MANUAL NOTE INTEGRATED TECHNICIAN IT9 Setting Resistance Baseline for Excitation Monitor Quick C2 Calibration Procedures 6 18 About Quick C2 Calibration to review more results or let the controller resume the self test until the tests are completed Step 5 There are two tests which are Pass Fail The Check Sum and the RAM test If the controller fails either one of these tests contact your local representative or Hardy Instruments Cus tomer Support Department To correct mistakes during calibration or to return to a previous calibration parame ter press the down arrow to bypass parameters press the up arrow 7 1 C2 Load Cells If C2 load cells are used in the weight control system the controller calculates the resistance value during power up and turns on the excita tion monitor 2 Non C2 Load Cells If Non C2 Load Cells are used in th
56. Hysteresis 50 mv Driver Output Capability 60 ma at 2 V differential Driver Short Circuit Limit 250 ma to 12 or 7 V Bus Loading By Unpowered Board One Receiver Load The HI 2151 30WC s serial options provide the user with a full comple ment of RS 232C RS 422 and RS 485 communications There is a standard RS 232C 422 485 serial port on the main board Each port can be an output only port to drive a printer or similar device or as a bi directional port for both status and control Below is an example of the printout with the weight controller format ted for Gross Net and Tare gt GROSS 1 430 LB NET 0 430 LB TARE 1 000 LB Hardy Instruments HI 2151 30 WC weight controller employs an ASCII command protocol and accompanying command set described in the following paragraphs The protocol is via RS 232 or RS 422 with the network being called Hardy Link Hardy Link supports a multidrop configuration e Serial Protocol Multidrop Mode Multidrop is a configuration denoting that there are multiple HI 2151 30WC units connected to a host computer whereby each HI 2151 30WC receives and sends data through a unique address The fastest possible instrument response will be from the multidrop configuration The multidrop configuration also lends itself well to host computer control of multiple weight controllers RS 422 485 is utilized and provides excellent noise immunity and drive capability sup porting long cable runs 7 9
57. Motion Tolerance must be greater than or equal to the Graduation Sizes Recommen dation would be three graduation sizes Step 2 The motion tolerance is the tolerance value used to determine if the scale is in motion Step3 The controller displays the MOTION LED when a change in the displayed averaged reading is outside the value entered Step 4 Default value is 3 units of measure Step 5 Press the Test Clr button to clear the current value Step 6 Use the numeric keys to type in the new tolerance value Step 7 Press Enter The Graduation Size GRAD is displayed The graduation size sets the minimum increment the instrument will compute and display The Base Graduation Number is calculated by dividing the total load cell capacity by 10 000 For example With two decimal points selected the graduation size 10 will display increments of 10 engineering units With two decimals points selected the gradua tion size 50 will display increments of 50 engineering units If you undersize your graduation setting to increase display resolution do not use auto zero tracking This combination will damage the SMM due to excessive write operations Step Press the Enter button The graduation size 20 appears on the display with the zero flashing Step 2 There are nine graduation size selection options 1 50 2 100 5 200 10 500 20 Setting the Zero Tolerance 0 TOL NOTE Setting The Auto Zero Tolerance A0 TOT NOTES
58. Press the Enter button The display will read NUMLS or LSALL e Number of Load Sensor NUMLS number after the NUMLS represents the number of C2 load points found NOTE Error Messages and Definitions Error Message E Hl Error Err 1 Err 2 Err 3 Err 4 Chapter 8 Troubleshooting e Press the Enter button to see the list of C2 load sensors LS1 LS2 LS3 etc e Use the up or down arrows to select the load sensor that you want to read e Press the Enter button to read the weight reading f TheIT Junction Box must be used to display individual load sensors Non C2 Load Points with the IT Junction Box The Default is 0 for NUMLSO e Press the Enter button Use the numeric key pad to enter the number of load sen sors e Press the Enter button to view the list of Non C2 load sensor LS1 LS2 LS3 etc e Use the up or down arrows select the load sensor you want to read e Press the Enter button to view the weight reading For A amp B The sense and signal load sensor lines are reconnected in the controller Next a switch in the Junction box disconnects all but one of the load sensors If the weight reading is stable the first load sensor is disconnected and the next load sensor is switched in by pressing the Enter button g LSALL Without an IT Junction Box Press the Enter button to view the weight reading for the sum of all the load sensors h Press the Exit b
59. Return To A I T Diagnostics 2151 30WC MANUAL C Guidelines for Instabilities on Formerly Operating Systems SYS TST cont REF LS Press ENTER This program checks individual Load Sensors Record Load m gt Sensor data for comparison If stable or not At the JUNCTION BOX Next Press ENTER NO loadpoint To continue checking Remove and Replace load Sensors the load sensor s determined to be faulty Repeat for all load Sensors YES NO Replace summing card SIBBEES Re install all load sensors Y TEST S gt COMPLETE If you are unable to isolate the instability Compare your results by testing the vessel when empty and then re testing under load GO TO B for additional system checks OR Contact Hardy Instruments Customer Support 800 821 5831 E Non Return to ZERO i Chapter 8 Troubleshooting Scale capacity limits at empty have been exceeded Check for product buildup The vessel must be within tolerance to Yes adjust this Gross zero reference point See box E1 for additional test NO suggestions t Select RTNTOO Return to zero Press ENTER Press TST CLR Intergrated Technician This program level checks records and compares the milli volt output of each individual loadpoint Down Arrow and S
60. Sd RS232JUMPERSETING 5 c c SH S8v ccY SH QOO oO 1 RS 422 485 JUMPERSETING 5 FIG 4 3 RS 232 DEFAULT S422 485 JUMPER SETTINGS Step 7 Ifthe controller is not in a termination position set all the dip switches to the OFF position See Fig 4 4 Step 8 If the controller is in a termination position i e at the end of the communication line set all the dip switches to the ON position See Fig 4 5 2 FIG 4 4 NON TERMINATING CONTROLLER ALL DIP SWITCHES SET IN THE OFF POSITION 4 3 2151 30WC MANUAL Analog Output Option Card Configuration Procedures B1 4 4 About the Analog Output Card Option Setting the Jumpers Disassembling the rear panel and setting jumpers 9 FIG 4 5 TERMINATING CONTROLLER ALL DIP SWITCHES SET IN THE ON POSITION Step 9 Replace the option board Step 10 Gently slide the rear panel back into the extrusion Step 11 Replace the four pan head machine screws that fasten the rear panel to the extrusion Step 12 Connect the power cord The analog transmitter outputs to a receiving device PLC Computer etc The transmitter outputs a user selectable Gross Net Rate of Change ROC Peak or Total Weight as 0 5V 0 10V 0 20mA or 4 20mA via the front panel you can reverse the voltage and current ranges See Chapter 5 for procedures When configuring the Analog O
61. See Fig 5 1 5 1 Zero 5 1 Mode 5 1 Tare 5 1 Print 5 2 Test Clr 5 2 1 Tare Val 5 2 2 Status Bar 5 2 3 Lb Kg 5 3 4l 5 3 5 3 6 Set Pt 5 3 iii 2151 30WC MANUAL Chapter 6 Calibration iv WOption 5 3 8 Cal 5 4 Of 5 4 O EXit 5 4 Enter 5 4 Block Diagram 5 5 RS 232C RS 422 485 Bi directional Serial Port Setup Procedures 5 5 Bar Graph Setup Procedures 5 6 About Bar Graph Setup 5 6 BCD Menu Setup Procedures 5 7 About BCD Communication See Section 4 for Configuration Procedures 5 7 BCD Print 5 7 Setup Procedures 5 7 Serial Port Menu Setup Procedure See Chapter 4 for Configuration Procedures 5 9 Serial Procedures 5 10 Analog O
62. Type 7 8 Cabling and Interconnecting 3 8 CAL button 4 7 CAL menu 4 7 Calibration Configuration without Security Code 4 7 Calibration Menu 5 14 Calibration Procedures 6 11 Calibration Results form 6 15 Calibration Setup Procedures 6 6 Case Dimensions 2 3 change values 7 2 Checking for Mechanical Problems 6 14 clean primary line 3 9 Clear Controller Memory 6 19 Clear to Send CTS 5 10 Cockpit Configuration Assistant 2 9 Combination Status Indicator Bar Graph LEDs 6 4 Command Meaning 7 13 command strings 7 11 Common Mode Rejection 2 2 Common Mode Voltage Range 2 2 communications ports 1 4 compact 1 1 complete hardware groups 8 1 config dip CAL switch 4 7 Configuring Lock S3 7 4 10 Configuring Multidrop S3 1 4 9 Configuring Option S3 4 4 9 Configuring Peak Hold Mode 4 8 Configuring Serial S3 3 4 9 Configuring Set Point S3 5 4 9 Configuring the Power amp Relay Board Dip Switches S2 See Fig 4 12 4 10 Conversion Rate 2 1 Current 4 5 cut off frequencies 1 2 2151 30WC MANUAL D D2 option card 3 11 Data Formats 7 10 Data Formats Binary Representation 7 10 Data Formats Weight Data Format 7 10 data status lines 3 20 DDE Installation and Operation Manual document number 0596 0221 3 22 Dead Band Limits 7 4 Dead Band Sub Menu 7 6 dead band value 7 4 deadband 1 4 default auto zero tolerance 6 9 Digital Volt Meter D V M 8 34 Digital Volt Meter DVM 1 3 Digital Voltmeter 2 2
63. aa 2 oo oo oo e to o o 8 lt TB2 BUSY t M9 9 000000 a 08 a rN OTH OR ANNKRAS ag X ox ox x eog998888xxxx 5 5 8 833585 18358238 rato 2 98 6846 898 244 Chapter 3 Installation FIG 3 14 BCD QUAD TERMINATION BOARD OPTION Step Locate a clear flat mounting area within five feet of all HI 2151 30WCs Step 2 Use the measurements shown in Figure 3 15 BCD Termina tion Board Installation Drill Template Illustration or P N 0596 0117 drill template to mark five mounting holes See Fig 3 15 Dia 1875 5 plac s FIG 3 15 BCD TERMINATION BOARD INSTALLATION DRILL TEMPLATE Step 3 Drill 3 16 inch holes where marked Step 4 Install five P N 2815 0053 standoffs in the holes Step 5 Install BCD terminal board on standoffs Step 6 Connect P N 0509 0389 01 ribbon cables between the BCD output instrument option Slot 2 of up to four HI 2151 30WCs and BCD terminal board jacks J1 through J4 Connect control lines from computer to TBI Step 7 For installations with more than four HI 2151 30WCs pro ceed as follows Step 8 Install a second BCD terminal board within two feet of installed BCD terminal board Refer to steps 1 through 7 Step 9 Connect
64. change modes press the round mode button until the desired mode display flashes Step3 To enter a new set point value press the Test Clr button Step 4 Use the numeric buttons to enter a desired set point value in our example 500 00 Step 5 Press the Enter button The controller indicates that the value was valid by briefly displaying GOOD The Dead Band Sub Menu DBND 1 appears Step Press the Enter button The Dead Band Sub Menu DBND 1 appears Step 2 Press the Test Clr button to clear the existing value Step 3 Press the Test Clr button again to enter a negative value if desired Step 4 Use the numeric buttons to enter dead band value e g 125 00 value Step 5 Press the Enter button The controller indicates that the value was valid by briefly displaying GOOD The Preact Sub Menu PRE 1 appears Step Press the Enter button Previously set preact value will be displayed For this example the preact value will be set to 20 Step 2 enter a new value press Test Clr button Step 3 Press the Test Clr button for a negative value if desired Step 4 Use the numeric buttons to enter a new preact value Step 5 Press the Enter button The controller indicates that the value was valid by briefly displaying GOOD Set Point 1 Sub Menu 1 appears Step 6 Press 0 Exit button to advance to Relay 2 RLY 2 Step 7 Repeat above procedure to enter set point parameters for relay 2 Serial
65. in the system e With an IT junction box the test will pass or fail the individual load sensors providing a true fault isolation capability e Without an IT junction box the test will pass or fail on the basis of a cumulative reading rather than an individual reading of each load sensor Requires the IT Junction Box This test does the following analysis to diagnose drifting or unstable weight reading problems 1 It disconnects the controller and engages an internal reference sig nal to see if the problem is within the instrument 2 It disconnects the load sensors and engages an internal in the junc tion box reference signal to see if the cable between the instrument and the Junction Box is causing the problem 3 It reads the weight of each load sensor to see if a load sensor might be causing the problem Weight readings from the individual load sensors makes this test useful for making cornering leveling and load sharing adjustments The Secure Memory Module stores critical HI 2151 30WC configura tion calibration and setup data excluding Peak Hold and protects it from corruption When a new parameter is entered during system oper ation the SMM automatically updates that value in its memory Since the SMM is conveniently accessible from the instruments rear panel data stored in one HI 2151 30WC may be restored to the new instru ment by physically transferring the SMM 1 3 2151 30WC MANUAL 1 4 NOTE
66. is reset to zero when the weight is within the set limits and not in motion When the Auto Zero Tolerance 0 TOT is enabled Set Dip Switch 8 See Chapter 4 any weight within the set zero tolerance limit will cause the display to automatically read zero when the scale is not in motion Normally an acceptable Zero Tolerance amount is less than or equal to 1 596 of the total load cell capacity The default auto zero tolerance is 10 units of measure and the maximum number you can enter is 32766 Incorrect graduation size or a drifting scale with auto zero tracking enabled can damage the SMM The amount of weight zeroed off is cumulative The autozero command will fail if the current gross weight plus any previously zeroed amount exceeds the zero tolerance Step Press the Enter button The default display will appear 10 or the previous set value Step 2 Press the Test Clr button to clear the current value Step 3 Use the numeric keys to enter the new value Step 4 Press the Enter button to accept the new value 6 9 2151 30WC MANUAL NOTE 6 10 Setting the Number of Readings Averaged AVRAGE Setting the Scale Capacity SC CAP Step 5 Step 6 Step 7 If the value does not exceed the maximum zero tolerance value or is not a negative value the screen will accept the new value If the value exceeds the maximum zero tolerance value or is a negative number an ERR 15 is displayed You need to change
67. load Step 2 Check for Binding on the Load Cell or other parts of the sys tem BINDING ON A SCALE VESSEL OR LOAD CELL DOES NOT ALLOW THE LOAD CELL FREE VERTICAL MOVEMENT AND MAY PREVENT THE INSTRUMENT FROM RETURNING TO THE ORIGINAL ZERO REFER ENCE POINT Aloadcell must be mounted in such a way that 10046 of the load Vessel w Contents is vertically passed through a load cell See Fig 6 1 e Check to see that nothing is binding the load cell This means that nothing is draped across the scale vessel or the load cell such as a hose electrical cord tubes or other objects 6 1 2151 30WC MANUAL Direction of the applied load Vessel FIG 6 1 PROPERLY INSTALLED LOAD CELL W NO BINDING Step 3 Check to see that nothing is coming in contact with the scale vessel other than service wires and piping that have been properly mounted with flexible connectors Electrical Check Step l Check to see that there is power to the controller Procedures e If there is power to the controller The front panel display should be lit e Ifan error message ERREXC appears in the display it means there is a problem in the system See Troubleshoot ing Chapter 8 for corrective action e If the display appears with a value the unit is ready for cali bration Step 2 Typical Load Cell Point Input Output Measurements EXC amp SIG Outputs The HI 2151 30WC is designed to supply 5 vdc excitation to as many as eight
68. or wires when disassembling or reassembling Always protect printed circuit boards from electrostatic discharge ESD Always use approved ESD wrist straps and anti static pads when working on the PROFIBUS Interface Card 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 HI 2151 30WC Always follow proper safety procedures when working on or around the HI 2151 30WC Weight Controller 8 1 2151 30WC MANUAL Trouble Shooting Using Integrated Technician Sensor signal levels established at calibration to verity bcn individual load sensor at gross zero etur to Helps in isolating vessel hinding build up sensor Zero Zero shift and load cell integrity Compares stored to actual signals DVMTST po EXE Displays individual TESTE OW aN load sensor M NU MLS gt Milli volt or milli volt volt Y signals C MV or MV gt Load Sensors Displays Individual gt sensor weight E NUM Is gt Integrated Technician See Junction Box Verifies signal cable u SISIST umi REFBOX box HI 2151 30WC gt internal INTREF gt electronics We
69. response after retries are exhausted Internally it performs the same operations as done on instrument power up Refer to the REL Sub Command under the X Xmit Serial Commands Command Set Step l The BCD option is setup by first entering the Option Menu and selecting the BCD menu The menu display shows a com bination of GNTDP gross n net T tare D display print See Chapter 5 for setup instructions Step 2 The user may select which data will be present at the output If the P or print flag is selected the data will only change at the output once the PRINT button is pressed or the remote functions print has been activated Otherwise the output will be continuous Step 3 You can trigger the output by any of the following methods By pressing the PRINT button sending a command over the serial port 2151 30WC MANUAL BCD Print Output Disable Rate of Change ROC Example 7 20 Byconnecting the remote functions print to the remote functions ground Step 4 The output can be tri stated if the OUTPUT DISABLE is brought low This is useful for multiple parallel outputs to be connected to the same device Once this input is brought high the latched data will be accessible again The PRINT output is normally low and goes high for 25 milliseconds If the oppo site polarity normally high pulsed low is desired move jumper from W1 to W2 Step The weight select mode tells
70. set the bar graph parameters by entering the lowest weight Setup value and the highest weight value of the scale or any portion of the scale When the user selects the Bar Graph function the bar graph dis plays the current reading as a percentage of the selected scale range e g 60 pounds on a scale from 0 100 Ibs will read 60 The bar graph can be setup to indicate Net Weight Gross Weight and the options Totalizer Rate of Change and Peak Keep in mind that the bar graph can be totally independent of the displayed values Step l Press the Options button The Options OPTINS sub menu appears Step 2 Press the up arrow until BAR GR appears Step 3 Press the Enter button BAR LO appears This is the sub menu to select the lowest weight in the selected scale range Step 4 Press the Enter button Step 5 Ifa value is present press the test clear button to clear the value Use the numeric key pad to enter the new low value Step 6 Press Enter to select the new value A GOOD will appear briefly if the setting is correct Step 7 BAR HI appears This is the sub menu to select the highest weight in the selected scale range Step 8 Press the Enter button 5 6 NOTE BCD Menu Setup Procedures About BCD Communication See Section 4 for Configuration Procedures BCD Print Setup Procedures NOTE Chapter 5 Setup Step 9 Ifa value is present press the test clear button to clear it Use the numeric ke
71. the Soft Calibration Process Soft Calibration Self Test Process Performing the Self Test Chapter 6 Calibration e The reference point the current live load on the scale platform Any known weight within the scale range can be used as the refer ence point The zero point no material load is recommended Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step Step 2 Step 1 Step 2 Step 3 Step 4 Press the Enter button A dash appears Press the Test Clr button to clear the entry and enter a value Use the numeric keys and enter the reference point For exam ple 0 00 Wait 12 seconds Press the Enter button A WAIT prompt appears then either a GOOD or an ERR 4 or ERR 18 appear If the GOOD appears Press the Enter button The RETURN Sub Menu appears If either of the two ERR statements occur go to Chapter 8 Troubleshooting for more details If you want to accept the Soft Calibration parameters press the Enter button The End Calibration ENDCAL message is dis played Press the Enter button DO NOT PRESS THE EXIT BUT TON This updates all the calibration parameters in the Cali bration Menu and saves the parameters to the Secure Memory Module The Weight Display appears Press the Test Clr button The Self Test SLFTST Sub Menu appears Write down all the Soft Calibration Self Test parameters on the Self Test Calibration Results form See Appendix A
72. the enclosure Drill four 156 inch either tapped or thru holes and use four 6 32 pan head machine screws to fasten the instrument to the enclosure See Fig 3 5 The enclosure can be mounted on any four 4 of the six 6 sides Step 1 Step 2 Step 3 Step 4 Make sure that all Electrostatic Discharge ESD precautions have been taken Mount the Instrument securely using all four mounting points See Fig 3 6 12 25 311 15 HI 2151 30WC r 14 75 374 65 10 00 254 00 D 9 31 7 87 4 PL FIG 3 6 INSTALLATION OF WALL MOUNT MODEL To conform to NEMA 4 or 4X ratings connections to the enclosure must be made with NEMA 4 or 4X conduit fittings Do not route any signal voltage or ground wires under or between printed circuit boards 3 7 2151 30WC MANUAL Step 5 Route wiring types through enclosure as shown in Fig 3 7 Le DISPLAY CONNECTOR J7 P7 e e REMOTE NUM T FUN
73. the output device which type of data is present Step 2 The user selects which type of data is desired by toggling under the option BCD sub menu Step 3 Ifall three types of data are requested then all three will appear on the output one after the other 10 milliseconds apart Step 4 If d is selected the output will follow the mode being dis played Data output is discontinued if the OUTPUT DISABLE pin 22 on the PWA pin 30 on the D Subminiature connector is low The data pins will be tri stated even though print pulses will be sent See Chapter 5 for Setup Procedures The Rate of Change Option is used to measure the rate at which a material enters or is dispensed from a vessel over a given period of time To develop ROC data a Register is used that is 21 entries in length New weight is input to the register at the rate of 1 20th of the Time Base The 1st register is subtracted from the 21st register The 21st reg ister is one Time Base older than the 1st register The results of this subtraction are divided or multiplied as necessary to equal the appro priate measurement time for display U SEC U MIN U HOUR In this example the units of display are units per minute U Min with a Time Base of 10 seconds Every second new data is inserted into the Ist register and old data is shifted down one register The Ist register is subtracted from the 21st register and the results are multiplied by 6 so the Time Base r
74. to the HI 2151 30WC It starts with the base model number HI2151 30WC Fig 1 1 shows dash alphanumeric code designations that indicate the capabilities of the weight controller For example A model HI2151 30WC A1 C2 D1 E3 is a Panel Mount Instrument with a factory con figured RS 232 serial port rate of change six TTL level outputs and an NTEP Certification Kit 1 7 2151 30WC MANUAL 1 8 HI 2151 30WC B3 C2 D1 E3 MOUNTING OPTIONS WC Panel Mount WC WS Wall Mount WC RM Remote Mount WC BR Blind Remote OUTPUT OPTIONS B1 Analog Output B2 BCD Data Output Tri Stated 37 pin conn w 6 Cable B5 BCD Data Output Tri Stated 60 Cable B6 BCD Single Termination Board Used w B5 B7 BCD Quad Termination Used w B5 B8 Remote Interface for Allen Bradley Network B9 BCD 24 cable wall mount version only B12 PROFIBUS Interface Option B14 Dynamic Data Exchange DDE 1 0 Server CONTROL OPTIONS C1 Peak Hold C2 Rate of Change C6 Weight Totalization SETPOINT OPTIONS D1 Six TTL level outputs w 60 unterminated cable D2 D1 a solid state relay card w 60 cable HARDWARE OPTIONS E2 240 VAC 50 60 Hz Operation E3 NTEP Certification Kit E4 Portable Display Blind Remote Only F2 NTEP Option F8 Used with Advantage load sensors and hazardous area approved load cells FIG 1 1 MODEL NUMBER BREAKDOWN Chapter 2 Specifications CHAPTE
75. 01 SB01 HI DSB01 2 501 EXC Green or Red Red Red Green Blue EXC Black or Black Black Black Black Grey Shield Orange or Orange or Orange or Orange or Yellow Clear Clear Clear TB2 4 6 8 HI LPH HI LPS HI LPD HI LPT BB01 5801 DSBO1 2 HI 501 2 Grey Grey Grey Grey 2 Violet Violet Violet Violet Sig White Green Green Green Sig Red White White White TB9 HI 2151 50WC EXC Red SEN Blue EXC Black SEN Brown Shield C2 Grey C2 Violet SIG Green SIG White The setpoint relay option board must be installed outside of the HI 2151 30WC See Fig 3 18 Step Locate a clear flat mounting area within five feet cable dis tance of the HI 2151 30WC Chapter 3 Installation PWA RELAY Op amm mw T t 5 O a 5855565 RIZ QE NM TEE gt i gt i re Quos 05 eem e 5 F4 5A F5 5A Od O FO Od O oc 5 ot 0 J3 J4 9 5 9 9 J6 J7 9 1 OO OO OO o o OO FIG 3 18 SET POINT RELAY OPTION BOARD Step 1 Use the measurements shown in HI 2151 30WC Installation Details See Fig 3 19 to make four mounting holes 2 7000 V x R0 0937 x 4 3 5000 2 2980 0 1920 0 2500 5 2000 FIG 3 19 INSTALLATION DETAILS Step 2 Drill 3 16 inch diameter hol
76. 1 2 2 1 WAVERSAVER WVRSVR 6 11 Weighing System Test 8 36 Weighing System Tests 1 3 weight differential 6 9 weight limit 6 9 When multiple load cells are used 6 16 Word length selection 5 9 X Xmit 7 13 Z Zero 5 1 ZERO button 7 1 Zero Key 5 1 zero reference point 6 3 Zero Sub Menu 6 14 Zero Tolerance amount 6 9 Index 2151 30WC MANUAL Appendix A System Data Survey Sheet SYSTEM DATA SURVEY SHEET TO Hardy Instruments Inc FROM ATTN Customer Support COMPANY FAX NO 858 278 6700 DATE Make a copy of this page and store it in a safe place This information helps us assist you if for any reason you need to consult Hardy Instruments Inc DATE OF INSTALLATION INSTRUMENT MODEL NUMBER INSTRUMENT SERIAL NUMBER The serial number is located on the back panel of the instrument CORNER FREQUENCY SELECTED LOAD CELLS Model Rated Capacity Number of Load Cells mv V Rating Type of Vessel Hopper Deadload or weight of vessel RESULTS OF SELF TEST Press the Test Clr button on the keypad while in the operating mode and record the results on the following page Use the down arrow to pause the display and the up arrow to resume the self test 2151 30WC MANUAL Accuracy Analog Shield Can Analog Transmitter Appurtenance Baud Rate BCD Bi Directional Clear Key CTS Dead Band Dead Load Decimal Point
77. 2 5 5 1 4 4 5 Enclosure and circuit with nine mating connectors installed 1 diameter push in plugs 1 12 diameter rubber gaskets 0 5 diameter steel locknut fasteners NPT nylon cord grip strain relief 375 500 Blue Grip NPT nylon cord grip strain relief 375 500 White Grip 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 4900 FAX 858 278 6700 Web Site http www hardyinst 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 Chapter 3 Installation Installing the HI 2151 30WC in a Panel Panel Cutout 1 Enclosure Size Requirements Specifications e Overall depth of the enclosure must be a minimum of 11 5 to allow for the 2 clearance between the rear panel of the HI 2151 30WC and the inside surface of the rear panel of the enclosure See Fig 3 1 There must be 1 clearance completely around the bezel and other installed units Bezel Rear Pane ZR 2 0 Front Panel FIG 3 1 2 REAR PANEL CLEARANCE REQUIREMENT 2 Dimensions of the enclosure cutout See Fig 3 2 e 5 75 06 146 05mm 1 52 Wide 3
78. 3 Check for correct setting of Config dipswitch S3 See Chapter 4 Configuration The HI 2151 30WC should have a quality power conditioning product installed between the controller and the AC power source to reduce the likelihood of faults caused by poor or intermittent AC power 2151 30WC MANUAL 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 snubbing network in parallel with the Silicon Controlled Rectifier SCR which does the actual switching This network presents an impedance of 30K ohms which means with 120 volts across it will pass 4mA of AC current HOT SOLID STATE RELAY 15000 ohm RELAY COIL NEUTRAL FIG 8 2 SCR SWITCHING LOAD CIRCUIT 1 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 resis tor in parallel with the light load to be sure leakage current is suffi
79. 7 20 ROC LED 5 13 Route wiring types 3 8 RS 232 1 4 RS 422 1 4 RS 422 485 ports 4 3 RS 485 1 4 RS 232C 7 7 RS 232C RS 422 485 Bi directional Serial Port 5 5 RS 422 485 7 7 RS 422 485 Configuration Wiring 7 8 RS 422 485 Electrical Specifications 7 9 RS 422 485 Wiring and Electrical Specifications 7 8 S Secure Memory Module SMM 1 3 Selecting the Hard Calibration Sub Menu 6 13 Selecting the Soft Calibration Sub Menu 6 16 Self Test 8 25 self test program 8 25 sequential tests 8 25 Serial Commands 7 11 Serial Commands Data Transmission Format 7 11 Serial Commands Command Set 7 12 serial communication parameters 7 11 Serial Communications 2 5 7 7 Serial Connector 7 8 Serial Port 1 4 Serial port configuration 5 9 Serial Port Menu Setup Procedure See Chapter 4 for Configuration Procedures 5 9 Serial Procedures 5 10 Serial Protocol Multidrop Mode 7 9 Set Point Limits 7 4 Set Point Options 1 6 Set Point Relay Option Board Installation D2 3 22 Set Point S3 6 4 9 Set PointRelays 1 4 Set Points 7 4 Set Up for Profibus Interface Card Option B12 5 14 Signal Grounds 7 8 Six External Solid State Set Point Relays D2 amp D3 2 9 Six TTL Level Outputs D1 2 9 Six wire shielded load cell point cable 3 13 sliding average 6 10 SMM 1 3 socket 3 16 Soft Calibration S CAL 6 11 Soft Calibration Procedures for Single Load Cell Point Systems 6 15 Soft Calibration Self Test Process 6 17 s
80. A 4 amp 4X Case Dimensions 3 23 H x 5 74 W x 10 40 D 82 04mmH x 145 8mmW x 264 2mmD Front Panel Dimensions 3 74 H x 7 00 W x 0 42 D 95mmH x 177 8mmW x 10 67mmD Panel Cutout Dimensions 3 09 H 5 75 W 78 4mmH x 146mmW Weight 4 6 pounds 2 1 Kilograms NEMA Ratings e Case None 2 3 2151 30WC MANUAL Blind Remote Mount HI 2151 30WC BR Portable Display HI 2151 30X X EA use with HI 2151 30WC BR IT Junction Box HI 215IT SS or PS Series IT Junction Box HI 215IT FG Series 2 4 e Font Panel NEMA 4 seal Cable 5 foot flat ribbon Case Dimensions 3 23 H x 5 74 W x 10 40 D 82 04mmH x 145 8mmW x 264 2mmD Weight 4 5 pounds 2 04 Kilograms Enclosure Rating None Case Dimensions 4 72 H x 7 39 W x 2 06 D 11 89mmH x 187 71mmW x 52 32mmD Weight 1 08 pounds 0 49 Kilograms Enclosure Rating None Cable 72 L Case Dimensions 6 25 H x 6 25 W x 4 50D 158 75mmH x 158 75mmW x 114 3nmD Weight 5 pounds 2 27 Kilograms Enclosure Ratings SSStainless Steel NEMA 4 amp 4X e PSPainted Carbon Steel NEMA 4 Case Dimensions 6 50 H x 8 0 W x 4 46D 165 1mmH x 203 2mmW x 113 28mmD Weight Approvals Serial Communications Bi Directional Communications Optional Equipment Analog Output B1 Chapter 2 Specifications 5 pounds 2 27 Kilograms Enclosure Rating Fiberglass NEMA 4 UL Certification CSA Certification Factory Mutual FM C
81. BCD Single Termination Card is an optional external interface point for a single BCD port signal line The card is designed for use with a single HI 2151 30WC B5 instrument The BCD Quad Termination Card is an optional external interface point for up to four sets of BCD port signal lines All terminal positions accept 20 to 26 gauge cable sizes Additional terminal boards may be interconnected to allow multiple BCD ports to exist in a tri state arrangement The RIO port allows bi directional communications with Allen Brad ley Programmable Logic Controllers PLC and Small Logic Control lers SLC Supporting up to 230 4 Kbaud transfer rates and both discrete and block data transfers the HI 2151 30WC represents a quar ter rack of discrete I O 32 bits in the Logic Controllers output and input image files to the Logic Controller This option provides six digits of parallel weight data representing Net Gross Tare and the present front panel display If all types of output data are requested they appear one after the other ten milliseconds apart This option provides a 24 inch cable for use with the HI 2151 30WC WS wall mount controller 1 5 2151 30WC MANUAL PROFIBUS Interface Option B12 Dynamic Data Exchange DDE B14 NOTE Control Options Peak Hold C1 Rate of Change ROC C2 Set Point Options TTL Transistor Transistor Logic Level Output D1 External Setpoint Relays Card D2 Al
82. CTION eto bea LOAD SERIAL o 1 AC CELL a INTRIN 731 FK ENTRY OPTION intrinsic saret fe d WIRE BARRIER OPTION Js A ENTRY m 4 c B OPTION OPTION a 25 1 PORT 2 isa L Ee 8 Lll POWER Pur 9 J WIRE zn l 7 ENTRY 26 5 lo o RELAY Bie o e TZ WIRE RELAY ENTRY F OPTION pa 9 n 1 E Ue r S 28 Lo FIG 3 7 WIRE ROUTING FOR WALL MOUNT MODEL WARNING DO NOT MOUNT THE HI 2151 30WC CONTROLLER NEAR HIGH MAG NETIC FIELD OR 120 VAC POWER SOURCE ROUTE RIBBON CABLE A MINIMUM OF 3 INCHES FROM ANY AC VOLTAGE CONDUCTING CABLES TO DO SO WILL EFFECT THE PERFORMANCE OF THE CON TROLLER AND MAY RESULT IN PROPERTY DAMAGE Electrical Installation Cabling and Interconnecting Recommended 1 Carefully plan the cable runs and wiring connections before rout Installation ing cutting and trimming cables and wires Procedures CAUTION INSTRUMENT POWER AND RELAY WIRES SHOULD BE ROUTED AWAY FROM ALL OTHER SIGNAL CABLES TO AVOID ELECTRICAL INTER FERENCE 2 All cabling should be neatly bundled tied and dressed 3 Use a6 inch service bend to relieve stress on the connectors and to ease servicing the unit 4 Make sure that all plugs are firmly in place Secure the power cord with the two captive screw on clips connections are made at the rear panel of the weight controller 3 8 Input P
83. D DBCONNECTOR SIGNAL VALUE 21 11 BCD digit 3 bit 1 2x10 23 12 BCD digit 3 bit 2 4x 107 25 13 BCD digit 3 bit 3 8 x 10 27 14 BCD digit 4 bit 0 1 x 10 29 15 BCD digit 4 bit 1 2x10 31 16 BCD digit 4 bit 2 4 x 103 33 17 BCD digit 4 bit 3 8 x 10 35 18 BCD digit 5 bit 0 1 x 10 37 19 BCD digit 5 bit 1 2x 10 2 20 BCD digit 5 bit 2 4 x 10 21 BCD digit 5 bit 3 8 x 10 2151 30WC MANUAL 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 BCD Terminator Boards B6 B7 BCD Termination Board Installation Procedures See Fig 3 14 22 BCD digit 6 bit 0 1 x 10 23 BCD digit 6 bit 1 2x10 24 BCD digit 6 bit 2 4 x 10 25 BCD digit 6 bit 3 8 x 10 26 5V OV 27 OVR 28 WEIGHT SELECT LSB SEE CHART 3 3 29 WEIGHT SELECT MSB SEE CHART 3 3 30 OUTPUT DISABLE 31 not used not used 33 MOTION 5V in motion 34 PRINT PRINT not used 36 LB KG 37 GND not used PIN MODE 28 29 0 0 GROSS 0 1 NET 1 0 TARE TABLE 3 3 WEIGHT MODE UNIT1 UNIT2 UNIT3 x 5 5 E E E E 2 2 z 6 o 2 5 5 5 5 bog oa oo oo ook oa oa oa oo oa oa oa oo oo oa oo oo oo oa oo oa oa oo ee oa aao oo ao oo oo oo EE oo oo oo oo oo oo oo oo oo na oo oa oo oa oo Bg aao aao oo oa oo oo oo oo oo oa oo oa oo oa oa oo oo na B t oo oo oa eg oa oa
84. D if value is a valid entry Step Step 2 Step 3 Step 4 To select Rate of Change Mode Push the MODE button until the ROC LED indicator is lit Press the 7 Option button ROC appears Press the Enter button UNITS appears Press the Enter button U SEC appears Previously set time value will be displayed For this example the time value will be set to seconds 2151 30WC MANUAL NOTE TOTAL Setup Procedures Set Up for Profibus Interface Card Option B12 Allen Bradley Remote I O Option B8 5 14 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Use the up T or down arrows J to select the appropriate mea surement of time seconds U SEC minutes U MIN or hours U HR Press Enter button BASE appears Press the Enter button Use the up or down arrows to select time base from one of the following 1 2 3 4 5 6 10 12 15 30 60 120 240 450 900 or 1800 Press the Enter button The UNITS re appears Press the Exit button twice to return to the weight display Display may vary depending on which options were installed in your instrument The HI 2151 30WC will show the first available option in this case ROC Step Step 2 Via the Calibration Menu select the desired decimal point position To add weight value to the Total Register The current net weight displayed will be added to the net weight accumulated in the total register when the total remote function input i
85. Discharge ESD precautions have been taken before installation Step2 The controller comes with a NEMA 4 rated compression gas ket Make sure this gasket is properly seated in the bezel before installation Step 3 The front panel comes with two mounting brackets mounted on the bezel Remove the nuts that fasten the brackets to the bezel and remove the brackets Step 4 Gently slide the front panel into the enclosure cutout until the gasket is seated against the front of the enclosure See Fig 3 4 The nuts on the mounting studs barely clear the cutout It might take a little adjusting to get the bezel into the cutout Step 5 Place the brackets 6 flat washer lock washer and hex nut on the four bezel studs Step 6 Make sure that the bezel is centered in the cutout 2151 30WC MANUAL 4 6 32 HEX NUTS 4 6 SPLIT LOCK WASHERS CUSTOMER MOUNTING PANEL 42 10 59 au 2 MOUNTING BRACKETS O I I B 4 6 FLAT WASHERS INCLUDED IN 0519 0514 01 REMOTE DISPLAY ASSY SS el 1 1 B 0509 0431 REMOTE DISPLAY RIBBON CABLE x LENGTH 55 00 1397 00 FIG 3 4 MOUNTING REMOTE DISPLAY TO ENCLOSURE Step 7 Tighten the 6 hex nuts finger tight in turn Step 8 Usea nut driver or box end wrench to tighten the nuts in turn so that the bezel is flush against the front surface of t
86. EC CD displays Press the Enter Button A flashing zero 0 appears Enter the security code number 5321 then press the Enter button The Unit of Measure UNIT Sub menu appears Press the down arrow J until the CALSub Menu appears Press the Enter button The Hard Calibration HD CAL Sub Menu appears Hard Calibration requires a zero point and the physical place ment of test weights on the scale Press the Enter button The ZERO sub menu appears Remove all weight live load from the scale Press the Enter button A dash appears Press the Test Clr button A appears Wait 12 seconds Press the Enter button Either a GOOD or ERR appears If an ERR number appears go to Chapter 8 Troubleshooting for more information 2151 30WC MANUAL NOTE Setting the Span Calibration Value NOTE The Return RETURN Display Checking for Mechanical Problems NOTE 6 14 Step 8 Ifa GOOD appears the Span SPAN display appears The resistance baseline for non C2 load cells is also set when the Zero Calibration Value is entered See Section 5 for more information Step Place a certified test weight on the scale Step 2 Press the Enter button A dash appears Step 3 Press the Test Clr button The previous span value appears Step 4 Press the Test Clr button 0 appears Step 5 Use the numeric keys to enter the value of the test weight If a 50 Ib weight is used enter 50
87. MEMORY IS CLEARED ALL OPERATING SETTINGS ARE RETURNED TO THE ORIGINAL FACTORY DEFAULT PARAMETERS ALL CALIBRATION OPTION AND SET POINT VALUES SHOULD BE RECORDED BEFORE CLEARING MEMORY OR THE CONTROLLER WILL HAVE TO BE RE CALIBRATED Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 Step 16 Contact Hardy Instruments Customer Support Department for instructions to clear controller memory Re enter the original Set point and Option parameters on the Self Test Calibration form Re enter the Calibration parameters From the CAL menu press the Enter button The Hard Cali bration Sub Menu HD CAL appears Press the Mode button The Zero Count sub menu ZR CNT appears Press the Enter button Enter the ZR CNT self test parameter from the Self Test Cal ibration form Press the Enter button The Span Sub Menu SPAN appears Press the Enter button Enter the SPAN self test parameter from the Self Test Cali bration form Press the Enter button The Full Scale Count FS CNT Sub Menu appears Press the Enter button Enter the FS CNT self test parameter from the Self Test Cal ibration form Press the Enter button The RETURN display appears Press the Enter button to set the parameters the END CAL display appears Press the Enter button to save the updated parameters to the SMM and return to the weight dis
88. N appears then the Bi directional or Print appears BI DIR or PRINT Use the up or down arrows TJ to choose between bi direc tional BI DIR or PRINT We used bi directional for the example below Press the Enter button twice First the Serial Type Sub Menu SERTYP appears then the Configured Serial Protocol appears For Example RS 232 See Chapter 4 for Configura tion Information If the Serial Protocol number displayed is not the one you want STOP the setup pro cess Reconfigure the serial protocol See Chapter 4 and begin the setup procedures again Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Press the Enter button twice First the Baud Rate Sub Menu BAUD appears then the current preset BAUD rate is dis played Use the up or down arrow buttons to select 1200 2400 4800 9600 or 19 200 The example uses 19 200 BAUD Press Enter twice First the Frame sub menu FRAME appears then 8 N 1 appears Press the down arrow J button five times First 7 0 1 appears then 7 E 1 appears then 8 N 2 appears then 8 0 1 appears and finally A E 1 appears The down arrow is used to select the Frame you want When the frame selection you want appears press the Enter button FORMAT appears Press the Enter button Gross Net Tare Rate of Change Set Point Print either one G or any combination such as G T or all GNTRSP may appear Use up arrow T to select P to output on d
89. NG THE INSTRUMENT Step Disconnect the power cord Step 2 Detach all interconnect cabling Step 3 Use a phillips screw driver and remove the four pan head machine screws that fasten the rear panel to the extrusion Step 4 Gently pull out the rear panel with the printed circuit boards attached The main board is in clear view Step 5 Remove the appropriate option cover from the rear panel Option 1 or Option 2 cover as required Option 1 cover has NOTE Options Cabling and Interconnect Analog Output Option B1 See Fig 3 12 Chapter 3 Installation two perforations to allow for installation of different options See Fig 3 11 Step 6 Each Option Board is furnished with four mounting screws to secure it to the main board The main board has pre mounted standoffs which accept any of the Option Boards in either position 1 or position 2 Note however the BCD board may be installed only in the Option 2 slot which is sized for the BCD connector Remove for Profibus Remove for BCD option in Option Option 2 slot Option Option Cover Eine Remove for Analog Option in Option 1 Slot or AB RIO FIG 3 11 OPTION LABEL COVER Pin number 1 will always be on the left side of the unit when facing the rear panel except for the parallel BCD board Step 7 Position the Option Board over the standoffs and carefully align the mating connector pins of the Option Board with the
90. ON INSTALLATION BLOCK DIAGRAM 3 20 RIO CARD PIN LAYOUT 3 21 SET POINT RELAY OPTION BOARD 3 23 INSTALLATION DETAILS 3 23 STANDOFF ASSEMBLY 3 23 SECURE MEMORY MODULE 3 24 INSTALLING AND REMOVING THE SECURE MEMORY MODULE 3 24 CHAPTER 4 SYSTEM MAIN BOARD JUMPER AND DIP SWITCH LOCATIONS 4 1 CONFIGURATION REMOVING THE REAR PANEL 4 2 RS 232 DEFAULT 5422 485 JUMPER SETTINGS 4 3 NON TERMINATING CONTROLLER ALL DIP SWITCHES SET IN THE OFF POSITION 4 3 TERMINATING CONTROLLER ALL DIP SWITCHES SET IN THE ON POSITION 4 4 ANALOG OUTPUT BOARD 4 6 BCD CARD JUMPER LOCATION 4 6 BCD JUMPER SETTINGS 4 7 CAL TOGGLE SWITCH LOCATION 4 7 AUTO ZERO DIP SWITCH SETTING 4 8 PEAK HOLD MODE DIP SWITCH LOCATION 4 9 POWER amp RELAY BOARD DIP SWITCH LOCATION 4 10 CHAPTER 5 SETUP FRONT PANEL 5 1 FRONT PANEL GRAPH DISPLAYED 5 3 CHAPTER 6 CALI PROPERLY INSTALLED LOAD CELL W NO BINDING
91. P N 0509 0389 02 ribbon cable from J5 on one BCD terminal board to J5 on the other BCD terminal board Step 10 Connect data status lines from BCD terminal board to com puter See Fig 3 16 e Wire Size 26 AWG to 20 AWG 2151 30WC MANUAL Allen Bradley RIO Interface Option B8 3 20 UNIT 1 UNIT 2 UNIT 3 LUE LAE BCD J BCD z UNIT 1 CONTROL CR TERMINAL UNIT 2 CONTROL MAIN FRAME BOARD Ti UNIT 3 CONTROL COMPUTER 1 UNIT 4 CONTROL i pon e U 3 J5 EXPANSION iy BCD UNIT 5 CONTROL i TERMINAL UNIT 6 CONTROL iid Hes BOARD us UNIT4 7 CONTROL 2 UNIT 8 CONTROL 8 gt Lo FIG 3 16 BCD TERMINATION INSTALLATION BLOCK DIAGRAM Refer to Hardy Instruments HI 2151 Series Weight Controllers Remote Installation and Operation Manual Document Number 0596 0173 for installation instructions The Allen Bradley RIO card can be mounted in either option slot one or two However there is a limit of one RIO card per instrument See Fig 3 17 Chapter 3 Installation FIG 3 17 RIO CARD PIN LAYOUT Connector Wiring 1 Blue 1 2 of twisted pair 2 Shield outer braided cable sh
92. Position Dip Switch Display Engineering Units Electrostatic Discharge ESD Enter Key EPROM Error Even Excitation Full Scale Graduation Size Appendix B Glossary ot Terms GLOSSARY OF TERMS Closeness of a reading to the actual value of the quantity being measured ALARM Indication of a tolerance deviation A metal enclosure placed over the analog section of the electronics to prevent radio frequency interference An option card which outputs an analog representation of net gross total weight or rate of change data Any added equipment other than the weigh vessel platform scale or feeder Baud rates are used as a measure of how fast serial data is transmitted BIT SEC Binary Coded Decimal a type of positional value code in which each decimal digit is binary coded into 4 bit words A capability used to transmit data in either direction at the same time for example to or from the instrument A key used to clear data or formats entered into a menu Clear to send an RS 232C level signaling a readiness to accept data A value used to prevent relay chatter once the setpoint is reached Weight of hopper assembly or platform assembly sitting on top of load cells Menu item used to set the decimal point position for all display readouts A switch installed in a circuit card with several individual switches built in Used to set different options in a system A device used to show information from th
93. R 2 SPECIFICATIONS Chapter Two covers the specifications for the HI 2151 30WC weight controller and optional equipment The specifications listed are designed to assist in the installation operation and troubleshooting HI 2151 30WC Specifications for a Standard Instrument Conversion Rate Resolution Excitation Voltage Averages Input Display Display Increments Graduations Key Pad Standard Setpoint Relays Non Linearity Maximum Zero Tolerance WAVERSAVER 20 updates per second Displayed 1 985 000 3 mV V 1 656 000 2 mV V Internal 1 1 048 576 0 5 VDC to 200 User Selectable in single Increments Up to eight 8 350 ohm Full Wheatstone Bridge Strain Gauge Load Sensors Cells 5 volt excitation on one vessel Signal Voltage Range0 15mV 6 digit 14 segment red LED 0 6 alpha numeric Bar Graph 30 segment LED 1 2 5 10 20 50 100 200 500 user selectable via the front panel key pad Corresponding weight is dependent on the decimal point location 16 tactile keys 6 dedicated functions 10 dual numeric and function 2 Standard SPDT Form C Relays Wire Size 12 AWG Maximum Maximum Switch Current 5 Amps Maximum Switch Power 150 Watts or 1250 Volt Amps Maximum Switch Voltage 5 Amps 3 VDC or 125 VAC 0 001546 of Full Scale 32766 7 5 Hz 3 5 Hz 1 0 Hz 0 5 Hz 0 25 Hz 2 1 2151 30WC MANUAL Excitation Monitor Digital Voltmeter Power and Utility Requirement
94. SUB CMD data as follows SUB CMD Meaning 5 xxxxxxx Set point value D y Deadband value xxxxxxx Preact value XXXXXXX is up to a seven digit ASCII value y is the Set point Relay number The above xxxxxx data may be followed by a MODE as follows Mode Meaning Mode Meaning N Net T Total G Gross P Peak R ROC 2151 30WC MANUAL For example to set point one to 1000 Lbs gross on instrument number 10 the outgoing command would be as follows START INSTRUMENT SUB TRE 2 BYTE CHEGKSUM CHAR ADDRESS CMD CMD CMD DATA MODE CR EOT D 7 D 1 1 CHK 2 10 5 5 1 1000 G CR CHK 1 CHK 2 EOT NOTE The example uses decimal and mnemonic abbreviation format for clarity however the actual data would be in ASCII format 7 18 Command C SUB CMD M U H Command A SUB CMD T Z Command P1 or P2 Meaning Allows you to change modes between Net Gross Ib kg or Hold Unhold Display Meaning Toggles between Net and Gross weight mode Unit toggles between Lbs and Kg Toggles between display hold and unhold Meaning Used to auto tare or auto zero the instrument Meaning Auto tare the instrument Scale must not be in motion Auto zero the instrument Scale must not be in motion and mode must be set to Gross Print command Functionally the same as the print button on the key board The data setup through the format c
95. TWEEN Chapter 3 Installation 120 VAC AND 240 VAC REQUIRES MODIFICATIONS AT THE FACTORY FOR FURTHER HELP CONTACT CUSTOMER SUPPORT C2 Load Cell Step Attach load cell cable shield under screw near J1 on back of Connections J1 weight controller See Fig 3 9 WEIGHT 0535 0465 f rev f s O Optional CONTROLLER 8 8 8 8 29 ei ajr AUXILLARY JUNCTIOI INSTRUMENT 1 2 1 4 BOX 2 4 exc OJ amp xe O e Pe O JUNCTION BOX CONNECTOR si m TS Tos 17 FOR 5 OR MORE E si SUMMING LOAD CELLS OR 5TH LOAD CELL 4SEN TB6 exc oja Toja o c2 c2 c2 c2 1 o mw Jesi 2 sic4 O 2 J sic4 le D x O00 OOO O00 000 E c T s Ls 2 H L ooo GREG EEA EEA SI Ee 290 299 999 99 747 e f SECOND HEX Ci INSTRUMENTS TION ew LOAD CELL 1 LOAD CELL 2 LOAC CELL 3 LOAD CELL 4 FIG 3 9 C2LOAD CELL CONNECTION Step
96. YLNI LSLSAS OOLNLY IT Test Menu Breakdown 159 5 5 dnyes sapun peioejes jurod euuroep Buisn juBieM e dsip IM uomeiqieo Suunp yAnisues uiejs s pue 92 19 09 eundeo 3t 104 9 ON 159 45 XXXXX TIY SI XXXXX vs XXXXX_ 251 XXXXX 2S1 XXXXX LST sesed XXXXX TY S1 XXXXX 51 XXXXX S1 XXXXX cs XXXXX_ 0197 aay Buipeei Aw eseq e dsip Ajuo HWM uogelquyeo oJez pee oneuoiny 9197 0 uma LST eug AW WAG AAW WAG LSLWAG WAC uopng 159 Hd H D 4009 1591 XXXXX peas XXXXX 5 JI 0113 m cL_IVANI 5 L 07 034 Pelee NONWOX3 Ll Ayunoag uonoeg 1591 LI YO s uo pue
97. able 3 1 Al A2 A3 J3 RS 232 RS 422 RS 485 Pins Signal Signal Signal 1 Cts Tx 2 Rts Tx Tr 3 Rxd Rx N C 4 Txd Rx N C 5 Gnd Gnd Gnd TABLE 3 1 FACTORY CONFIGURATION Wire size 22 AWG minimum to 12 AWG maximum For WS wall mount models route the wiring to J3 through the upper left side enclosure access hole when facing the front of the enclosure Some functions are level conditions and some are activated by momentary grounding Both use the remote functions ground found on pin 9 Wire Size 22 AWG Min to 12 AWG Max Shielded 2151 30WC MANUAL Momentary Functions require 100 mSEC or greater contact to ground for proper activation Use remote functions ground only for activating remote functions e For the WS wall mount version route the wiring to J2 through the enclosure access hole upper left side when facing the front CAUTION REMOTE FUNCTIONS ARE NOT ISOLATED DO NOT BUNDLE WIRING FROM REMOTE FUNCTIONS WITH POWER CABLE RELAY CABLE OR WITH ANY OTHER HIGH ENERGY CABLES USE SHIELDED CABLE 50 OR LESS TO DO SO MAY RESULT IN UNSTABLE PERFORMANCE Load Cell Point Connections J1 About Load Cell The unit is capable of powering a maximum of eight 350 ohm load Wiring cells points If more than eight load cells points are used an external power supply is required Figures 3 9 3 10 Load cell point connec tions J1 shows how to connect a full six wire hoo
98. ad cells installed in the sys tem do the following 1 2 3 Press the Enter button Press the Exit button three times Press the Tst Clr button The Self Test SLFTST menu appears Press the Enter button to perform the Self Test The Self Test will give the serial numbers of the load cells that are found by the instrument If one of the serial numbers is not found it means that a load cell is not communicat ing with the instrument Verify that the load cell wires are properly connected See the Load Cell certificates for color code information The controller can detect up to 8 C2 load point cells on one vessel The load points cells are detected during power up 5 Press the Enter button The Reference Point REF PT sub menu appears Step 4 Setting the Reference Point REF PT Press the Enter button Press the Tst Clr button to clear the current entry Use the numeric keys to enter the reference weight or use the default reference weight 0 by pressing the Enter but ton Any known weight within the scale range can be used as the reference weight The recommended and default value 15 zero 0 Make sure that there is no vibration on or around the scale vessel or is as low as possible Press the Enter button The RETURN display appears Step 5 Using the Return button RETURN l If you want to change any setting s in the C2 Calibration procedures push the up arrow which takes you back to t
99. added capabilities They are easily installed into the option board slots labeled Option 1 and Option 2 on the rear panel of the instrument If your options have already been installed at the factory move on to Set points The options are implemented by installing the appropriate optional cir cuit board onto the main analog digital board in the instrument See Chapter 3 for installation instructions The following option boards are available for the HI 2151 30WC Analog Output board voltage and current outputs Net Gross Total ROC or Peak Hold Prt 0551 0326 model 2151 30 7 3 2151 30WC MANUAL NOTE Set Points About Set Points NOTE Set Point Limits Dead Band Limits 7 4 if ordered e Parallel BCD board tri stated With 6 cable P N 0551 0327 model HI2151 20XX B2 With 24 cable Prt 0509 0389 02 model HI 2151 30X X B9 With 60 cable Prt 0551 0330 model HI2151 30XX B5 e Allen Bradley RIO Prt 0551 0351 model HI2151 30XX B8 PROFIBUS Field Bus Interface Prt 0535 0439 model HI2151 30XX B12 e DDEI O Server Prt 0551 0419 01 HI2151 30XX B14 e Setpoint Option Card Prt 0551 0288 model HI2151 30XX D2 Option slots are labeled on the top circuit board as follows READ PANEL LABEL 26 PIN CONN NUMBER Option 1 J5 Option 2 JA Output Option Boards may be ordered and installed into these slots as follows BOARD QUANTITY OPTION SLOT Analog 2
100. aged peak hold Off is instantaneous peak hold NBS NBS Re Cal toggle switch Spare Spare Spare Spare Meaning Excitation Monitor ERR OKK OFF E serial command Results Description OKK No Errors Detected ERR Error Detected OFF IT is Not Turned On I Load cell input command Used primarily to check the analog input section of the unit The command will return the number of averaged counts that is currently being read from the load cell input 2151 30WC MANUAL SUB CMD Meaning REM Level status of the Remote Input connector J2 pins Bit Remote Function Bit Remote Function 01 Rate of change 10 Net 02 Totalizer 20 Lbs Kgs 04 Display Hold 40 Tare 08 Option Hold 80 Print 5 Q The query command obtains a block of information as follows SUB CMD Meaning Gross weight 6 bytes plus label Net weight 6 bytes plus label Peak gross value reached 6 bytes plus label Internal counts 6 bytes Total net accumulation 6 bytes plus label Rate of change value 6 bytes plus label Not Used 6 bytes set to 000000 Not Used 6 bytes set to 000000 LED status 4 bytes Relay status 2 bytes toe um me creo Command Meaning F Format the output data Used to configure data to be sent on a TRANSMIT or PRINT request The SUB CMD letters can be issued in any combination or order and are as follows SUB CMD Meaning G Gross N Net T Tare R ROC S Set point Deadband Preact NOTE The last 6th p
101. alog serial and BCD communications The weight controller can also be 1 1 2151 30WC MANUAL used as a front end for a control system transmitting weight values via a standard operator selectable serial port RS 232 RS 422 485 to pro grammable logic controllers PLC s computers and printers Data is displayed alpha numerically on the six digit fourteen segment LED display and graphically on the 30 segment bar graph display Weight values can be based on either net gross Rate of Change ROC peak hold or totalized weight values in pounds or kilograms An optional Allen Bradley Remote I O and PROFIBUS interface is available for communication to programmable logic controllers The weight controller s 20 bit analog to digital converter updates twenty times per second and is capable of 985 000 counts of display resolu tion This provides enough resolution for accurate weight measurement and enough control to tolerate large dead loads and over sizing of load cells sensors Users can enter commands either from the commu nication ports or locally from a sixteen button front panel keypad A portion of the keys can be locked out to limit operator access and pro tect data A limited number of commands can be entered through a rear Remote Functions connector WAVERSAVER Typically mechanical noise from other machinery in a plant environ ment exists in all industrial weight control and measurement applica tions WAVERSAVER
102. artment Soft Cal is a procedure that quickly calibrates a scale system on site without test weights material substitution or forced calibra tion The process uses the certified full scale mV V output sensitivity and range of each load cell The full scale mV V output of each load cell is mathematically combined with a measured reference point usually but not always Zero to calibrate the scale The full scale mV V data is on the calibration certificate which is shipped with every Hardy load cell The process assumes a consistent center of gravity on the scale with even distribution 2151 30WC MANUAL NOTE NOTE 6 16 Selecting the Soft Calibration Sub Menu Setting Sensitivity Values Setting the Scale Range RANGE e All load cells must be correctly installed with no binding of any kind on the scale e You must use the same length cable as supplied with the load cell DO NOT CUT THE CABLE e A multiple load cell system using a junction box all balance poten tiometer and resistors must be zero For multiple load cell systems contact your local dealer or Hardy Instruments Cus tomer Support Department The Soft Cal menu cannot be entered while in the National Bureau of Standards NBS mode Step l From the Weight Display Press the 8 Cal button The Unit of Measure UNIT Sub menu appears Step2 Press the down arrow until the CAL Sub Menu appears Step 3 Press the Enter button T
103. ave 1 HI 2151 30WC Panel Mount 1 1 HI 2151 30WC instrument with mating connectors and ordered options installed Mounting Rail Kit Prt 0551 0287 01 4 mounting Rails 4 6 32 UNC phillips pan head machine screws Installation and Operation Manual 2 HI 2151 30WC RM Remote Mount 1 1 1 Instrument with mating connectors and ordered options installed Remote display keypad with gasket and mounting hardware attached 60 inch display to instrument interconnect ribbon cable Installation and Operation Manual 3 HI 2151 30WC WS Wall Mount 1 1 Instrument with mating connectors and ordered options installed Installation and Operation Manual 4 HI 2151 30WC BR Blind Remote 1 1 Instrument with mating connectors and ordered options installed Installation and Operation Manual 3 1 2151 30WC MANUAL Mechanical Installation 3 2 5 Dynamic Data Exchange DDE I O Server B14 p p Lm DDE Server Software Diskette 6 foot test cable 9 pin to 25 pin adapter Installation and Operation Manual 6 HI215IT SSI PS1 FG1 Integrated Technician Junction Box 1 N Enclosure and circuit card with nine mating connectors installed 1 diameter push in plugs 1 12 diameter rubber gaskets 0 5 diameter steel locknut fastener 10 NPT nylon cord grip strain relief 375 500 7 HI215IT SS2 PS2 FG2 Integrated Technician Junction Box No C2 1
104. ce 6 8 Multidrop function 4 9 multipurpose 1 1 N National Institute of Standards and Technology NIST 1 7 Negative Pulse 4 7 NEMA 4 or 4X conduit fittings 3 7 NEMA Ratings 2 4 Net 1 2 NIST NTEP Certification Mode Kit except for F4 wall mount 1 7 No Keypad Operation 8 31 Non C2 Load Cell Connections J1 3 14 Non Linearity 2 1 ntrinsic Barrier Assembly F1 F3 thru F7 1 7 numeric keypad 7 2 numeric keys 6 16 Operating Procedures 7 19 Operating Temperature Range 2 2 Option Board 3 15 Option Boards 7 3 option connector pins 3 16 Option Menu 7 19 Option Menus and Option Parameters 7 3 Optional Equipment 2 6 Optional Modes 7 1 Optional Relays or TTL Level Outputs 3 10 Options button 5 6 Options Cabling and Interconnect 3 16 Ordering Replacement Parts 8 40 Index original voltage reading 1 3 Output Device Options 1 5 OUTPUT DISABLE 7 20 Output Disable 7 20 OUTPUT OPTION BOARD INSTALLATION PROCE DURES 3 15 Output Setpoint Relay Wiring 3 10 Overview of Typical Load Cell System 8 30 Panel Cutout Dimensions 2 3 Panel Cutout Specifications 3 3 Panel Mount Model HI 2151 30WC 2 2 Panel Mount Instrument 1 7 Parallel BCD Board Connector to DB Connector 3 17 Parallel BCD Board Print Configuration Procedures B2 B5 B9 4 6 Parallel BCD Communication 7 19 Parity selection 5 9 Peak Hold 1 2 7 3 Peak Hold C1 1 6 2 8 Peak Hold Mode 7 1 7 21 Perform the Hard Calib
105. ck OFF Spare No remote clear total No remote clear peak 8 29 2151 30WC MANUAL Out Only setpoint 1 Is Active No partial setpoint lock out 10 Remote CAL Ib Kg Override for CAL Switch No remote CAL override 20 Zero Button Enable on Key Lockout No zero button enable 40 Remote Function Zero Spare KEY BD Indicates next display will be the keyboard test Ensure the keyboard operates properly by pressing each key starting with the ZERO key in the upper left corner of the keypad and moving from left to right The LED will display each key as it is pressed Do not press the O exit key until you are ready to leave the keyboard test IT 9Section appears Press the Exit key to resume weighing mode of operation Interpreting These techniques are limited to external observations Checking of Diagnostic Error internal test points and voltages requires special test equipment and Messages exposure of the circuit cards during normal operation This should only be done by qualified technicians Overview of Typical 1 The typical system consists of or more load cells points a sum Load Cell System ming junction box and a weight controller the HI 2151 30WC See Figure 8 1 USE SYMMETRIC BEAM LOADED UNIVERSAL JOINT THROUGH SHEAR CENTER 10 oR AVOID TWIST WITH LOAD HOSE if T P d Pd LOAD CELLS 2151 2006 WEIGHT CONTROLLER
106. d mode is indicated When Total Option is selected the display will indicate the accumu lated total net weight stored in the total register To Setup the Totalizer Mode Option See Chapter 5 Press MODE button until the TOTAL indicator is illuminated The value displayed is the total accumulated net weight With the Total displayed press the PRINT button 7 21 2151 30WC MANUAL To clear the Total To exit the Total Mode NOTE Allen Bradley Remote I O Option B8 Profibus Interface Option B12 7 22 With the Total displayed press the TEST CLR button The Total Regis ter will now be reset to zero Press the MODE button until the desired mode is indicated The Peak Hold and Totalizer modes do not support the LB KG button or LB KG remote input They will display and transmit only the mode the instrument was cali brated in See the Allen Bradley Remote I O Installation and Operation Manual P N 0596 0173 for complete Operating Instructions See the Profibus Installation and Operation Manual Prt 0596 0211 for complete Operating Instructions Chapter 8 Troubleshooting CHAPTER 8 TROUBLESHOOTING PROCEDURES Disassembly and Reassembly Notes and Cautions Chapter Eight covers the procedures for troubleshooting the electrical mechanical and firmware elements of the HI 2151 30WC Weight Con troller in the event of a malfunction A flow chart provides a road map for troubleshooting a weight contr
107. d sensor s performance characteristics and weight signals to the weight controller The IT Junction Box when used with the HI 2151 30WC allows for some automated system diagnostics It uses connectors for isolation and troubleshooting of the weight system The IT Junction Box allows an operator to automatically switch in an internal test circuit to perform a system stability test and read the individual load sensor voltages in millivolts or millivolt volt for up to 4 load sensors from the HI 2151 30WC front panel Bias volt ages will come from the load sensor excitation voltage and will not affect calibrated weight readings Switching commands come over the C2 lines from the weight controller Nomenclature on the board will identify positions The user will know where load sensors 1 4 are physically located by filling out a label mounted to the inside top cover of the IT Junction Box c Weight Controller is an electronic instrument which among other functions is used primarily to power the load cell s point s take the millivolt signal output from the load cell s point s and digi tize interpret communicate and display the results as a weight indication 1 Config dipswitch 53 set to keypad lockout reposition switch 2 Check for on display Whenever HI is displayed the keypad will be disabled except for the Cal Menu and the Test Clr buttons 1 Check wiring at J2 2 Ensure correct ground is used J2 pins 9 or 10
108. e 5 3 2151 30WC MANUAL Analog Transmitter s BCD Port e Remote I O PROFIBUS e key also enters the digit 7 8 Cal This key opens the Calibration set up menu e key also enters the digit 8 9 This key moves backward through menu step by step and will wrap to the beginning of the menu e Selects user selectable formats in the Serial and optional BCD menus e Pauses the Self Tests key also enters the digit 9 e This key Exits a menu sub menu back to normal operating mode when text is on the screen NOTE The zero key is used to exit a menu when numbers are entered See Zero e key also enters the digit Enter When changing numerical values in a sub menu this key accepts or rejects the value e When a value is accepted a GOOD message will appear on the display and step forward to the next item on the menu e When a value is rejected an ERR message appears on the display along with the entered value allowing the user to change the value For a list of error messages see Chapter 7 Troubleshooting 5 4 Block Diagram RS 232C RS 422 485 Bi directional Serial Port Setup Procedures NOTE Chapter 5 Setup Il Option Card A Option B Card Bus Drivers Keypad AAAA Display and jl onfiguratio Switches Flay C Driver Pemot
109. e Functions 2 2 gt lt x e dos oma Pemoveable EEPROM 2k x 8 bit Microcontroller 64k x 16 bit l Fesident EEPROM 2k x 8 bit X g Bcitation Monito Load Cell Interface and Diagnostics Step 1 Check the jumpers and dip switches to see that they are in the correct position See Chapter 4 Remove jumpers with all barriers Step 2 Press the Options button Step 3 Select the Serial Port SERPRT sub menu 2151 30WC MANUAL Step 4 Press the Enter button RS 232 appears RS 232 is the default setting from the factory Step 5 To select RS 232 press on the Enter button Step 6 To select another port use the up or down arrows to select another serial option Step 7 Select either RS 422 or RS 485 Step 8 Press the Enter button to set the port setting If the jumpers are in the correct position the unit accepts the setting Press exit to return to the main menu Step 9 If the jumpers are not in the correct position or there are no jumpers installed a jumper error JMPERR will appear Go through the configuration again to select the correct jumper position or install a jumper in the correct position See Chapter 4 for instructions e Repeat steps 2 8 e Press the Enter button to set the port setting e Press the Exit button to return to the main menu Bar Graph Setup Procedures About Bar Graph The user can
110. e Jumpers WARNING CAUTION NOTE CAUTION DANGEROUS VOLTAGE IS PRESENT WITHIN THE ENCLOSURE OF THE INSTRUMENT AND PRESENTS A RISK OF ELECTRICAL SHOCK ALWAYS UNPLUG THE POWER CORD BEFORE OPENING AND SERVIC ING THE INSTRUMENT SERVICING OF THIS UNIT SHOULD BE PERFORMED BY AUTHORIZED AND QUALIFIED SERVICE PERSONNEL ONLY FOLLOW ALL ELECTRO STATIC DISCHARGE ESD PROCEDURES WHEN OPENING THE INSTRUMENT Remove jumpers with all barriers Step Disconnect the power cord Step 2 Usea phillips screw driver and remove the four 4 pan head machine screws that fasten the rear panel to the extrusion See Fig 4 2 Step 3 Gently pull out the rear panel with the printed circuit boards attached The main board is in clear view Phillips pan head machine Screws FIG 4 2 REMOVING THE REAR PANEL WHEN OPENING THE BACK OF THE HI 2151 30 WC MAKE SURE THAT YOU USE PROPER ELECTROSTATIC DISCHARGE PROCEDURES TO PREVENT DAMAGE TO THE INSTRUMENT Step 4 If an option board is installed above jumpers remove the option board Step 5 The factory default position is for the RS 232 setting See Fig 4 3 The dip switches do not function when in the RS 232 configuration Chapter 4 Configuration Step 6 select the RS 422 485 ports move the jumper to the RS 422 485 position See Fig 4 3 NOTE The selection for the RS 422 or the RS 485 is done from the front panel QUO WO XO IO XJ 60 SH S8v ccY
111. e altered Request to send an RS 232C level signaling a readiness to send Received data at a serial port Accepts RS 232C data signals The maximum amount of weight the scale is capable of supporting Live load plus deadload The Secure Memory Module stores and protects vital information from corrup tion including calibration configuration of setpoints RS 232C Serial Port Optional Serial BCD Bar graph and Rate of Change Also allows the trans ference of data from one unit to another with no re calibration or re configura tion necessary Ordered weight of a particular ingredient Weight reading at which a relay will be actuated The total amount of test weights used placed on the scale when performing a Hard Calibration Another name for Secure Memory Module Artificial zeroing of the weight hopper so that a net weight can be displayed Also the action of adjusting out the known weight of the container from the total indicated weight so that the indicator reads net weight directly The change in indication due solely to a change in temperature from a refer ence temperature Expressed as a percentage of span value for a specified temperature change Time in seconds between values subtracted to determine rate of change Value the transmitter puts out with the maximum weight on the load cell Value the transmitter puts out with minimum weight on the load cell 2151 30WC MANUAL TTL TXD Update Rate Zer
112. e instrument Pounds or Kilograms Electrostatic Discharge is an electric charge static electricity which occurs when an electrically charged object such as a person touches the HI 2151 30WC To avoid damage to personnel and to the unit a grounded static con trol wrist strap should always be worn when opening and or servicing the HI 2151 30WC This key is used to accept user input into the memory Electrically programmable read only memory A message that indicates an unacceptable input has been entered A parity configuration D C voltage supplied to the load cell for power Full scale input as defined by instrument and load cell parameters Example 3MV V load cell 10 volts 30mV full scale Minimum increment displayed by the instrument 2151 30WC MANUAL Gross Weight Input Average Keypad Lockout Kilograms LED Load Cell Menu Menu Driven Microprocessor Midpoint Linearity Correction Motion NEMA 4 NEMA 4X Net Weight Next Key Non Linearity Number Of Readings Per Average Odd Option Option Slot Parity Pounds An overall weight exclusive of tare deductions Weight of material plus con tainer The number of readings averaged into a displayed value A selectable switch used to prevent input from the keyboard A unit of mass in the metric system Equal to 1000 grams or 2 2046 pounds Gr represents kilograms on the display Light Emitting Diode These are used in the fro
113. e weight control system the con troller will capture the resistance value when performing the Hard Cal ibration when setting the Zero Calibration Value The quick C2 calibration should be used when the controller has already been properly calibrated and when the system is determined to be slightly out of specification for a scheduled periodic calibration e The Quick C2 calibration procedures do not replace the regular C2 calibration procedures Step l From the CAL menu press the Enter button The HD CAL menu appears Step 2 Press the down arrow The C2 Calibration sub menu C2 CAL appears Step 3 Press the Enter button The Load Cell Count LC CNT appears Step 4 Press the up arrow The Reference Point sub menu appears Step 5 Press the Enter button Step 6 Enter the weight of the current live load that is on the scale Step 7 Press the Enter button The RETURN display appears Step 8 Press the Enter button The END CAL display appears Procedures to Restore Calibration Parameters Before Clearing Memory CAUTION Clear Controller Memory Step 9 Chapter 6 Calibration Press the Enter button to set the changes Ifthe parameters for the controller are on the Self Test Calibration Form Prt 0575 0016 enter the values from the form If the user does not have the parameters from Self Test Calibration Form handy go through the Self Test again and write them the parameters IF CONTROLLER
114. el weight material 5 1 2151 30WC MANUAL Print NOTE NOTE Test Clr 1 Tare Val 2 Status Bar NOTE weight You can also type in the Tare Value by using the 1 Tare Val key The Tare function can also be actuated by activating the appropriate remote function pin See Remote Function Configuration in Chap ter 4 Transmits data to the printer The serial port must be configured as a printer If the serial port is not configured as a printer port the print key is not going to respond and you cannot print The print function cannot print data if the weight is in motion or exceeds the capacity of the scale The Test Clr function Initiates one of the selected tests e Self Test SLFTST on the display e Integrated Technician IT SEC on the display This key is used to enter a minus sign for a negative num ber This function can be used only when the display reads the num ber 0 The clear CLR function is operable when the controller is a menu requiring a numeric input Use CLR to clear the display before entering a new value This function displays the current Tare value stored in the Tare Reg ister See paragraph 5 1 3 e This function allows the user after pressing the Clr button to enter a Tare Value using the numeric keys To exit the Tare Val menu press the Zero button e The key also enters the digit 1 The Status Bar toggles between the mode set
115. elect TEST E Press ENTER This program level reads and compares the milli volt output of each individual loadpoint to the values recorded at calibration Out of tolerance readings flag an error Yes ERROR Check load sensor ONE V NO Yes ERROR Check load sensor TWO NO Yes ERROR Check load sensor THREE NO Yes ERROR Check load sensor FOUR TEST COMPLETE j Additional Testing Suggestion Verify cable connections and cable integrity REVIEW TROUBLE SHOOTING SECTION F Individual loadcell Milli volt readings Verify Sensor readings are stable B Electrical and Mechanical Guidelines 2151 30WC MANUAL F Verify Individual Load Cell Milli volt Readings Press TST CLR START INTEGRATED TECHNICIAN KT diagnostic program Using the load cell certificate verify the Milli volt per volt rating Example 3 mV V load cells will produce approximately 15 mV at full load That is 5 volts excitation X mV V A scale capacity of 1 000 Ibs with 100 lbs of deadload at empty the loadpoint mV reading should equal 1 5 mV 1 No dead load Apply load and re test 2 Wiring error Verify color code using the Zero mV reading load cell certificate 3 Open bridge circuit Disconnect power and verify Select DVMTST DVMMV Press ENTER DVMTST check
116. emand or to output continuously Use the left arrow to move cursor one space to the left to highlight the letter S The S starts flashing Use the up arrow T to select S to output set points or will not output set points Use the left arrow lt to move the cursor one space to the left to highlight the letter R The letter R starts flashing Use the up arrow to select R to output the rate of change or will not output rate of change 2151 30WC MANUAL NOTE NOTE Analog Output Setup Procedures Option 5 12 About Analog Output See Chapter 4 for Configuration Procedures e Use left arrow lt to move cursor one space to the left The letter T starts flashing e Use the up arrow T to select T to output the tare value om Or tare value will not be output e Use left arrow lt to move the cursor one space to the left The letter N starts flashing ow e Use up arrow to select to output net weight or will not output net weight Use the left arrow to move the cursor one space to the left The letter G starts flashing e Use up arrow T to select to output gross weight or _ will not output gross weight At least one of the letters T or S must be selected or Error 54 will be displayed Step 13 Press the Enter button twice First the control Sub Menu CONTRL appears then SOFTRE or HARDRE ap
117. es where marked See Fig 3 19 Step 3 Install four P N 2815 Eois 0063 standoffs in drilled holes Step 4 Install the relay T option board on the em standoffs Fig 3 20 FIG 3 20 STANDOFF ASSEMBLY 3 23 2151 30WC MANUAL Profibus Interface Step 1 Card Option Wiring Diagram Step 2 Connect P N 0509 0390 ribbon cable between relay option board jack and J4 on the rear panel of the HI 2151 30WC See Fig 2 12 For WS wall mount versions the card can be mounted within the enclosure Route the wiring to 73 thru 78 via the lower left side of the access hole For more complete instructions see the Profibus Interface Option Card Operation and Installation Manual 0596 0211 Installation of the Secure Memory Module Step 1 Step 2 Step 3 Step 4 FIG 3 21 SECURE MEMORY MODULE Make sure that the module has the notch facing up Fig 3 21 Slide the module with the notch up into the module housing Press the module in until it stops To remove the module pull the module straight out of the housing See Fig 3 22 FIG 3 22 INSTALLING AND REMOVING THE SECURE MEMORY MODULE Chapter 4 Configuration CHAPTER 4 SYSTEM CONFIGURATION Standard RS 232C RS422 485 Configuration Procedures About RS 232 RS422 485 Bi directional Serial Ports See Chapter 5 for Setup Procedures Chapter Four covers procedures for configuring the HI 2151 30WC
118. esults of 10 seconds corresponds to Units per Minute 100 102 104 106 108 110 21st 1st 6 ROC 112 Rate of Change Data Peak Hold Mode Option To display PEAK HOLD To reset the Peak Value to zero To exit Peak Hold mode Totalizer Mode Option To display the Total Value To print the Total Value Chapter 7 Operation 114 140 100 40 x 6 240 116 118 At time one there is 100 lbs on the scale One half second later there is 102 lbs on the 120 scale At time twenty one 10 seconds later there is 140 Ibs on the scale A 40 Ib change 10 seconds converts to 240 105 194 Per minute 122 126 128 130 132 134 136 138 140 e Rate of change data can be transmitted through the standard or optional serial ports or the analog output It can also be displayed numerically or as a bar graph The Peak Hold Option when selected will display the highest gross value that has been measured or the averaged peak gross value Peak does not need to be displayed in order to capture the peak value See Chapter 4 Section 4 6 for Configuration Information Step Press the MODE button until the PEAK LED indicator is lit Step 2 The value now displayed is the highest gross value that has been measured since last RESET With the Peak Value displayed press the TEST CLR button Press the MODE button until desire
119. eturning any product to Hardy Instruments call the Customer Support 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 for the customer service representative In addition please have Appendix completed and ready to FAX to us before calling Customer Support 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 2151 30WC MANUAL Ordering Contact the Hardy Instruments Sales Department to order replacement Replacement Parts parts and option boards Have your equipment model number ready as well as your completed System Data Survey Sheet Appendix A Data Survey Sheet 8 40 Index Index Symbols Test Clr 5 2 Numerics 14 AWG power line 3 9 2 Status Bar 5 2 240 VAC 50 60 Hz Input Voltage E2 1 7 3 pin terminal block connector 3 9 4 connector pin description 3 10 5 AMP 250 VAC Slow Blow 3AG 3 9 5 volts DC Excitation Voltage 8 31 A Allen Bradley Remote 1 2 Allen Bradley Remote Installation and Operation Manual P N 0596 0173 7 22 Allen Bradley Remote I O Interface B8 2 7 Allen Bradley Remote I O Option B8 5 14 7 22 Allen Bradley RIO Interface Option B8 3 20 analog card 4 4 Analog Card Adjustment 4 5 Ana
120. f the front panel Compression Gasket Rear Pane E Front Panel FIG 3 3 NEMA 4 GASKET FLUSH AGAINST THE FRONT PANEL CAUTION NOTE NOTE Installing the HI 2151 30 Remote Mount Model Install the Front Panel Chapter 3 Installation Install the four 4 6 32 pan head machine screws into the threaded slots at each corner of the controller Hold the controller so that it is aligned and flush against the enclosure front panel throughout the entire tightening pro cess e Facing the rear panel of the controller tighten each screw in a clockwise direction from corner to corner until each screw is finger tight e Using a phillips screw driver continue the clockwise direc tion and partially tighten each screw until the NEMA 4 bezel gasket is completely compressed and the bezel is flush against the front panel of the enclosure Do not tighten one screw down completely and then go on to the next screw Each screw must be tightened a little before going on to the next to maintain the alignment between the controller and the front panel of the enclosure DO NOT OVER TIGHTEN THE MACHINE SCREWS OVER TIGHTENING CAN DEFLECT THE BEZEL SO THAT IT WILL NOT BE WATER TIGHT AND OR BREAK OFF THE CORNERS OF THE BEZEL Step 6 The Panel Mount installation is complete See Figure 3 2 for information about the panel cutout Step Ensure that all Electrostatic
121. g M HI Error HI The Load sensor output Signal has exceeded the millivolt limits set in Configuration and or the Internal factory setting 1 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 Weight controller to dampen EMI RFI signals 2 The load cell output Signal voltage has exceeded 15 mV dc a Use INTEGRATED TECHNICIAN to verify mV levels 1 Verify total milli volt signal level 2 Verify individual load cell milli volt signals a An individual load cells may be over ranged and exhibit high milli volt readings b Possible physical damage to the load cell c Internal Strain gauge bond broken d Moisture in the load cell cable or body 3 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 This is used only as a warning and does not effect calibration d Optional communication signals are unaffected by this indication 4 Weight in the hopper exceeds the load cell capacity a Mechanical forces or product acting on the scale overloads the load cells b Use INTEGRATED TECHNICIAN to verify Milli volt levels 5 Review Mechanical and
122. he Hard Calibration HD CAL Sub Menu appears Step 4 Press the down arrow J until the Soft Calibration S CAL Sub Menu displays Step 5 Press Enter The Sensitivity Sub Menu SNSTVY appears Step Use the numeric keys and enter the load cell full scale output in mV V found on the load cell calibration certificate Step 2 You must enter five digits If a load cell is listed at less than five digits add 0 5 to make up the five digit number For example When the full scale output in mV V is 2 99 You need to enter the number as 29900 The least significant numbers are on the right when looking at the display Step 3 When multiple load cells are used contact Hardy Instruments Customer Service Department to compute the system total full scale output sensitivity Step 4 Press Enter The Scale Range sub menu RANGE appears Step Press the Enter button Step 2 Usethe numeric keys and enter the sum of the rated capacities of all load cells being used An example There are 3 load cells rated at 1 000 Ibs capacity each The value to enter is 3000 Step 3 Press the Enter button The Reference Point Sub Menu REF PT appears For HI 2151 20WC users the next setting would normally be the sticker value The sticker value for the HI 2151 30WC is entered at the factory and cannot be changed Therefore it is not necessary to set the sticker value in Soft Cal Setting the Reference Point Using the Return RETURN Function End of
123. he enclo sure front panel CAUTION DO NOT OVER TIGHTEN OVER TIGHTENING CAN DEFLECT THE BEZEL SO THAT IT WILL NOT BE WATER TIGHT AND OR BREAK OFF THE CORNERS OF THE BEZEL Installation of the Step Drill four 156 inch tapped or thru holes and use four 6 32 Instrument pan head machine screws to fasten the enclosure to a panel Enclosure 0519 0515 01 HI 2151 30WC WITH REMOTE DISPLAY 5 41 137 31 ADAPTER TOP VIEW 10 00 254 00 4 DA ALLOW EMOTE DISPLAY RIBBON CABLE 2 00 50 80 0509 0431 R LENGTH 55 00 1397 00 9 23 254 32 MIN FOR CABLE CLEARANCE 1 J2 0519 0515 01 cca HI 2151 30WC WITH REMOTE DISPLAY ADAPTER a AP FIG 3 5 INSTALLING ELECTRONICS ENCLOSURE A PLATE 3 6 NOTE NOTE Installing the HI 2151 30WC BR Blind Remote Model Installing the HI 2151 30 Wall Mount Model Step 2 Step 3 Chapter 3 Installation Connect the 60 inch 40 pin ribbon cable to the 40 pin con nection 75 on the electronics and the 40 pin connection J4 at the rear of the front panel display Remote panel mechanical installation is complete The electronics can be mounted on any of the four sides Step Step 2 Place the instrument in the enclosure so that there is two inches of clearance from the each end of
124. he front panel key pad or a remote source The ROC option measures and displays the rate at which a material enters or is dispensed from the scale over a period of time The register for ROC holds 21 entries New weight values are input to the register at the rate of 1 20th of the time base The first register is subtracted from the 21st Register which is one time base older than the Ist register The time frame can be set to units per second minute or hour A time base of discrete values is selectable from 1 to 1800 Provides six TTL level outputs rated at 500 milliamps per line A mat ing connector with eight 24 gauge unterminated wires 60 inches long is also provided This externally mounted card is equipped with six solid state triac relays See Chapter Two for Specifications Individual relays can be configured as form A or form B by an on board dip switch Each can be programmed to respond to the standard Net or Gross modes of opera tion or the optional ROC Totalizer or peak hold modes Each have individual setpoint preact and deadband parameters A 60 inch inter face cable is provided This option should not be used with the wall mount enclosure External Setpoint Relays Card D3 Miscellaneous Options 240 VAC 50 60 Hz Input Voltage E2 NIST NTEP Certification Mode Kit E3 except for F4 wall mount Portable Display and Keypad E4 Intrinsic Barrier Assembly F8 Interpreting the Model Code Number
125. he load cell count LC CNT sub menu Press the up arrow until the sub menu you want to change appears then press the Enter button Follow the procedures above for the menu NOTE End of C2 Calibration NOTE Hard Calibration Procedures HDCAL NOTE NOTE Selecting the Hard Calibration Sub Menu Setting the Zero Calibration Value Chapter 6 Calibration 2 If you want to accept the C2 Calibration parameters press the Enter button The End Calibration END CAL message is displayed 3 Press the Enter button again This seals all calibration set tings and exits the C2 Calibration Menu 4 The instrument returns to the normal weight display If the Enter button is not pushed after End Cal appears three leds will flash indicat ing that the settings are not sealed in memory To correct mistakes during calibration or to return to a previous calibration parame ter press the down arrow to bypass parameters press the up arrow f Hard Calibration is the traditional method of calibration that uses test weights We recommend that the test weights total 80 to 100 of the scale weight Hard Calibration must be performed with the instrument in GROSS MODE Step Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Make sure that the instrument is in Gross Mode From the Weight Display Press the 8 Cal button The Secu rity Code S
126. he vibration frequency Adjust the Average and WAVERSAVER settings to establish minimal weighing time Use WAVERSAVER settings 1 3 for low amplitude high fre quency vibrations Use WAVERSAVER settings 3 5 for high amplitude low frequency vibrations Press the Enter button A value appears The Default setting is 4 There are 5 selectable levels 1 provides the least vibration immunity with the fastest response time and 5 provides the most vibration immunity with the slowest response time Press the up arrow T to select the setting 1 5 6 Press Enter to accept the value The Calibration CAL sub menu appears Press the Enter button The Hard Calibration HD CAL Sub Menu appears Use the Up or Down arrows 11 to select one of the Calibra tion procedures C2 Calibration C2 CAL Hard Calibration HD CAL Soft Calibration S CAL Select one calibration process only C2 and Hard Calibration are used most often C2 Calibration is only possible with Hardy Instruments Load Cells Sensors or Points 2151 30WC MANUAL C29 Second Generation Calibration Procedures NOTE 6 12 Step 1 Step 2 Step 3 From the CAL menu press the down arrow button The C2 CAL sub menu appears Press the Enter button The Load Cell Count LC CNT sub menu appears Verify that the load cells detected by C2 calibration equal the actual number of load cells installed in the system If the load cells detected do not match the lo
127. he weight b Does the weight return to ZERO NET c The weight value will not be correct until a proper calibration is complete Use the load cell certificates to verify color code Input is excitation Output is signal Shielding a Grounded only at the weigh controller Continuous shield connection from the Load cell cable to the controller Single point EMI RFI drain Terminated but not grounded at the summing box Sense lines installed a Jumpers or sense lines in the J1 connector b Sense lines must be installed for C2 of Softcal calibration Using Integrated Technician SYSTST verify readings 8 19 2151 30WC MANUAL K Load Sharing and Load Sensor Checkout Does the mV signal increase in a positive direction If you receive a negative results check if load cell is mounted correctly a The arrow goes with the direction of force If there isn t an arrow you must manually verify the correct direction A negative reading indicates the load cell is upside down Load cells in tension will not reflect a negative reading if install upside down If upside down Load cell wiring is only the force applied by the cable would be complete and included in the weight readings correct If you are still receiving a negative signal verify load cell wire color code Verify a positive reading from each load cell using Intergrated Technician s DVMTST DVM MV Record the mV reading and compare each corner f
128. ield 3 Clear 1 2 of twisted pair 4 No Connection 3 No Connection 6 Wire to instrument chassis ground Profibus Interface Refer to Hardy Instruments Profibus Interface Option for the HI 2151 Option B12 30WC Installation and Operation Manual for installation instructions The Profibus option card can be mounted in either option slot one or two However there is a limit of one Profibus card per instrument Connector Cable Wiring Top Row Right to Left J1 1 Ground outer braided shield J1 2 No Connection J1 3 Transmit 1 2 of twisted pair 1 4 Connection J1 5 No Connection Bottom Row Right to Left J1 6 Connection J1 7 Connection J1 8 Receive 1 2 of twisted pair J1 9 Connection 3 21 2151 30WC MANUAL Dynamic Data Exchange DDE I O Server B14 HI 215IT Series Junction Boxes Set Point Relay Option Board Installation D2 RS 232C Requires an interface cable with a 9 pin or 25 pin serial port female connector to connect to a computer Wire the cable to the 5 pin Phoenix connector J3 located on the rear panel of the weight controller Refer to Hardy Instruments optional DDE Installation and Operation Manual document number 0596 0221 for more details Refer to Fig 3 11 Load Cell Sensor Connections for specific details Wiring to Hardy Instruments Load Points and Load Sensors TB1 3 57 HI LPH LPS LPD HILPT MT HI BB
129. ificates The Advantage load sensor certificates are located on the WWW Hardyinst com website Load cell input is actually damaged Load cell Excitation wires are disconnected NO ErrEXC Displayed on a new system 1 Was calibration completed System is not 2 Are all wires properly terminated calibrated NO 3 Verify individual load cell resistance readings 4 If using C2 calibration was the load Contact cell count correct Hardy Instruments 5 Compare readings with the BaseR YES Service and the ReadR If correct check for 800 821 5831 barriers or miswired load cells 8 23 2151 30WC MANUAL P Stuck on HARDY Screen Power Down then Power Up Able to Yes lt Change Screen NO Y Remove all Connectors Other than Power Connector Able to Yes lt Change Screen NO Y Disconnect the Power Cable Remove the Back Plate with Printed Circuit Boards Push the EPROM down into its socket until it is securely seated Able to Yes Change Screen lt NO Y Contact Customer Support 1 800 821 5831 Y Problem Solved System Integrity Check and Fault Determination To determine if an instrument or cabling problem exists verify the basic operation of the system by per forming the following system checks Self Test DISPLAY SLFTEST VER
130. ight Controller Excitation Monitor Verifies Excitation EKCMON Resistance NOTE 8 2 Systems using the Integrated Technician features relating to the isolation or measure ment of the instrument junction box cable the junction box and individual load sen sors or the measurement of weight or voltage of the individual load sensors require an HI 215T series junction box Chapter 8 Troubleshooting ARROW keys will move you between menu selections ENTER key will advance or display T Press EXIT to return to the last menu level X SELF TEST enter gt Displays System Information Down Arrow to Stop Up Arrow to Continue
131. kup a four wire hookup and an external excitation supply Load cell point cables are connected to J1 through a furnished mating plug P1 NOTE Contact Hardy Customer Support for installation information when using an external power supply To ensure a clean signal from the load cells points follow these pre cautions e Load cell point cables MUST be run separate from all other cables and in their own conduit Load cell point cable shield should be attached to ground screw on rear panel only e Six wire shielded load cell point cable should be used for lengths of 50 feet or more or if intrinsic safety barriers are used Eight wire shielded cable preferably Hardy C2 cable must be used for C2 cal ibration Avoid load cell point cable splices If cables are longer than needed coil up and tape excess cable If cables are short use an appropriate junction box When terminal lugs are installed on load cell point cables Hardy Instruments recommends the lug be crimped and sol dered When connecting the HI 2151 30WC weight controller to the HI 215IT junction box using C2 load cell point cable 6020 0001 use the following color code Model Sen Sig Sig Sen Exc 2 C2 J BOX RED BLUE GRN WHT BROWN BLK GREY VIO TABLE 3 2 C2 CABLE COLOR CODE WARNING DO NOT OPERATE AT INCORRECT LINE VOLTAGE THE UNIT WILL BE DAMAGED CHANGING THE INPUT VOLTAGE RATING BE
132. lass I IL III Div 2 Groups A G CE Approval NTEP Approval MC Measurement Canada Approval Baud Rates 600 1200 2400 4800 9600 19200 RS 232 A1 Full Duplex RS 422 A2 Full Duplex 4 wire RS 485 A3 Half Duplex 2 wire RS 232C SPECIFICATIONS SPECIFICATION DESCRIPTION High Level Output 11V at 5 mA Low Level Output 11V at 5 mA SPECIFICATION DESCRIPTION High Level Input 4 to 15V Low Level Input 1 6V to 15V Schmit trigger input disallows logic changes with voltages between these ranges Slew Rate 15V per microsecond maximum Input Impedance 20K ohms GND SIGNAL GND Update Time 10 updates sec Serial port connections are made to J3 located on the rear panel through the mating plug P3 RS 422 485 Specifications Interface specifications per EIA Electronic Industries Association Standards RS 422 and RS 485 Resolution 16 000 counts Linearity 0 0146 with 1 average selected 2 5 2151 30WC MANUAL 2 6 Binary Coded Decimal BCD B2 Response Time millisecond after update Isolation from Main Board 300 VAC or 450 VDC Update 50 milliseconds 20 times sec Voltage Out e Range 0 5 VDC 0 10 VDC or reverse of these Max Current 5 2 ohm load 10 V e Temp Stability 10 ppm C or 4 mV total from 30 to 120 degrees F Current Out e Range 0 20 mA 4 20 mA or reverse of these Max Voltage 12 V allowing 0 600 ohm load at 20 mA e Mati
133. lf Test Display Options General Policies and Information 8 39 System Support 8 39 Warranty 8 39 FOR FURTHER INFORMATION CONTACT 8 39 Ordering Replacement Parts 8 40 Vii 2151 30WC MANUAL viii Table of Illustrations Table of Illustrations CHAPTER 1 OVER MODEL NUMBER BREAKDOWN 1 8 VIEW CHAPTER 3 INSTAL 2 REAR PANEL CLEARANCE REQUIREMENT 3 3 LATION PANEL CUTOUT DIMENSIONS 3 4 NEMA 4 GASKET FLUSH AGAINST THE FRONT PANEL 3 4 MOUNTING REMOTE DISPLAY TO ENCLOSURE 3 6 INSTALLING ELECTRONICS ENCLOSURE TO PLATE 3 6 INSTALLATION OF WALL MOUNT MODEL 3 7 WIRE ROUTING FOR WALL MOUNT MODEL 3 8 POWER WIRING DIAGRAM 3 9 C2 LOAD CELL CONNECTION 3 13 LOAD CELL CONNECTION NON C2 LOAD CELLS 1 3 14 OPTION LABEL COVER 3 15 ANALOG OUTPUT BOARD 3 16 PARALLEL BCD BOARD 3 17 BCD QUAD TERMINATION BOARD OPTION 3 19 BCD TERMINATION BOARD INSTALLATION DRILL TEMPLATE 3 19 BCD TERMINATI
134. lies six TTL level outputs rated at 300 mA It is available as a D1 option which includes the firmware and a sixty inch eight wire 24 gauge customer terminated cable A D2 option includes the following Firmware Sixty inch eight wire 24 gauge customer terminated ribbon cable Six 6 115 VAC solid state triac relays on an externally mounted option card Mounting hardware includes 4 standoffs 8 6 split lock washers 8 6 flat washers 8 6 32 UNC pan head screws D2 option card contains a 5 amp fuse for each relay Each relay has a two pin terminal connector J3 Set Point 3 J4 Set Point 4 Pin 1 Lo Pin 1 Lo Pin 2 Hi Pin 2 Hi NOTE CAUTION J3 Serial Port Wiring Remote Functions Wiring Chapter 3 Installation J5 Set Point 5 J6 Set Point 6 Pin 1 Lo Pin 1 Lo Pin 2 Hi Pin 2 Hi J7 Set Point 7 J8 Set Point 8 Pin 1 Lo Pin 1 Lo Pin 2 Hi Pin 2 Hi Use 22 AWG minimum to 12 AWG maximum wire for J3 through 78 See Output Option Board Installation for board installation procedures THE CONTACTS ON THE SOLID STATE RELAY WILL OPEN IF A POWER FAILURE OCCURS A LIT LED INDICATES THAT THE RELAY HAS BEEN ACTIVATED The standard serial port J3 is located on the second board inside the instrument and is configured either as an RS 232 or RS 422 485 port See Section 4 1 for port configuration instructions The A model designator in the model number indicates how the instrument was configured from the factory See T
135. ll capacity divided by 10 000 01 requiring two decimal points or less is recommended Step 2 Press the Enter button Six number eights 88888 8 are dis played Step 3 select the decimal point location push the left arrow until the decimal point is in the correct position The decimal point will wrap from left to right There is no right arrow Step 4 Press the Enter button to accept the decimal location This parameter sets the number of decimal places to use in total weight values The Total Decimal Point must be less than or equal to the standard decimal point position For example A Decimal Point that equals 88888 8 the Total Decimal Point should equal 88888 8 or 88868 2151 30WC MANUAL Setting the Motion Tolerance Value MOTION NOTE Setting the Graduation Size GRAD NOTE 6 8 Step If the optional weight totalizer is installed TOT DP appears on the display Step 2 Press the Enter button There are six number eights 888888 displayed Step 3 select the decimal point location push the left arrow lt until the decimal point is in the correct position The decimal point will wrap from left to right Step 4 Press the Enter button to accept the decimal location The Motion Tolerance sub menu MOTION appears on the display Step l The base motion number can be calculated by using the fol lowing formula Base Motion Number Total Load Cell Capacity 10 000 x 3
136. log Output B1 1 5 2 6 Analog Output Menu Setup Procedures 5 13 Analog Output Option B1 See Fig 3 12 3 16 4 4 Analog Output Setup Procedures Option 5 12 analog transmitter 4 4 Approvals 2 5 Auto Zero Tolerancing Configuration Procedures 4 8 Auto Zero Tracking 1 4 averaged gross 4 8 Averages 2 1 B B1 Option Connector Wiring 3 16 bar graph parameters 5 6 Bar Graph Setup Procedures 5 6 Base Graduation Number 6 8 base motion number 6 8 Baud rate selection 5 9 Baud rates 1 4 BCD Menu Setup Procedures 5 7 BCD option board 5 7 BCD Option Board Installation B2 B5 B9 3 17 BCD Print 5 7 7 20 BCD Quad Termination Board B7 2 7 BCD Quad Termination Card B7 1 5 BCD Single Termination Board B6 2 7 BCD Single Termination Card B6 1 5 BCD sub menu 7 20 BCD terminal board 3 20 BCD Termination Board Installation Procedures See Fig 3 14 3 19 BCD Terminator Boards B6 B7 3 19 Before Clearing Memory 6 19 Bi Directional Communications 2 5 Bi directional Communications 7 7 bi directional communications 1 6 Bi directional serial ports 4 1 Binary Coded Decimal BCD 2 8 Binary Coded Decimal BCD Output 1 5 Binding on the Load Cell 6 1 Blind Remote Mount HI 2151 30WC BR 2 4 C C2 Load Cell Connections J1 See Fig 3 9 3 13 C2 weighing system 1 2 C20 Calibration 1 2 C2 Second Generation Calibration Procedures 6 12 C2 Calibration C2 CAL 6 11 Cable Pinouts 3 17 cable runs 3 8 Cable
137. lows bi directional communications to Profibus Process Fieldbus products including those made by Siemens GE Fanuc and Texas Instruments This interface supports PROFIBUS DP Decentralized Periphery and processes both Selectable Predetermined and Block transfer commands It supports up to 12 Mbaud transfer rates Allows bi directional communications with a PC over the serial port using Windows 3 x Windows 95 or Windows NT The DDE links the HI 2151 series weight controllers to a Windows based application software such as Wonderware Visual Basic Excel Lotus 12 39 or Quattro Pro Windows Visual Basic and Excel are all registered Trademarks of the Microsoft Cor poration Wonderware is a registered trademark of the Wonderware Corporation Lotus 1 2 3 is a registered trademark of I B M Quattro Pro is a registered trademark of the Corel Corporation All terms mentioned in this manual that are known to be trademarks or service marks have been appropriately capitalized Hardy Instruments cannot attest to the accuracy of this information Use of a term in this manual should not be regarded as affecting the validity of any trademark or service mark This option is generally used in testing to determine peak forces a prod uct or material can withstand It can also be used to track the highest force applied to the scale It displays and stores the highest gross weight value measured until that value is cleared by a command from t
138. m ple ROC Step 2 Press the up or down arrow until the sub menu BCD P1 appears Step 3 Press the Enter Button the FORMAT sub menu appears Step 4 Press Enter A series of letters GNTDP and spaces appear For example G N__ D P Note that in our example the is not displayed and that there are 6 spaces total The sixth value is used in other communication protocols 2151 30WC MANUAL NOTE 5 8 Print Output Options If you want to print mode value s selected such as G Gross weight N Net weight or T Tare on demand select P Press the up or down arrow until the letter P appears b Now when the Print button is pressed it will print the Gross Net or Tare weights whichever one is selected c If you select all three GNT it will print all three in sequential order If your input device cannot handle rapid input of data do not select more than one mode Step 5 If you don t want this function press the up or down arrow until a space appears To output what appears on the display select D a Press the left arrow one time to select D BCD b Press the up or down arrow until the D appears c Now whatever mode appears on the display it is output If you do not want output press the up or down arrow until aspaceappears Output Mode Options Tare Mode a Press the left arrow two times to select T Press the up or down arrow until the T appears c No
139. main board used to install an option card A binary digit error correction appended to an array of bits to make the sum of all the bits always odd or always even A unit of mass in the Avoirdupois System Equal to 16 ounces or 0 4536 kilo grams Previous Key Prompts RAM Rate of Change Relay Sense Selection Remote Function Repeatability ROM RTS RXD Scale Capacity Secure Memory Module SMM Set Point Span Tag Tare Temperature Coefficient Time Base Transmitter Span Transmitter Zero Appendix B Glossary ot Terms The number of units above or below the set point value of which the relay will trip Use as an in flight compensation value A key used to step back through menus Instructions or options presented in a menu by the instrument Random Access Memory Read write memory out of which the microproces sor can both write and read data A measure of the rate at which weight is changing For example if 100 pounds were dispensed in 1 minute the rate of change would be 100 Ib minute Optional procedure which reverses the relay sense from normally energized to normally de energized or back again A function in the instrument that can be accessed away from the instrument The maximum difference between readings for repeated readings under iden tical conditions Read Only Memory This permanent non volatile memory gives the proces sor instructions and cannot b
140. mode and the display mode are totally independent Make sure you know what mode each are in before reading Step Place a load weight on the scale or vessel Step 2 Check to see if the weight reading changes on the display in the proper direction e e g if the display reads 100 pounds and a 20 pound load is placed on the vessel or scale the display should read 120 or some value over 100 If the display reads 80 pounds and a 20 pound load is placed on the vessel or scale the reading is going in the wrong direction and indicates a problem See the Chapter 8 Troubleshooting for corrective action If the display is reading improperly or shows no change something is wrong either with the setup or configuration Step 3 If the display changes in the proper direction remove the weight and proceed to calibrate the controller When calibrating the instrument for the first time go from one sub menu to the next in sequence If you want to change one of the sub menus continue to press the Up Arrow button until you reach the sub menu you want to change After entering a value in each sub menu the display will flash a GOOD if the value is accepted If the value is not accepted the display will flash an ERR statement NOTE Setting the Unit of Measure UNIT Pounds Lb or Kilograms Gr NOTE Setting the Standard Decimal Point DECPNT NOTE Setting the Total Decimal Point Option C6 TOT DP NOTE
141. n Monitor EXCMON Digital Volt Meter Test DVMTST Return to Zero Test RTNTOO System Test SYSTST or Self Test SLFTST Select System Test SYSTST 5 Press the Enter button The Internal Reference INTREF appears Use the up or down arrows to select either the Internal Reference INTREF or the IT Junction Box Reference REFBOX To read the Internal Weight reading of the controller press the Enter button with the INTREF displayed a This disconnects the instrument from the sense and signal load sensor lines and connects the instrument to an internal resis tance The controller stays in this mode until it is determined if the weight reading with this resistance pulled in is stable and repeatable the input section of the controller is functioning cor rectly Press the Enter button The controller goes to the REFBOX if the IT junction box is used If the IT junction box is not used the display will read NUMLS or LSALL To read the internal weight reading of the IT Junction Box press the Enter button a The sense and signal load sensor lines are reconnected in the controller b Next a switch in the Junction disconnects the IT junction box from the load sensors and connects a resistance in the junction box c Itstays in this mode until the weight reading with this resistance pulled in is stable and repeatable the input section of the con troller along with the cable connecting it to the junction box is functioning correctly d
142. n and wiring is dependent on how the board is configured The following notes are typical methods of connection It should be realized that these methods vary and are only furnished to offer a starting point for configuration Signal Grounds A direct connection between signal grounds of the different devices is not desirable rather a connection with approxi mately 100 ohms of resistance is recommended Signal ground should NOT be used as a shield Earth Ground Cable Shield Typically cable shields are tied to the frame ground at the end that is the best earth ground Pick up frame ground on the HI 2151 30WC with the phil lips head screw on the rear of the instrument labeled Shield Cable Type The and wires are twisted pair with outer shield Serial Connector Each function is wired to two pins to allow only one wire to be put in each terminal position The same electrical signal is routed to pins one and two on the board HI 2151 GND FIG 7 4 WIRING DIAGRAM SERIAL COMMUNICATIONS RS 422 485 Electrical Specifications Instrument Serial Communications About Instrument Serial Communications Printer Output Serial Protocol Multidrop Mode About Serial Protocol Multidrop Mode Chapter 7 Operation Description Specification Receiver Impedance 12 k ohm Description Specification Receiver Common Mode Range 12 to 7 V Maximum Input Threshold 200 mv Minimum Input
143. n ss fet wap Jsme JUNCTION BOX CONNECTOR sc h Wis 8d 187 FOR 5 OR MORE RSEN e SUMMING PWA oJ e LOAD CELLS fl OR 5TH LOAD CELL safe m x el Ly OVE em ep ep 7 S i o d o mw UH Jesse 564 SIGI j sic2 J sie3 J sic4 0005 9005 900 988 2 ia 1 m 5 99 99 Bele OE 989 GIFT e INSTRUMENTS 5 CALIBRATION aw s LOAD CELL 1 LOAD CELL 2 LOAC CELL 3 LOAD CELL 4 FIG 3 10 LOAD CELL CONNECTION NON 2 LOAD CELLS J1 Contact Hardy Customer Support for installation information when using an external power supply The Auxiliary Junction Box connector is an optional item and must be ordered from the factory Record all load cell serial numbers and location on the label located on the inside cover of the junction box DANGEROUS VOLTAGE IS PRESENT WITHIN THE ENCLOSURE OF THE INSTRUMENT AND PRESENTS A RISK OF ELECTRICAL SHOCK ALWAYS UNPLUG THE POWER CORD BEFORE OPENING AND SERVIC ING THE INSTRUMENT INSTALLATION AND SERVICING OF THIS UNIT SHOULD BE PER FORMED BY AUTHORIZED AND QUALIFIED SERVICE PERSONNEL ONLY FOLLOW ALL ELECTROSTATIC DISCHARGE ESD PROCE DURES WHEN OPENI
144. ng installed in slot 2 if any 2 Try card in other slot 3 Swap with spare option card How instrument was calibrated None One of the next three messages will be displayed depending on the type of calibration that was performed C2TM Second Generation Calibration None Hardware Calibration None Software Calibration None Indicates next parameter will be units None of measure DISPLAY KGS or LBS WSVRz4 GRAD l or 2 or 5 etc SPAN 10000 example ZR CNT 36780 example FS CNT 992000 example SC CAP 999999 example 0 TOL 10 example AO TOL 10 TEST Kilograms or pounds Indicates WAVERSAVER that was selected In Calibration Indicates next parameter will be graduation size Graduation size calibrated in unit least significant digit on display will change by this amount Indicates next parameter will be Span Span value calibrated in unit Indicates next parameter will be A to D counts representing the Zero Count A to D counts that indicate the calibrated Zero Indicates next parameter will be Full Scale Count 0 in most significant digit indicate value 71 000 000 A to D counts that indicate the Calibrated Span Value Indicates next parameter will be Scale Capacity Scale capacity value calibrated in unit Indicates next parameter will be Zero Tolerance Zero Tolerance value calibrated in unit Indicates next parameter will be Auto Zero Tolerance Auto Ze
145. ng Connector 6 pin Phoenix Resolution 6 digits Data Drive 15 LSTTL loads 6 mA total Print Not Print Drive 10 LSTTL loads 4 mA Transmit Distance 50 feet 15 24 meters Cable 6 40 pin right angle to 37 pin Dshell Connector Use with B6 and B7 Options Binary Coded Decimal BCD B5 BCD Single Termination Board B6 BCD Quad Termination Board B7 Allen Bradley Remote I O Interface B8 Binary Coded Decimal BCD B9 Chapter 2 Specifications Resolution 6 digits Data Drive 15 LSTTL loads 6 mA total Print Not Print Drive 10 LSTTL loads 4 mA Transmit Distance 50 feet 15 24 meters Cable 60 40 pin right angle to 40 pin right angle Use with B6 and B7 Options Overall Dimensions 7 75L x 5 0W 196 85mmL x 127 00mmW TB Wire Gauge 20 to 26 AWG Overall Dimensions 7 75L x 5 0W 196 85mmL 127 00mmW TB Wire Gauge 20 to 26 AWG Resolution 986 000 counts Represents 1 4 Rack of Discrete I O Type Transfers Discrete and Block Read amp Write Baud Rate 57 6 Kbaud 115 2 Kbaud 234 4 Kbaud Resolution 2 7 2151 30WC MANUAL Profibus I O Interface B12 Peak Hold C1 Rate of Change ROC C2 Totalizer C3 2 8 6 digits Data Drive 15 LSTTL Loads 6mA Total Print Not Print Drive 10 LSTTL Loads 4mA Transmit Distance 50 feet 15 24 meters Cable 24 For use with WS Wall Mount Instrument Protoc
146. nt panel displays and indica tors A device which produces an output signal proportional to the applied weight or force A set of prompts used to configure the instrument Operational prompts supplied in common language statements via the system display to guide an operator through a procedure A semiconductor device that performs control input output arithmetic and logical operations by executing instructions obtained from memory sources Allows operator to BEND the response of an instrument to match a non lin ear input The amount of allowable deviation between consecutive readings before a weighment is accepted as being complete An enclosure that is watertight dust tight and usable both indoors and out doors Will protect the enclosed equipment against splashing water seepage of water falling or hose directed water and severe external condensation An enclosure that is watertight dust tight and usable both indoors and out doors Will protect the enclosed equipment against splashing water seepage of water falling or hose directed water and severe external condensation Corrosion Resistant Gross Weight minus the Tare value A key used to step through menus or increase the value of a digit A deviation of an instrument response from a straight line The number of weight readings used to compute the displayed weight A parity configuration A device not supplied with a standard instrument A location on the
147. number the ERR 3 statement will appear Press the Test Clr button Enter a new number Press the Enter button The Scale Capacity SC CAP sub menu appears If this value is exceeded by 5 an 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 The value you set should be the small value between the capacity of the vessel volume in Gallons or Liters converted to weight in Lbs or Kgs and the combined weight capacity of the load cells Lbs or Kgs The value you set should be the smaller value between the capacity of the vessel volume in gallons or Liters converted WAVERSAVER WVRSVR This ends the Calibration Setup Process Calibration Procedures NOTE Step 3 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step Step 2 Chapter 6 Calibration to weight in Lbs or Kgs and the combined weight capacity of the load cells Lbs or Kgs For example A vessel s capacity in volume is 2 000 gallons in this case water One gallon of water weighs approximately 8 54 lbs The weight will be 17 080 Ibs The combined live load capacity of the load cells is 20 000 Ibs Select the lesser of the two values which in our example is 17 080 Ibs Enter 17 080 Press the Enter button The WAVERSAVER WVRSVR sub menu appears The lower the vibration the more steps and time required to calculate t
148. o Zero Calibration Zero Tolerance Zero Track Transistor transistor Logic Transmit Data Number of times per second a new weight reading is taken Weight reading once the dead load has been offset Offset of the value of the dead load of the weight hopper The number of graduations from zero that will be accepted as zero by the instrument Logic command used to adjust the instrument automatically from small vari ances in zero readings Appendix C Self Test Display SELF TEST DISPLAY SELF TEST DISPLAYYOUR RESULTS EPROM VER CALDAT CALTYP UNITS WSVR GRAD SPAN ZR CNT FS CNT 0 TOL A0 TOL MOTION AVRAGE LINCOR DIP 1 DIP 2 TAG 1 TAG2 2151 30WC MANUAL OPTIONS Press the 7 Option key to enter the optiOns menu and record the results The order of parameters may vary from this list depending on which options were installed OPTIONS FORMAT AN OUT 1 AN OUT 2 SERIAL PORT SERCON Print bi dir BAUD PARITY odd even none STOPS 1 bit 2 bits LENGTH 17 bits 18 bits FORMAT CONTRL hardre ECHO off ADDRES Appendix C Self Test Display SETPOINT MENU Press the 6 Set Pt key to enter the Setpoint menu and record settings SETPOINT MENU SEtPnt rLy 1 2 MODE SPNT DBND PRE PRINTER INFORMATION Make and Model Baud Rate Parity
149. o indicate the fol lowing weight controller conditions DISPLAY CTR ZERO MOTION ZERO TRACK RELAY 1 MEANING Indicates when the sensed weight is within 1 4 of a display grad of calibrated zero Indicates when the variation in consecutive weight readings exceeds the calibrated motion tolerance Indicates when the zero track function is activated Zero track is toggled on or off by the 0 Trk dipswitch S3 on the rear panel The status relay LED flashes when the respective set point value has been reached Indication is only for the standard internal set points 2151 30WC MANUAL NOTE NOTE Load Check Calibration Setup Procedures The Calibration Menu NOTE NOTE 6 6 DISPLAY RELAY 2 GROSS NET TOTAL ROC MEANING The status relay LED flashes when the respective set point value has been reached Indication is only for the standard internal set points Indicates the mode of the measured value on the display All calibration should be done in Gross mode Indicates the mode of operation currently PEAK configured Total Rate of change and Peak are options that must be installed before these led indicators will function Lb Kg Bar Graph Indicates U S or metric unit of measure of the weight parameter on the display The Bar Graph function displays in graphical form the value of the mode Total Gross Net ROC Peak selected in the bar graph setup menu The bar graph
150. o the Allen Bradley Network 8 1 5 Binary Coded Decimal BCD Output B9 1 5 PROFIBUS Interface Option B12 1 6 Dynamic Data Exchange DDE B14 1 6 Control Options 1 6 Peak Hold 1 1 6 Rate of Change ROC C2 1 6 Set Point Options 1 6 TTL Transistor Transistor Logic Level Output D1 1 6 External Setpoint Relays Card D2 1 6 External Setpoint Relays Card D3 1 7 Miscellaneous Options 1 7 240 VAC 50 60 Hz Input Voltage E2 1 7 NIST NTEP Certification Mode Kit E3 except for F4 wall mount 1 7 Portable Display and Keypad E4 1 7 Intrinsic Barrier Assembly F1 F3 thru F7 1 7 Interpreting the Model Code Number 1 7 Model Code Breakdown 1 7 Chapter 2 Specifica HI 2151 30WC Specifications for a Standard Instrument 2 1 tions Conv tsion Rate 22 2020 2 Doy cub Pu n munem Be 2 1 Resolution 2 1 Excitation Voltage 2 1 Averages
151. ol DP Decentralized Periphery Data Configuration 16 words or 32 bytes Standard Reference Process Fieldbus DIN 19 245 Baud Rate 9 600 Kbaud to 12 Mbaud Auto Selectable Display Highest Gross Value Average Peak Gross Value Time Units Seconds Minutes and Hours Time Base 1 6 10 12 15 30 60 120 240 450 900 or 1800 Display Accumulated Net Weight Activation Level Momentary connection to remove functions ground min 0 1 sec onds Six TTL Level Outputs D1 Six External Solid State Set Point Relays D2 amp D3 Chapter 2 Specifications Rating 300 ma per line Cable Length 5 feet 1 52 meters Type Solid State individually configurable form A or B Rating 115 VAC 3 Amperes Continuous 115VAC 5 Amperes Momentary Board Dimensions 5 7 L x 2 5 W 144 78mmL x 88 9mmW 2 9 2151 30WC MANUAL 2 10 Chapter 3 Installation CHAPTER 3 INSTALLATION Unpacking Chapter 3 covers unpacking cabling interconnecting and installing the HI 2151 30WC weight controller Users and service personnel should be familiar with the procedures in this chapter before installing or oper ating the HI 2151 30WC weight controller Step Step 2 Step 3 Before signing the packing slip inspect the packing for dam age of any kind Report any damage to the carrier company immediately Check to see that everything in the package matches the bill of lading You should normally h
152. ol system including load cells weight controller and cabling Chapter Eight also provides instructions for using Hardy s INTEGRATED TECHNICIAN software utility to isolate problems that may occur in a weight system Always disconnect the power cord before disassembling Make sure that any disassembly is done in a clean well ventilated properly controlled static environment Always make sure that the assemblies and sub assemblies are well supported and insulated when doing any repairs on HI 2151 30WC Weight Controller Place small fasteners connectors and electrical parts in closed con tainers so as not to lose parts during reassembly 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 Instru ments Customer Support Department for additional information and assistance Do not disconnect any electrical plug connector or terminal unless an identification tag is present or one is attached Always note where the connector or plug was attached to the electrical compo nent or wiring harness Always install complete hardware groups Screws Washers Lock Washers Spacers Etc back to the original point of removal Always replace broken or damaged modules or hardware immedi ately Always check to be sure that no loose parts are sitting on printed circuit boards or electrical connectors
153. olenoid 8 32 special test equipment 8 30 standard RS 232C 422 485 serial port 7 9 Standard RS 232C RS422 485 Configuration 4 1 Standard Setpoint Relays 2 1 Standard SPDT Form C Relays 3 10 standoffs 3 23 Status Bar button 6 5 Stop bit selection 5 9 Storage Temperature Range 2 2 strain gauge based force transducer 8 30 switch eight of S3 1 4 System Configuration 4 1 System Integrity Check and Fault Determination 8 25 System Support 8 39 T Tare 5 1 Tare button 5 1 Tare Value 5 1 target weight or level 7 4 Temperature Coefficient 2 2 The Calibration Menu 6 6 The Full Scale Count Sub Menu 6 20 The Return RETURN Display 6 14 Three General Rules for Setpoints 7 5 toggle switch 2 4 8 Total C6 7 2 Total Option 7 21 TOTAL Setup Procedures 5 14 Totalized 1 2 Totalizer C3 2 9 Totalizer Mode 7 21 Transmission speed 7 7 Trouble Shooting Using Integrated Technician 8 2 TTL level outputs 3 10 TTL Transistor Transistor Logic Level Output D1 1 6 two main operating menus Set Point and Option 7 2 U Unpacking 3 1 user selectable 7 7 Using Solid State Relays with Light Loads Optional Set Relays 8 32 Using the Return RETURN Function 6 17 Using the Return button 6 12 V valid 7 6 value is accepted 5 4 value is rejected 5 4 vessel 6 6 Voltage 2 2 4 5 voltage reading 1 3 W Wall Mount Model HI 2151 30WC WS 2 3 Wall Mount Version WS 3 10 Warranty 8 39 WAVERSAVERO 1 1
154. olerance Exits a numeric entry in a menu without chang ing the original value MODE MODE Standard mode Selects Standard Net Gross modes and any installed optional modes Optional Modes Peak Hold Mode C1 The PEAK mode dis plays the highest measured average gross weight The peak value is continuously moni tored and stored in any mode of operation The user can reset the peak hold mode by pressing the clear button while the Peak Value is dis played The peak value is stored in memory but will not be retained in the event of a power fail ure 7 1 2151 30WC MANUAL Operator Displays Instrument Operation Overview 7 2 ITEM LABEL BRIEF DESCRIPTION Rate Of Change Mode C2 The ROC mode displays the rate of change of the input with respect to a pre selected time base Total C6 The TOTAL mode displays the accumulated total weight The instrument adds the current net weight to the total net weight when a remote function is entered The value is available for displaying clearing or printing TARE TARE Captures current displayed gross weight and places value in the tare register Sets display to zero in net mode PRINT PRINT Outputs to RS232C serial port NOT used with multidrop ITEM LABEL BRIEF DESCRIPTION LEDs 30 discrete LEDs that displays either weight controller status or a bar graph representation of the selected weight display mode Display Fourteen segment LED display for displa
155. ommand will be sent to the port configured as a printer Meaning Print to either ports 1 or 2 An optional subcommand of up to 37 ASCII characters may be entered and will be printed before the formatted data SUB CMD Meaning 37 ASCII characters maximum H The ASCII characters supplied in the subcommand maximum of 20 characters will be printed as a heading and saved for each subsequent X transmit Parallel BCD Communication Operating Procedures H1 or H2 Chapter 7 Operation or P print command requested Heading is not stored in the Secure Memory Module To remove the heading transmit H with no subcom mand The ASCII characters supplied in the subcommand maximum of 20 characters will be printed as a heading and saved for each subsequent X transmit or P print command requested To remove the heading transmit H1 or H2 with no subcommand Adds the current net weight to the accumulated total A two ASCII digit hex number is transmitted with this command to enable a relay to be under the con trol of it s set point value The power on default is all relays enabled This command is used to reset instrument communi cation It is typically used when an error or unintelli gible response is received from the instrument and should used sparingly It is recommended that it not be used during normal communication retries i e unintelligible response but instead be used as a last resort no
156. or proper load sharing Proper load sharing should see only a difference of 5 mV Larger differences due to motors and piping should not exceed 2 mV Multiple load cells If there isn t any motors valves or piping to MAP the mV reading explain the mV difference adjust the Balance the load 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 Using a sprit level verify the vessel is vertically and horizontally correct Verify if any height change will effect the attitude of adjacent vessels or piping Adjust each legs to dynamically match mV outputs Verify the mV readings and physical level when complete Four load cells or more present a challenge Use Integrated Technician DVMTST DVM MV 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 a proper correction Repeat step 3 and 4 to achieve a proper load sharing vessel Verify the mV readings and vessel level when complete Monitor system for proper operation Check out complete 8 20 Chapter 8 Troubleshootin
157. osition is one of the following must be accompanied by at least one of the above SUB CMDs Continuous printing P Button on front panel triggers output NOTE The default FORMAT is GNTRSP 7 16 CAUTION NOTE Chapter 7 Operation M Monitors the specified SUB CMD data as fol lows by requesting a report whenever a change in the type of status occurs DO NOT USE THIS MCOMMAND IF THE SYSTEM IS CONFIGURED IN RING OR MULTIDROP MODES IF USED IN MULTIDROP MODE IT WILL CAUSE DATA TRANSMISSION PROBLEMS IT IS INTENDED ONLY FOR SINGLE UNITS SUB CMD Meaning R xx Relay number where xx is a two ASCII digit value D xx Dipswitch number where xx is a two ASCII digit value L xx LED number where xx is a two ASCII digit value Use this command to request a report when a change in status occurs in the subcommand selected You may request the status of the Relays Dipswitches or LED s Only one MONITOR subcommand may be issued per command After the command is received the instrument immediately sends back the present status of the subcommand request ed followed by a sign and a bell character cntrl This can be used to mark the beginning of the MONITOR command To select which particular relays dipswitches or LED s you want to monitor enter the appropriate 2 byte Hexadecimal number after the subcommand To shut off MONITOR command enter the MONITOR command sub command and Hex 00 SUB CMD Meaning 5 Set specified
158. ost computer Operation of the RS 422 485 consist of properly configuring the board See Chapter 4 Section 4 1 for configuration information and execut ing commands over the port Commands available and their actions are identical to the commands for the RS 232C Many devices available today are called RS 422 485 because their electrical signals meet or exceed both specifications This does not nec essarily mean they both meet the strict intent of RS 485 to provide for two wire multidrop networks They are instead multidrop RS 422 or four wire RS 485 networks The RS 485 mode when configured as two wire 2 wire jumper with the transmitter enabled If the unit is in the four wire 4 wire jumper mode with the transmitter always enabled then the board operates in a true RS 422 mode This flexibility allows compatibility between the host computer and the HI 2151 30WC 7 7 2151 30WC MANUAL 7 8 Additional Non standard Transmission Mode RS 422 485 Wiring and Electrical Specifications RS 422 485 Configuration Wiring e Used most frequently Only one host permitted Four wire RS 485 or multidrop RS 422 mode e When configured in four wire mode with the transmitter selectively tri stated the board is operating in a four wire RS 485 or multidrop RS 422 mode This configuration doesn t meet either specification but can be easier to program than either true specification Serial communication signal configuratio
159. ower Wiring WARNING Chapter 3 Installation DO NOT OPERATE WITH INCORRECT LINE VOLTAGE TO DO SO WILL RESULT IN PROPERTY DAMAGE OR PERSONAL INJURY CHANGING THE INPUT VOLTAGE RATING BETWEEN 120 AND 240 VAC REQUIRES MODIFICATIONS TO THE POWER RELAY CIRCUIT BOARD AND RELAY OUTPUT BOARD THIS PROCEDURE SHOULD ONLY BE DONE BY AUTHORIZED PERSONNEL FOR FURTHER ASSISTANCE CONTACT HARDY INSTRUMENTS CUSTOMER SUPPORT Step Step 2 Step 3 Step 4 Option po Option The HI 2151 30WC is factory configured to operate from either 120 or 240 VAC 50 or 60 Hz power Check the model number of your unit to verify the voltage If the unit is config ured for 240 VAC an E2 will be printed on the name plate The power and relay circuit card filters and conditions AC power However for noisy power lines external conditioning may be required Contact Hardy Instruments Customer Sup port for more information The AC power should be supplied by a clean primary line directly from the power panel This line should not supply any other equipment including the feeding unit and should be supplied with a minimum 10 amp breaker To connect power to the controller install a 3 wire minimum of a 14 AWG power line to the 3 pin terminal block connec tor See Fig 3 8 Fuse 5 AMP 250 VAC Slow Blow 3AG located behind J6 on the power relay printed circuit board
160. pears Step 14 Use the up or down arrows Tl to select either option Step 15 Press the Enter button twice First the Echo Sub Menu ECHO appears then ON or OFF will be displayed Step 16 Use the up or down arrows N to select either parameter For our example select OFF Step 17 Press the Enter button twice First the Address Sub Menu ADDRES appears then the current two digit address appears Step 18 Press the Test Clr button to clear the display Step 19 Enter the desired instrument address 99 maximum 10 unit 10 is used for this example Step 20 Press the Enter button three times to return to the weight dis play and normal operation Available only when BI DIR mode is selected The analog output option allows the user not only to output gross net ROC Peak or total weight as 0 5V 0 10V 0 20 mA or 4 20 mA or the reverse of these via the front panel but makes it possible to span these ranges over a portion of the weight data A full analog output is obtained over the range desired Resolution of the analog out is 16 000 counts or the number of display counts available in the range selected whichever is less All of this is accomplished via the front panel or the serial port Two analog option boards may be installed in each unit Analog Output Menu Setup Procedures NOTE NOTE NOTE Setting the Rate of Change Procedures NOTE Step Step 2 Step 3 Step 4 Step 5 Step 6 S
161. play 2151 30WC MANUAL Restoring Calibration When Changing Decimal Points NOTE 6 20 Restoring Decimal Points Step 1 Step 2 Step 3 If you wrote down the parameters for this controller on the Self Test Calibration Form Prt 0575 0016 enter the val ues from the form If you didn t write down the parameters on the Self Test Cal ibration Form get the form and write them down Check all Set point Option and Calibration entries for the correct decimal position You must complete procedures c before moving to procedure d to be sure that the decimal points in the correct position If you don t check the decimal positions the cal ibration will be incorrect Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 From the CAL menu press the Enter button The Hard Cali bration Sub Menu HD CAL appears Press the Mode button The Zero Count Sub Menu ZR CNT appears Press the Enter button The current value is displayed Press Test Clr button and enter the correct ZRCNT or Press the Enter button to accept the current value The Span Sub Menu SPAN Sub Menu appears Press the Enter button The current value is displayed The new decimal point will be displayed in the SPAN Sub Menu but it might be in the wrong place and displaying the wrong span value If the Span Value should be 2000 00 and the current display shows
162. play not functioning New System Calibration has not been completed Load Cell is faulty Broken or Open excitation wire 8 25 2151 30WC MANUAL DISPLAY RAMTST PASSED or FAILED OE OE example PASSED or FAILED SLOT 1 NONE or OPTION SLOT 2 NONE or OPTION CALTYP NOTE C2 CAL HCAL 5 CAL UNITS 8 26 TEST FAILURE SOLUTIONS Ram Test Writes to each location None in RAM amp reads back and verifies data Test 15 non destructive Indicates whether RAM test passed 1 With most RAM failures system will not operate failed 1 Check that EPROM 013 on main board is seated 2 Contact Hardy Instruments for assistance Two hex numbers displayed right one Discrepancy between two is actual checksum left one is numbers indicates EPROM calculated from test The two numbers must faulty match For each revision to EPROM numbers will be different If the two numbers matched test will pass otherwise fail is indicated It is possible for EPROM to loose one or more If failed replace EPROM If this doesn t eliminate the problem there could be a bits amp still operate BUS problem Indicates next display is for slot 1 Indicates which type of option card is 1 Check connector for installed in slot 1 if any proper mating 2 Try card in another slot Indicates next display is for slot 2 1 Check connector for Indicates which type of option card is proper mati
163. proper voltage level has been supplied Chapter 8 Troubleshooting DO NOT POWER UP THE CONTROLLER UNTIL INPUT VOLTAGES CAN BE VERIFIED Check the specification label attached to the weight controller chassis 110 vac or 220 vac 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 Keep ground cable runs as short as possible Excessive ground cable runs can act as an antenna for AC noise Install grounding straps around load cells to direct static away from the load cell and directly to ground Install ground straps on the input and discharge piping and the vessel to a common earth ground Apply power to the controller only if supply voltage is correct lt Verify the front display illuminates Completes the initialization process Displays a weight reading This weight value will not be correct if a calibration procedures was not performed Does the scale reflect a weight change Cabling TT To Verify Proper Load Cell Operations Go to K Press the MODE Button to display NET weight Press the TARE button to ZERO the NET weight Apply weight to the vessel a Does the weight increase and decrease in the correct direction with t
164. r ERR statement Option Menus and Option Parameters NOTE Option Boards General Information NOTE Chapter 7 Operation appears A list of error statements are provided in Chapter 7 Trouble shooting After checking the error statement correct the error To simply view a parameter value without changing the value push the Enter button If when changing a value you decide to retain the original value press the ZERO button instead of the Enter button This will save the original value and advance to the next parameter Option menus are used to set parameters for the various option boards option parameters except for Peak Hold are automatically saved and updated in the Secure Memory Module The following sections describe menu operation Do not modify ANY Sub menus while the serial interface or A B RIO are attempting to modify information OPTION MENU TREE Rate of Change Analog Ouput Analog Ouput BCD Port Bar Profibus Allen Bradley Graph RIO Units Node Rate Address Analog Analog Analog Analog BarHi BarLo HI 1 Rack Number Format Number Gross Net Tare Display Print Last Quarter Sercon Ser Type Baud Frame Format Control Echo Address Bi Dir RS 422 19200 8 N 1 G HARDRE ON Print RS 485 9600 7 0 1 N SOFTRE OFF 4800 7 E 1 T 1 99 2400 8 N 2 R 1200 8 0 1 5 600 8 E 1 P FIG 7 2 OPTION MENU TREE The Hardy Instrument option boards provide
165. r sin gle digit addresses for serial port 2 4 There is one space 20 hex required between each type of data fol lowing the INSTRUMENT ADDRESS hence the outgoing com mand represented in hex format would be 3E 31 30 20 58 20 47 00 34 44 04 gt 1 0 X G CR 4 D EOT An example using the x transmit command without Hardy Link 15 2 BYTE CHECKSUM START cmp sUB CMD CR EOT CHAR CHK 1 CHK 2 gt x G CR CHK 1 CHK2 EOT Serial Commands The checksum is computed by totaling the bytes in the command Command Set stream starting with the INSTRUMENT ADDRESS through and including the CR and then subtract 256 from the total until the remain der is less than 256 to achieve a one byte maximum The result is then represented as two ASCII bytes and appended to the command fol lowed by an EOT 04 Value Description 31 address instrument number 10 ASCII 1 30 address instrument number 10 ASCII 0 20 space 58 X 20 space 47 G 0 CR 144 Value Description z 100 4d Serial commands are transmitted from the instrument back to the host in the format they were received from the host with the return data and units added to the message and an LF added to the CR Using the above example the return data would be 7 12 Chapter 7 Operation NOTE Command Meaning 7 BYTE 2 BYTE CHECKSUM START INSTRUMENT SUB
166. ration Self Test 6 15 Performing the Self Test 6 17 phillips screw driver 3 5 Physical Characteristics 2 2 Portable Display and Keypad E4 1 7 Portable Display HI 2151 30XX E4 use with 2151 30WC BR 2 4 positive dead band 7 5 Positive Pulse 4 7 Power 2 2 preact 1 4 Preact Limits See Fig 7 3 7 5 preact value 7 5 Pre Calibration Procedures 6 1 Print 5 2 Procedures to Restore Calibration Parameters 6 19 Process Weighing Function Buttons 7 1 Profibus I O Interface B12 2 8 Profibus Installation and Operation Manual Prt 0596 0211 7 22 Profibus Interface Card Option Wiring Diagram 3 24 PROFIBUS Interface Option B12 1 6 Profibus Interface Option B12 3 21 7 22 Programmable Logic Controller 4 5 Q Quick C20 Calibration Procedures 6 18 R Rate of Change ROC 7 20 Rate of Change ROC C2 2 8 Rate of Change ROC 1 2 Rate of Change ROC C2 1 Rate Of Change Mode 7 2 2151 30WC MANUAL readings per average 6 10 Rear panel input 1 4 Reassembling Rear Panel 4 5 re calibrated periodically 6 1 Recommended Installation Procedures 3 8 Register 7 20 Remote Functions 1 4 Remote Functions Non operational 8 31 Remote Functions Wiring 3 12 Remote RIO Interface to the Allen Bradley Net work B8 1 5 Remote Mount Model HI 2151 30WC RM 2 3 Report any damage 3 1 Request to Send RTS lines 5 10 Resolution 2 1 4 10 Return to Zero Test 1 3 8 35 ribbon cables 3 19 ROC data
167. re returned If turned off only data transmitted from the instrument will be displayed Selects hardware and software handshaking control The hardware mode controls Request to Send RTS lines In this mode the receiving device must set Clear to Send CTS lines to high to enable transmission The software mode controls the trans mission by the following control codes XOFF CTRL S halt transmission XON CTRL Q resume transmission When a serial port is configured for bi direc tional communication with a Print Trigger for mat the control port will respond to the remote function print or serial print command just like a print port If you have a problem with weight readings not changing or not being able to exit from a menu check to see that the instrument has not been set in the Display Hold mode by a serial command A C H change hold command will toggle between Hold and Unhold There is no visual indication showing the present mode Step l Enterthe Option Setup Menu by pressing the 7 Option button The Rate of Change Sub Menu ROC appears Display may show an option other than ROC depending upon the options installed The HI 2151 30WC will show the first available option in the example ROC NOTE Step 2 Step 3 Step 4 Step 5 Chapter 5 Setup Press the up arrow until the Serial Port SER is dis played on the screen Press the Enter button twice First the Serial Connect display SERCO
168. ro Tolerance set during calibration Chapter 8 Troubleshooting FAILURE SOLUTIONS Default is Lb Default is 4 None Default is 1 None Default is 10 000 Default is 36780 None Default is 992000 None Default is 10 000 None Default is 10 None None 8 27 2151 30WC MANUAL DISPLAY TEST MOTION Indicates next parameter will be motion value 3 Motion value calibrated in unit example AVRAGE Indicates next display will be number of values set in the running average table 1 200 100 Number of values set up to be averaged example LINCOR Indicates next display will be single point linear correction 0 If 0 linear correction is not used Number example other than 0 indicates single point calibrated value AD OFF Indicates next display will be A to D Off Set 28012 A to D Offset Value ADGAIN Indicates next value will be A to D gain 828238 A to D Gain Value DIP 1 Indicates next display will be settings of rear panel Config dipswitch S3 segments Settings represented by hexadecimal notation 00 thru FF SWITCH VALUE ON POSIT 2 01 Cal toggle 4 02 Opt menu lock 5 04 S P menu lock 7 08 Tare Ib kg N G lock 8 10 Zero track on 6 20 Spare 3 40 Serial requests only 1 80 P2 multidrop 8 28 FAILURE SOLUTIONS None Default is 3 None Default is 100 None Default is O None None None None If value is other than desired reset dipswitch segment and retes
169. ro or negative value not allowed Err 14 Scale capacity of zero or at negative value not allowed or indicates Err 15 Zero tolerance of zero or a negative value not allowed or indicates lin ear correlation value entered is not gt 0 or lt Span value Err 16 Tare greater than span NTEP only Err 17 Acquire tare cannot be used with zero gross weight NTEP only Err 18 Difference between zero and span is less then 100 counts in the positive direction or indicates the linear correction point is not 100 counts gt 0 or 100 counts lt Span point Err 19 Occurs when configuring Serial Port 1 and entering a negative address Err 20 Option held when a print command was requested Option hold active on remote functions TB when print command from serial port requested Serial Port only Err 24 Clock malfunction Err 25 Invalid total decimal point Err 26 Faulty time or date entry Err 40 Software Cal sticker value too small Err 41 Software Cal reference point weight out of range Err 42 Software Cal load cell overloaded Err 43 Software Cal range is zero error Err 44 Sensitivity out of range Err 45 No Software Cal in NBS range Err 50 Too many BCD Options Err 52 Too many Serial Options Err 54 Invalid serial or BCD format entry Por Error Message Err Err Err Err Err Err Err Err 55 60 61 62 63 64 65 99 General Policies and Information System Support Warranty NOTE FOR FURTHER INFORMATION
170. s Voltage Frequency Power Common Mode Voltage Range Common Mode Rejection Environmental Requirements Operating Temperature Range Storage Temperature Range Temperature Coefficient Humidity Range Physical Characteristics Panel Mount Model 2151 30WC Current less than 10 Accuracy 2 of full scale Resolution e mV VA4 digits to the right of the decimal e mV digit to the right of the decimal 120 VAC 10 Standard 240 VAC 10 E2 Factory Option 47 63 Hz 10 Watts maximum with options 2 5 VDC 100dB 50 60Hz 10 to 50 C 14 to 122 F 20 to 85 C 4 to 185 F Less than 0 005 of full scale per degree C for zero and span 0 90 non condensing Depth 11 35 288 29mm Back of the Bezel to rear cable clearance Case Dimensions 2 99 H x 5 65 W x 9 02 D 75 9mmH x 143 51mmW x 229 11mmD Wall Mount Model HI 2151 30WC WS Remote Mount Model HI 2151 30WC RM Chapter 2 Specifications Front Panel Dimensions 3 74 H x 7 00 W x 0 42 D 95mmH x 177 80mmW x 10 67mmD Panel Cutout Dimensions 3 09 H x 5 75 W 78 5mmH x 146mmW Case Material Aluminum alloy 6063 T5 Chem Film MIL C 541 Weight 4 6 pounds 2 1 Kilograms Rating Front Panel NEMA 4 Seal Case Dimensions 15 5 H x 12 94 W x 6 42 D 393 7mmH x 328 68mmW x 173 07mmD Case Material 304 Stainless Steel Body 14 gauge Cover 16 gauge Weight 19 8 pounds 9 Kilograms Enclosure Rating NEM
171. s REL Relay REM Remote ROC E Excitation Monitor SUB CMD Meaning REL Relay Bit RELAY 01 5 02 4 04 3 08 1 10 2 20 8 40 7 80 6 SUB CMD Meaning The L command returns a two byte status each bit describing the LED status The values returned are the hex values of the two bytes Byte 1 LED STATUS BYTE 1 Byte 2 LED STATUS BYTE 2 Bit 0 Pounds led Bit 1 Zero track led Bit 2 Not used Bit 3 Center zero led Bit 4 Motion led Bit 0 Rate of change led Bit 1 Alarm 2 led Bit 2 Alarm 1 led Bit 3 Peak led Bit 4 Total led Byte 1 LED STATUS BYTE 1 Byte 2 LED STATUS BYTE 2 Bit 5 Gross led Bit 6 Net led Bit 7 Kilograms led Bit 5 Not used Bit 6 Not used Bit 7 Not used SUB CMD Meaning DI The HI 2151 30WC will return two bytes for the dip switches Dip switch 1 is the one on the rear panel and Dip Switch 2 is internal to the unit located on the bottom power relay board Chapter 7 Operation Dip Switch 1 53 Position Bit Function ON position 1 80 Multi drop 2 01 Calibrate toggle Non NBS applications 3 40 Serial command lockout Requests OK 4 02 Option menu lockout 5 04 Set point menu lockout 6 20 Spare 7 08 Lb Kg N G Tare and Zero lockout 8 10 Zero track SUB CMD Meaning Dip Switch 2 S2 Position Bit 1 08 2 10 3 20 4 04 5 40 6 80 7 02 8 01 SUB CMD E Function ON position Ignore incoming checksums On is aver
172. s detected this is accomplished by providing a momentary switch to the remote function connector between J2 Pin 8 and J2 Pin 9 or 10 See the Profibus Interface Option Card Operation and Installation Manual 50596 0231 for complete instructions See the Allen Bradley Remote I O Installation and Operation Manual 0596 0173 for complete instructions Chapter 6 Calibration CHAPTER 6 CALIBRATION Pre Calibration Procedures Mechanical Check Procedures CAUTION Chapter 6 covers calibration procedures for the HI 2151 30WC weight controller Users and service personnel should be familiar with these procedures before installing or operating the HI2151 30WC For the weight controller to work properly it must be calibrated prior to operation We also recommend that the instrument be re calibrated periodically or when not in use for extended periods Be sure to follow the procedures completely to ensure that the weights read by the con troller are accurate calibration should be done in the Gross mode Step l Check to determine if the load cells have been installed prop erly e Refer to your load cell I amp M manual for proper installation instructions Onsome single and double ended shear beam load cells there is an arrow J that indicates the direction of the applied load If the arrow is pointing in the wrong direction change the position of the load cell so that it is mounted in the direction of the applied
173. s individual load sensor output mV readings Press ENTER To check load sensor Record load sensor mV output level for comparison Repeat for all load sensors NEXT loadpoint bridge resistance reading with an Ohmmeter 1 Stressed load cell remove all load and re test 2 Excessive loading For additional testing go to egative mV reading Unstable reading mV 8 16 readings cceptable Defective load cell Replace and repeat TEST F Yes If you are unable to determine the Milli volt readings Go to TEST COMPLETE Load sharing OR Contact Hardy Customer Support 800 821 5831 Chapter 8 Troubleshooting G Error 18 During Hard Calibration ERROR 18 The difference between zero and span is less than 100 counts There are two places during HARD CAL where error 18 can occur ZERO and SPAN ZERO SPAN The new Zero Reference ZRCNT is larger The milli volt signal reading did not show a positive than the original Span FSCNT increase 1 At ZERO arrow to SPAN 1 Use INTEGRATED TECHNICIAN to verify 2 Add the test weight to the scale Milli volt levels and perform the SPAN entry 2 Compression Load cells can be installed 3 After SPAN GOOD arrow back to upside down Giving negative signal readings ZERO 3
174. setup proce dures Alternatives to these procedures are not recommended HI 2151 80W C WAVERSAVER IT PETTITT 8 8 8 8 8 Test Clr Val Status I lb kg Set Pt Option FIG 5 1 FRONT PANEL Used in Gross mode to zero the display to within the tolerance level This function can be used as many times as desired as long as the total does not exceed the value entered as the zero tolerance The zero key is also used to exit a menu after entering number s without changing the original number For example when entering a Span value 18 the user decides that the original number 15 is OK By pressing the Zero Key you can exit the menu without changing the original number 15 even though you have typed new numbers and they appear on the display In standard controllers the mode key toggles between gross and net weight In controllers with any one or all of the mode options Total Mode Peak Hold Mode or Rate of Change Mode installed the mode key toggles between gross net weight and the option s To order Total Peak or ROC options contact your local Hardy Representative or call FAX E mail Hardy Instruments Sales Department The Tare button captures the current Gross weight at the instant the Tare button is pressed and places it in the tare register setting the Tare Value The tare value is the difference between the Net e g Vessel weight and Gross weight e g vess
175. side loading from piping or external forces Install flexures on all piping to insure a free floating vessel Insure the vessel and loadcell mounts are mechanically stable and fixed Stable No Large changes in individual Loadcells indicate a shift in COG or faulty Loadcells Piping and motors will effect the individual loadcell readings Allow for a higher reading on Loadcells that support motors and piping Insure pneumatic lines are not applying pressure to the vessel when energized Use check stay rods to minimize vessel movement Insure the check rods are loose and not interacting with the vessel Power down all vibration vacuum and pressurization equipment during the test process Stable Configuration settings Incorrect Waversaver settings can cause unstable weight readings Adjust to the lowest WS setting that gives you a stable reading Higher frequencies with low amplitude vibrations Use WS settings 1 or 2 Low frequency with high amplitude vibrations Use WS setting 3 and higher Incorrect number of decimal places Reading weight increments beyond the equipments applications level see guideline caluculations below Repeatability Divide the total loadcell capacity including decimal points by 10 000 expected stable weight reading Resolution Divide the total loadcell capacity including decimal points by 30 000 The amount you can expect to see but not necessarily stable
176. sor operation Error 18 Mechanical Inspection Electrical Inspection Load Sensor Installation HI Error Indication Blank Display Excitation Monitor Display Stuck on HARDY Screen Chapter 8 Troubleshooting A Guidelines for Instabilities on Formerly Operating Systems Press TST CLR To START INTEGRATED TECHNICIAN LT diagnostic program Select System Check SYS TST Press ENTER This program level isolates the instrument from the rest of the weigh system EN Monitor the display for checks the internal stability electronics stability NC STABLE NO This next step isolates the controller and v loaqpolnit signal Cable Eres ENTER Verify tight cable connections and from the weight to continue testing Yes cable integrity vessel Tests the controller and loadcell Y signal cable to the I T Monitor the JUNCTION BOX Display for stability NO NO STABLE Y Replace Integrated Technician Summing card YES NO 2151 30WC MANUAL A1 Guidelines for Instabilities on Formerly Operating System Cont d UNSTABLE WEIGH CONTROLLER Internal check SYSTST cont INTREF Disconnect external signal cables shields except AC power
177. ss parameters press the up arrow f Hard Calibration Self Test Procedures Traditional Method Using Test Weights Perform the Hard Calibration Self Test Soft Calibration Procedures for Single Load Cell Point Systems NOTE About Soft Calibration Chapter 6 Calibration Step Press the Test Clr button The Self Test SLFTST Sub Menu appears Step 2 Write down all the Hard Calibration self test parameters on the Self Test Calibration Results form See Appendix C HI Document 0570 0016 01 for single controllers or 0575 0016 02 for multiple controllers Please photocopy as many copies of the form s as you need Step3 Press the down arrow 4 button to pause the test Step 4 review the test results Slot 1 for example Press the down arrow to pause the Self Test Press the up arrow one time and the value for Slot 1 appears for example none Write none down in the results column for Slot 1 on the Self Test Calibration form The user can continue to push the up arrow to review more results or let the controller resume the self test until the tests are completed Step 5 There are two tests which are Pass Fail The Check Sum and the RAM test If the controller fails either one of these tests contact your local representative or Hardy Instruments Cus tomer Support Department Soft Calibration for systems with more than one load cell point contact Hardy Instru ments Inc Customer Support Dep
178. t OFF Cal toggle No opt menu lock No S P menu lock zero Keys not locked Zero trk off Spare All serial I O Not multidrop DIP 2 00 thru FF LC CNT 20 8 SN SN8 xxxx XXXx NOTE TAG DISPLAY 00 thru FF TAG 2 00 thru FF Indicates next display will be settings of Chapter 8 Troubleshooting If value is other than desired internal dipswitch S2 on power relay board reset dipswitch segment and retest Settings represented by hexadecimal notation SWITCH VALUE ON OFF POSIT 8 01 Spare 7 02 Spare 4 04 NBS Re Call toggle switch 1 08 Ignore incoming checksums 2 10 On is averaged gross Off is instantaneous gross 3 20 NBS 5 40 Spare 6 80 Spare LC SNI through SN8 is for C2 only Indicates next display will be value of software control options Settings represented by hexadecimal notation TEST VALUE ON 01 Bar graph 02 Rate of change 04 Peak hold 08 Hardy link 10 Optional relays 20 Spare 40 CAL SW override 80 Totalizer If options are not as desired another memory key must be ordered Contact Hardy Instruments Customer Support Department FAILURE SOLUTIONS OFF No bar graph No ROC No peak hold No Hardy link No optional relays Spare Normal CAL mode No totalizer Indicates next display will be value of software control options VALUE ON 01 Spare 02 Remote clear total 04 Remote clear peak 08 Partial Setpoint Lo
179. t B5 BCD Single Termination Card B6 BCD Quad Termination Card B7 Remote I O RIO Interface to the Allen Bradley Network B8 Binary Coded Decimal BCD Output B9 Analog Output is configured from the front panel or the serial port and set up by jumpers on the printed circuit card The option allows the transmission of Gross Net Optional ROC Peak or Total weight as 0 5V 0 10V 0 20mA or 4 20mA or the reverse of these and makes it possible to span these ranges over a portion of the weight data Resolu tion is either 16 000 counts or the number of display counts available in the range selected whichever is less Two analog optional boards can be installed in each instrument Both voltage and current data are avail able simultaneously This BCD Option provides six digits of parallel weight data represent ing Net Gross Tare and the present front panel display If all types of output data are requested they appear one after the other ten millisec onds apart The BCD option provides a 37 pin D subminiature con nector on a 6 inch cable This BCD option provides six digits of parallel weight data represent ing Net Gross Tare and The Present Front Panel Display If all types of output data are requested they appear one after the other ten millisec onds apart The BCD option provides a 40 pin connector on a 60 inch cable for use with either the optional B6 or B7 external termination boards The
180. t Instrument Serial Communications 7 9 Printer Output 6 7 9 Serial Protocol Multidrop Mode 7 9 About Serial Protocol Multidrop Mode 7 9 Data Formats 7 10 Data Formats Binary Representation 7 10 Data Formats Weight Data Format 7 10 Serial Commands 7 11 Serial Commands Data Transmission Format 7 11 Serial Commands Command Set 7 12 2151 30WC MANUAL Chapter 8 Trouble shooting vi Command Meaning 0 6 7 13 Parallel BCD Communication 7 19 Operating Procedures 7 19 BCD Print 7 20 Output Disable 7 20 Rate of Change ROC 7 20 Example 7 20 Rate of Change Data 7 21 Peak Hold Mode Option 7 21 To display PEAK HOLD 7 21 To reset the Peak Value to zero 7 21 To exit Peak Hold mode 7 21 Totalizer Mode Option 7 21 To display the Total Value
181. tallation Procedures 3 15 Options Cabling and Interconnect 3 16 Analog Output Option B1 See Fig 3 12 3 16 BCD Option Board Installation Procedures B2 5 9 3 17 BCD Terminator Boards 7 3 19 BCD Termination Board Installation Procedures See Fig 3 14 3 19 Allen Bradley RIO Interface Option B8 3 20 Profibus Interface Option B12 3 21 Dynamic Data Exchange DDE I O Server 14 3 22 HI2ISIT Series Junction Boxes 3 22 Set Point Relay Option Board Installation D2 3 22 Profibus Interface Card Option Wiring Diagram 3 24 Installation of the Secure Memory Module 3 24 Standard RS 232C RS422 485 Configuration Procedures 4 1 Setting the Jumpers 4 2 Analog Output Option Card Configuration Procedures Bl 4 4 About the Analog Output Card Option 4 4 Setting the Jumpers 4 4 Disassembling the rear panel and setting jumpers 4 4 Reassembling Rear Panel 4 5 Front Panel Setup Procedures 4
182. tation Monitor Digital Volt Meter DVM Return to Zero Test Weighing System Tests Secure Memory Module SMM Chapter 1 Overview Continuously monitors the system excitation current for evidence of open or shorted load sensors or damaged or broken excitation wire s including the wires between the instrument and the junction box If the measured current deviates from a 10 tolerance an ERRExC Error Excitation displays on the front panel In a system with C2 load sensors IT computes the correct current and displays alarms if the ini tial measured current is out of tolerance Without C2 load sensors the initial read is assumed to be correct and is used as the standard The DVM displays millivolts mV to one digit to the right of the deci mal point and millivolts per volt mV V to four digits to the right of the decimal point for both the whole system and individual load sen sors The DVM helps enables the user to isolate a faulty component from the front panel The voltage reading can be used to level a bal anced system and to make corner adjustments to platform scales Accu is 2 or better of full scale This test compares the original voltage reading saved at calibration against the current voltage reading of an empty vessel and displays either a pass OK or fail ERR message The test checks for load sen sor damage due to electrical zero shift or abnormal mechanical forces that causes binding sensors
183. tection Allows parity to be set at even odd or no parity Stop bit selection Sets number of bits used to indicate end of a transmission frame The number of stop bits can be set to 1 or 2 Word length selection Sets the number bits for each data word Word length can be set to 7 or 8 bits Formats the serial data output To configure the output use the left arrow button to select the code letter corresponding to the specific parameter s When the letter is flashing use the up or down arrow buttons to toggle the code letter on the display To enable a specific parameter the code letter must be shown on the display Pressing the Test Clr button will restore all code letters The codes are G Gross Weight N Net Weight T Tare Value R Rate of Change ROC S Set point Deadband Preact Values 5 9 2151 30WC MANUAL Serial Procedures NOTE NOTE 5 10 DISPLAY PRINT BI DIR ADDRESS ECHO CONTRL MEANING Selects print mode P sets print trigger and sets continuous output Selects bi directional mode The bi directional codes are A Altered print removes checksums P Bi directional with print trigger Bi directional without print trigger Selects the instrument address This is a two digit value being 01 to 99 Selects whether instrument commands are returned or displayed Echo can be turned on or off If the bi directional only Echo is turned on commands sent to the instrument a
184. tep 7 Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 Step 16 Chapter 5 Setup Press the 7 Option button ROC appears Press the up arrow until Analog Output ANAOUTI or Analog Output 2 ANAOUT is displayed Press the Enter button ANLO appears Press Enter button Press Test Clr button to clear the entry Use the numerical keypad to enter the value desired Enter for loss in weight systems The value displayed will equal 4 milliamps 0 milliamps volts depending on which output and configuration is used Press the Enter button A GOOD will momentarily appear and AN HI appears Press the Enter button Press Test Clr button to clear the entry Use the numerical key pad to enter the numerical value desired Enter for loss in weight systems The value displayed will equal 20 milliamps 10 volts or 5 volts depending on which output and configuration is used Set mode by pressing the MODE button until the cursor is flashing under the desired option Select from total gross net ROC or peak The default is gross Press the Enter button AN LO re appears Press the Exit button ANOUT re appears Press the Exit button again to return to the weight display Display may show an option other than ROC depending upon the option boards installed Previously set numerical value will be displayed 0 is the default Display momentarily flashes GOO
185. ter 5 Section 5 4 Step 2 Check to see if CTR ZERO MOTION and ZERO TRACK leds are flashing When the Auto Zero Tolerance is enabled any weight within the entered tolerance of zero and not in motion will cause the display to automatically read zero 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 2151 30WC MANUAL Dip Switch Location See Fig 4 10 Dip Switch Setting Configuring Peak Hold Mode About Configuring Peak Hold NOTE 4 8 Auto Zero Tolerance 2 Dip Switch S3 Ct i FIG 4 10 AUTO ZERO DIP SWITCH SETTING Step To enable the Auto Zero Tolerancing set dip switch 8 to ON Step 2 disable the Auto Zero Tolerancing set dip switch 8 to OFF Highest gross or averaged gross is selectable on dip switch S2 position number 2 located internally on the Main Controller board See Fig 4 11 Dip Switches S2 on the Power Relay Board are all normally in the OFF position Contact Hardy Instrument Customer Support Department before changing any of these switch positions Configuring Multidrop 53 1 Configuring Serial S3 3 Configuring Option S3 4 Configuring Set Point S3 5 Set Point S3 6 Configuring Lock S3 7 Chapter 4 Configuration
186. that the display on your Programmable Logic Controller reads precisely with the display on your weight controller Use the procedure below which corresponds to the input card in your PLC Make sure the Analog Option card is programmed correctly prior to performing any adjustments If 0 volts represents other than empty put weight on your load cells equal to your 0 volt selection Otherwise with the hopper empty adjust R4 for the correct reading Put weight on your load cells equal to your 10 volt selection Adjust R16 for the correct reading Put weight on your load cells equal to your 4 ma selection if 4 ma represents other than empty Adjust R19 for the correct reading Put weight on your load cells equal to your 20 ma selection Adjust R5 for the correct reading 2151 30WC MANUAL Parallel BCD Board Print Configuration Procedures B2 B5 B9 About the BCD Board Print Output Signal Jumper Location Jumper Settings See Fig 4 7 and 4 8 4 6 0535 0406 REV E ANALOGOUT Pwa 2 C z 5 700125 00000000 200 265 8 2 yu 00000000 x att NT o o 500 0 slloooll zl QUI z 2 o RN2 u 0000000 SN
187. the current resistance and display the value Press the Enter button TEST R appears TEST R Test the base reading against the current reading and displays RZGOOD or R ERR Press the Enter button and ONLINE re appears Press the Exit button The Digital Volt Meter Test DVMTST appears NOTE The IT Junction Box must be used to display individual load sensors 1 Press the Enter button NUMLS appears indicating the number of C2 load cells Press the Enter button The Digital Volt Meter in Mil livolts DVM MV appears NOTE Return to Zero Test Chapter 8 Troubleshooting 2 Use the up or down arrows to toggle between Millivolts MV and millivolts per volt DVMMV V 3 Press the Enter button to select either one LS1 Load Sensor 1 appears The display may also show LS1 indicating that the load sensor is a C2 load sensor 4 Usetheupordownarrows to select whichever load sensor you want to check LSI LS2 LS3 54 OR LS ALL or press the Enter button to move onto the next load sensor 5 Press the Enter button The controller reads the present value in millivolts or millivolts volt whichever was selected The Millivolt scale will display to one decimal place The Millivolt volt scale will display to four decimal places 6 Press the Exit button The Return to Zero Test RTNTOO appears The IT Junction Box must be used to display individual load sensors 1 1 Press the Enter button NUMLS appears indicating the number
188. tings and the bar graph e Status function indicates the following e Selected Mode e Selected Engineering Unit Ibs kg e Status of Relays 1 amp 2 The Bar Graph function displays in graphical form the value of the mode Total Gross Net ROC Peak selected in the bar graph setup menu See Fig 5 2 The bar graph mode and the display mode are totally independent Make sure you know what mode each are in before reading e key also enters the digit 2 3 Lb Kg AIT 5 lt 6 Set Pt 7 Option Chapter 5 Setup Toggles between read pounds Lb or kilograms Kg The key also enters the digit 3 This key moves forward through a menu step by step and will wrap to the beginning of the menu The key also enters the digit 4 Resumes the Self Test Bar Graph HI 2151 30WC WAVERSAVER ce IT MODE TARE PRINT Tare Val Status Bar lb kg tT Test Clr FIG 5 2 FRONT PANEL BAR GRAPH DISPLAYED Moves the decimal point position to the left when in Calibration Mode Selects user selectable formats in the serial and optional BCD menus The key also enters the digit 5 This key is used to enter the Set point Menu e Values for standard and optional Relays Set point Values Deadband Values Preact Values The key also enters the digit 6 This key selects the standard serial ports and available option menus Rate of Chang
189. uld you not under stand any information in this manual or experience any problems with the product please contact our Customer Support Department at Phone 858 278 2900 FAX 858 278 6700 Every Hardy Installation and Operation manual is organized into easily referenced chapters that are almost always the same Chapter One Provides an introduction to the instrument and an Overview of the equipment and its capabilities Chapter Two Provides a list of Specifications Chapter Three Contains information needed to Install the HI 2151 30WC both standard equipment and optional equipment and the HI 215IT series Junction Box Chapter Four Provides Hardware Configuration instructions for setting dip switches and jumpers Chapter Five Describes the Firmware Setup and preparation proce dures to calibrate and operate the instrument Chapter Six Provides Calibration instructions Chapter Seven Describes the Operation of the HI 2151 30WC Chapter Eight Describes Troubleshooting procedures for repair of the instrument The HI 2151 30WC is a compact multipurpose microprocessor based weight controller See Fig 1 1 that is used for a wide variety of pro cess weighing applications including batching blending check weigh ing filling dispensing force measurement level by weight and weight rate monitoring As a standalone product the HI 2151 30WC can con trol as many as eight set point relays and transmit data via an
190. uncated since only 5 numerics the minus sign is legal B above 12345 67 N 12345 6 The 7 would be truncated since only a maximum of 6 numerics 4 decimal points is legal A above Serial commands are transmitted to the instrument in ASCII format Each command has a single letter corresponding to the command The instrument will accept command strings up to 40 characters the 40th will internally default to a carriage return The front panel serial port menu allows setup of serial communication parameters i e BAUD parity etc The following table uses the mnemonics corresponding to the outgoing command format some of which are optional Mnemonic Meaning Number of ASCII Bytes CMD Command 1 SUB CMD Subcommand 1to3 DATA n Data byte n 1 to 7 MODE Mode 1 Carriage return 1 Serial commands are transmitted from the host to the instrument in ASCII bytes in the format 2 Control characters are transmitted in HEX See the ASCII to HEX table in Appendix A 3 Anexample using the x transmit command with Hardy Link and an address of 10 is 2 BYTE CHECKSUM CMD SUB CMD CR 4 EOT CHK 1 CHK 2 START INSTRUMENT CHAR ADDRESS 10 X G CR CHK 1 CHK 2 EOT 2151 30WC MANUAL NOTE The example uses decimal and mnemonic abbreviation format for clarity however the actual data would be in ASCII format leading zero i e 01 is required fo
191. use the level to remain between 200 and 1 000 pounds 1 3 Set points activate at the set point plus the preact Set points deactivate at the set point plus the deadband The deadband should be numerically larger than the preact to pre vent relay chatter RELAY TRIPS WEIGHT WEIGHT TIME LOW TRIP LIMIT FIG 7 3 LOW AND HIGH PREACT TRIP LIMITS The preact value is the number of units below negative value or above positive value the set point value at which the relay will trip It is used as an in flight compensation value when filling a vessel If set to zero there will be no compensation Used to enter the set point dead band and preact values for the two standard internal relays Used to enter the associated values for the six optional external relays when installed To scroll forward or backward through the Set Point Menus press the Up or Down arrow N buttons 7 5 2151 30WC MANUAL NOTE NOTE NOTE Entering Set Point Procedures Entering Dead Band Tolerance Procedures Entering Preact Values Procedures A previously assigned set point value will be displayed For this example the set point value will be set to 500 Step Press the 6 SetPt button to select set point menu RLY 1 appears with the 1 flashing Step 2 Press the Enter button Set Point 1 appears SPNT 1 The mode status display indicator flashes on the present set point mode To
192. used to Tare the instrument activate a print sequence totalize the display force the Net mode toggle between pounds or kilograms initiate the optional ROC Rate of Change mode freeze the front panel display or one of the communications ports and clear the totalizer or peak hold values This is useful for adding large additional industrialized switches to the control panel Auto Zero Tracking causes the display to indicate zero as long as any live weight on the scale is below the set zero tolerance and the scale is not in motion This capability allows the instrument to ignore mate rial build up in the weigh system within the set zero tolerance Do not use auto zero tracking to correct a drifting scale problem Auto zero tracking will zero and write to the SMM every second if there is a change in weight A correct graduation size is required to stop excessive weight changes and reduce write commands to the SMM See Chapter Six for graduation size setup guidelines The amount of weight zeroed off is cumulative The autozero command will fail if the current gross weight plus any previously zeroed amount exceeds the zero tolerance Auto Zero Tracking is enabled when switch eight of S3 the configura tion dipswitch labeled Config on the instrument s rear panel is in the on position Chapter 1 Overview Output Device Options Analog Output B1 Binary Coded Decimal BCD Output B2 Binary Coded Decimal BCD Outpu
193. utput Card both the receiver and the HI 215130WC must be in the same mode e g Gross Net Rate of Change ROC Peak or Total Weight The analog card can also span the voltage or milliamp ranges over a portion of the weight data The outputs are electrically and optically isolated from the main board The Analog Output Card is adjusted at the factory See Chapter 5 Section 5 6 for Setup Instruc tions Step Repeat steps 1 4 above See Fig 4 2 Step 2 Set the jumper that matches the system s feedback voltage or current configuration See Table 4 1 NOTE Reassembling Rear Panel Front Panel Setup Procedures Analog Card Adjustment Voltage Current Chapter 4 Configuration JUMPER CONFIGURATION CHART CURRENT VOLTAGE JUMPER 0 20 mA 0 5V WI amp W3 0 20mA 0 10V Factory Default W1 amp W4 4 20mA 0 5V W2 amp W3 4 20mA 0 10V W2 amp WA TABLE 4 1 ANALOG OUTPUT JUMPER SETTINGS WI amp W4 are factory default settings Step 1 Step 2 Step 3 Gently slide the rear panel back into the extrusion Replace the four pan head machine screws that fasten the rear panel to the extrusion Connect the power cord To complete the Analog Option Card installation you must complete the Setup procedures before operating the system See Chapter 5 for instructions Step 1 Step 2 Step Step 2 Step 3 Step Step 2 Slight adjustments may be necessary to insure
194. utput Setup Procedures Option 5 12 About Analog Output See Chapter 4 for Configuration Procedures 5 12 Analog Output Menu Setup Procedures 5 13 Setting the Rate of Change Procedures 5 13 TOTAL Setup Procedures 5 14 Set Up for Profibus Interface Card Option B12 5 14 Allen Bradley Remote I O Option B8 5 14 Pre Calibration Procedure 6 1 Mechanical Check Procedures 6 1 Electrical Check Procedures 6 2 Fourteen Segment Display 6 4 Combination Status Indicator Bar Graph LEDs 6 4 Load Check 6 6 Calibration Setup Procedures 6 6 The Calibration Menu 6 6 Setting the Unit of Measure UNIT Pounds Lb or Kilograms Gr 6 7 Setting the Standard Decimal Point DECPNT 6 7 Setting the Total Decimal Point Option C6 DP 6 7 Setting the Motion Tolerance Value MOTION 6 8 Setting the Graduation Size GRAD 6 8 Setting the Zero Tolerance 0 TOL
195. utton to return the INTREF Menu Press the Exit button again to return to the Weight Display Definition A Load cell s is wired backwards and load cell point signal displays a weight lower than the scale capacity i e negative number Load cell point signal represents a weight higher than scale capacity 10 comparison error has been detected by the load cell excitation monitor Invalid character entry Invalid grad size Grad size must be 1 2 5 10 20 50 100 200 500 Err NTEP grad size error Grad size must be greater than the full scale divided by the range Average out of range Average must be from 1 to 200 Instrument in motion when value entered 2151 30WC MANUAL Error Message Definition Err 5 Not in Gross mode when trying to enter CAL menu Err 6 Invalid zero Zero must be less than zero tolerance Err 7 Invalid grad size Grad size must be greater than the full scale divided by the range minus one valid grad size Err 8 Unable to enter Calibration Menu without toggling ReCal segment on S3 or using the proper security code Err 9 Invalid zero When the instrument is in NTEP mode the zero must be within the zero tolerance Err 10 Invalid motion tolerance Motion must be greater than 0 and greater then or equal to Grad Size Err 11 Negative gross weight during acquire tare NTEP only Err 12 All decades after decimal point must be active NTEP only Err 13 Full scale calibration of ze
196. w when the Output is triggered by the BCD Control ler the Tare Weight is sent d If you do not want to select the Tare mode press the up or down arrow until a space appears Net Mode a Press the left arrow one time to select N Press the up or down arrow to until the N appears Now when the BCD Controller triggers the output the Net Weight is sent d If you do not want to select Net mode press the up or down arrow until a space appears _ Gross Mode Serial Port Menu Setup Procedure See Chapter 4 for Configuration Procedures Chapter 5 Setup Press the left arrow on time to select Press the up or down arrow until the appears Now when the BCD Controller triggers the output the Gross Weight is sent If you do not want to select Gross mode press the up or down arrow until a space appears Step 6 Press the Exit button three times to return to the Main Menu e The standard serial port is setup through the option menu and is identified as SER P1 following is a brief description of each parameter followed by details on menu operation DISPLAY SERCON BAUD PARITY STOPS LENGTH FORMAT MEANING Serial port configuration The port can be used as either a print output port or as a bi directional communication port Baud rate selection The baud rates that can be selected are 1200 2400 9600 or 19 200 Parity selection for transmission error de
197. will read XXXXXX ZERO the Load Sensor selected Pressing ENTER a second Ey IN Y time will exit and advance gt ise LS ALL Y SYSTST you to the next Load Sensor 1 enter XXX omer When you have finished reading all the load sensor enter YXXXXX locations inr Press EXIT will send NE 1 ress will send you to the last menu item Aes KXXXXX MM 4 Y _ Return to weight readings NOTE Systems using the Integrated Technician features relating to the isolation or measure ment of the instrument junction box cable the junction box and individual load sen sors or the measurement of weight or voltage of the individual load sensors require an HI 215T series junction box 2151 30WC MANUAL Test keys will move you between menu selections N Button ENTER key will advance or display i Press EXIT to return to the last menu level gt SELF TEST enter Displays System Information gt hee River e vO error ENTER 3 4 IT SEC enter J 5321 INVAL enter Y EXCMON DVMTST exit lt exit cas TESTE i gt BASEE ZERO enter NUM LS Y
198. wires between the instrument and the junction box If the measured current ReadR deviates from the BaseR an ERRExC Error Excitation displays on the front panel In a system with C2 load sensors IT computes the correct current and displays alarms if the initial measured current is out of tolerance Without C2 load sensors the initial current read becomes the standard whether the initial current is right or wrong A comparison error has been detected by the load cell excitation monitoring system For more information on Excitation monitor ERREXC setup see chapter 8 in the HI2151 30WC manual The current measurements stored during calibration is that of a simulator or system with Intrinsic Barriers and not the present load cells You will need to turn off the Excitaion monitor The YES values can only be set during calibration using the load cells Record the readR value and use for future comparison System was calibrated using a simulator or Intrinsic barriers are present NO ErrEXC Displayed on a formerly operating system jm Compare the BaseR and the ReadR readings YES These are the readings in ohms of the load cell s connected in parallel a A low reading indicates a shorted or miswired load cell NO b A high reading indicates an open or missing load cell 2 Isolate and measure the individual load cell excitation OHMS and YES compare to the load cell cert
199. y isolated from ladders and connecting structures Floors or structure does not interact Local traffic does not interact Protected from forklifts and adjacent processing equipment Are the load cells properly mounted 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 Are Check rods installed to dampen vessel movement 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 Are cables routed properly Housekeeping Verify Electrical To Go to J Separate conduit for low and high voltage cables Do not bundle Low voltage with High voltage cables Maintain at least 3 inches of seperation Maintain 14 seperation 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 protect equipment from environmental damage Insure openings are sealed to keep water and environmental contaminates from damaging a Instrument cabinet or enclosure b Summing card Load Cells Conduit runs covers are properly installed J Electrical Inspection Verify the
200. y pad to enter the new high value It is important to know that the high setting can be a lower value than the low setting which is necessary for some applications such as dispensing The high setting value can also be a negative number Step 10 Press the Enter button e A GOOD will appear briefly if the setting is a value other than the value for the low setting e AnERR will appear if the value is equal to the LO value e To correct the error simply set the high value to a value other than the low value The BCD option board provides parallel output of a sensed gross net or tare weight The BCD option is setup by first entering the Option Menu and selecting the FORMAT menu The menu display shows a combination of GNTDP gross n net T tare D display P print The weight select mode tells the output device which type of data is present The user selects which type of data is desired by toggling under the Option BCD sub menu e fall three types of data are requested then all three will appear on the output one after the other 10 milliseconds apart e f D is selected the output will follow the mode being dis played Step Press the 7 Option key This gives the user access to the Setup Sub Menu ROC or another option displays The display may show an option other than ROC depending upon which options were installed The HI 2151 30WC will show the first available option in our exa
201. ying menus operator inputs and selected weight displays There are two main operating menus Set Point and Option To enter these menus press the proper button Once in a particular menu use the upanddownarrow buttons to scroll through the choices of that menu Some of the menus have sub menus To select an item for viewing and or changing press the Enter button when the menu item displays the current value or status of the menu item is displayed To change values use the numeric keypad or press the Exit button if no changes are made Use the Test Clr button when a value is shown on the display to clear the display to all zeros When clearing the dis play the unit will always keep the decimal location intact by putting zeros to the right and one zero to the left of the decimal point Some menu selections can be toggled using the lt and buttons Pressing the arrow buttons will display all available selections for the menu item Whether altering a value or not when you are ready to stop viewing this parameter and go on to the next press the Enter button to accept the value or press the exit button to keep the original value This will save the parameter as shown on the display The instrument will also verify that the value entered is a logical choice If a parameter has been entered correctly a GOOD will briefly appear and the display advances to the next item in the menu If a parameter has been entered incorrectly an erro

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