HI3300Servicebk
Tension Controller
HI-3300
INSTALLATION AND SERVICE MANUAL
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Table of Contents
Table of Contents
Table of Contents
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Chapter 1
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - General Introduction to the Hardy Tension Controller
HI 3300 Service Manual - - - - - - - - - - - - - - - - - - Description- - - - - - - - - - - - - - - - - - - - - - - - - - Typical Applications - - - - - - - - - - - - - - - - - - - - - Hardy Web Tech - - - - - - - - - - - - - - - - - - - - - - - Connectivity - - - - - - - - - - - - - - - - - - - - - - - - - Setup Dialogs - - - - - - - - - - - - - - - - - - - - - - - - Mapped I/O - - - - - - - - - - - - - - - - - - - - - - - - - WAVERSAVER® - - - - - - - - - - - - - - - - - - - - - - - C2® Calibration - - - - - - - - - - - - - - - - - - - - - - - On-Board Diagnostics - - - - - - - - - - - - - - - - - - - - Secure Memory Module (SMM)- - - - - - - - - - - - - - - - Relays - - - - - - - - - - - - - - - - - - - - - - - - - - - - Analog Output - - - - - - - - - - - - - - - - - - - - - - - - Options - - - - - - - - - - - - - - - - - - - - - - - - - - - -2S4
HI 3000-RC - - - - - - - - - - - - - - - - - - - - - - - -PB - - - - - - - - - - - - - - - - - - - - - - - - - - - -AC - - - - - - - - - - - - - - - - - - - - - - - - - - - -RIO - - - - - - - - - - - - - - - - - - - - - - - - - - - -CN - - - - - - - - - - - - - - - - - - - - - - - - - - - -MB - - - - - - - - - - - - - - - - - - - - - - - - - - - Communication Options - - - - - - - - - - - - - - - - - DeviceNet™ - - - - - - - - - - - - - - - - - - - - - Remote I/O (RIO) Interface to the Allen Bradley Network
PROFIBUS - - - - - - - - - - - - - - - - - - - - - OPC - - - - - - - - - - - - - - - - - - - - - - - - - EtherNet/IP™ - - - - - - - - - - - - - - - - - - - - Modbus Over TCP/IP - - - - - - - - - - - - - - - - ControlNet - - - - - - - - - - - - - - - - - - - - - - -
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Chapter 2
Specifications- - - - - - - - - - - - - - - - - - About Chapter 2 - - - - - - - - - - - - - - - - - Specifications for a Standard Instrument - - - - - Wall Mount (HI 3300-MB)- - - - - - - - - - - Analog CCA - - - - - - - - - - - - - - - - - Specifications for I/O Option Boards - - - - - - - Profibus Option Board - - - - - - - - - - - - ControlNet Option Board - - - - - - - - - - - EtherNet/IP™ Option Card (Pending) - - - - - RIO Option Board - - - - - - - - - - - - - - Specifications for Peripherals/Systems Components
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Chapter 3
Installation - - - - - - - - - - - - - - - - - - About Chapter 3 - - - - - - - - - - - - - - - - Unpacking - - - - - - - - - - - - - - - - - - - Disassembly and Reassembly Notes and Cautions
Mechanical Installation - - - - - - - - - - - - - Installing the HI 3300 in a Panel - - - - - - Panel Cutout Specifications - - - - - - -
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HI 3300 Tension Controller
Service Manual
Installing the HI 3300 Tension Controller
Installing the HI 3300 in a Swivel/Wall Mount
About the Swivel/Wall Mount - - - - - Installing Printed Circuit Boards- - - - - - Removing Printed Circuit Boards - - - - - Electrical Installation - - - - - - - - - - - - - Cabling and Interconnecting - - - - - - - Recommended Installation Procedures AC Power Wiring - - - - - - - - - - - - - -DC Power Wiring - - - - - - - - - - - - Load Point Connections - - - - - - - - - - - C2® Load Point Connection - - - - - - - Non-C2 Load Point Connection - - - - - - LVDT Tension Sensor - MB Series Connection About LVDT Connections- - - - - - - Junction Box Wiring - - - - - - - - - - - - - Network Option Card Installation - - - - - - - Installation of Secure Memory Module (SMM) - Transferring a Secure Memory Module - - Chapter 4
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Configuration - - - - - - - - - - - - - - - - - - - - - - About Chapter 4 - - - - - - - - - - - - - - - - - - - - - Getting Started - - - - - - - - - - - - - - - - - - - - - - Help - - - - - - - - - - - - - - - - - - - - - - - - - - - About Help - - - - - - - - - - - - - - - - - - - - - - Operating the Tension Controller from the Front Panel - - Front Panel Display - - - - - - - - - - - - - - - - - Button Functions - - - - - - - - - - - - - - - - - - - Start Button - - - - - - - - - - - - - - - - - - - Stop Button - - - - - - - - - - - - - - - - - - - Help Button - - - - - - - - - - - - - - - - - - - Auto/M Button - - - - - - - - - - - - - - - - - - Product Button - - - - - - - - - - - - - - - - - - Left/Right Arrow, +/- Buttons - - - - - - - - - - - Enter Button - - - - - - - - - - - - - - - - - - - Exit Button - - - - - - - - - - - - - - - - - - - - Clear Button - - - - - - - - - - - - - - - - - - - Gain/1 Button - - - - - - - - - - - - - - - - - - 2/ABC Button - - - - - - - - - - - - - - - - - - Setup/3/DEF Button - - - - - - - - - - - - - - - Taper/4/GHI - - - - - - - - - - - - - - - - - - - 5/JKL Button - - - - - - - - - - - - - - - - - - - 6/MNO Button - - - - - - - - - - - - - - - - - - Calibrate/7/PQRS Button - - - - - - - - - - - - - 8/TUV Button - - - - - - - - - - - - - - - - - - Test/9/WXYZ Button - - - - - - - - - - - - - - - User/./_/@ Button - - - - - - - - - - - - - - - - 0/Char. Button - - - - - - - - - - - - - - - - - - Starting Up for the First Time - - - - - - - - - - - - - - - Tension Controller Configuration From the Front Panel - - Setting the P (Proportional) + I (Integral) + D (Derivative)
Parameters (PID) - - - - - - - - - - - - - - - - - About PID - - - - - - - - - - - - - - - - - - - - Instrument Setup Procedures - - - - - - - - - - - - - - - Instrument ID - - - - - - - - - - - - - - - - - - Operator ID - - - - - - - - - - - - - - - - - - - Unit of Measure Parameter - - - - - - - - - - - - -
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Decimal Point Parameter - - - - - - - - - - - - - - - - Averages Parameter - - - - - - - - - - - - - - - - - - The WAVERSAVER® Parameter - - - - - - - - - - - - MaxTension Parameter - - - - - - - - - - - - - - - - Sensor Type Parameter - - - - - - - - - - - - - - - - Infra Red (IR) Port Parameter - - - - - - - - - - - - - Set Clock Parameter - - - - - - - - - - - - - - - - - - About Timezones (Greenwich Mean Time) - - - - - - - Ethernet Parameters - - - - - - - - - - - - - - - - - - Set LCD Contrast Parameter - - - - - - - - - - - - - - Process Setup Procedures - - - - - - - - - - - - - - - - - - - Setpoint in Use Parameter - - - - - - - - - - - - - - - Prod 1 Parameter - - - - - - - - - - - - - - - - - - - Prod 2 Parameter - - - - - - - - - - - - - - - - - - - Prod 3 Parameter - - - - - - - - - - - - - - - - - - - Start Level Parameter - - - - - - - - - - - - - - - - - Start Time Parameter - - - - - - - - - - - - - - - - - Start Multiple Parameter - - - - - - - - - - - - - - - - Stop Level Parameter - - - - - - - - - - - - - - - - - Stop Time - - - - - - - - - - - - - - - - - - - - - - - - - About The Stop Time Parameter - - - - - - - - - - - - Splice Level Parameter- - - - - - - - - - - - - - - - - - - About Splice The Level Parameter - - - - - - - - - - - Hold Level Parameter - - - - - - - - - - - - - - - - - - - About The Hold Level Parameter - - - - - - - - - - - - Low Alarm Parameter - - - - - - - - - - - - - - - - - - - About The Low Alarm Parameter - - - - - - - - - - - - Low Alarm Delay Parameter - - - - - - - - - - - - - - - - About The Low Alarm Delay Parameter- - - - - - - - - High Alarm Parameter - - - - - - - - - - - - - - - - - - - About The High Alarm Parameter- - - - - - - - - - - - High Alarm Delay Parameter - - - - - - - - - - - - - - - - About The High Alarm Delay Parameter - - - - - - - - Misalignment Tolerance Parameter - - - - - - - - - - - - - About Misalignment Tolerance - - - - - - - - - - - - - Proportional Parameter- - - - - - - - - - - - - - - - - - - About Proportional Parameter - - - - - - - - - - - - - Integral Parameter - - - - - - - - - - - - - - - - - - - - - About The Integral Parameter - - - - - - - - - - - - - Derivative Parameter - - - - - - - - - - - - - - - - - - - - About the Derivative Parameter - - - - - - - - - - - - AutoGain Parameter - - - - - - - - - - - - - - - - - - - - About the AutoGain Parameter - - - - - - - - - - - - - Taper Percent Parameter (Rewind Only) - - - - - - - - - - About The Taper Percent Parameter - - - - - - - - - - Web Width - - - - - - - - - - - - - - - - - - - - - - - - - About Web Width - - - - - - - - - - - - - - - - - - - Defaulted I/O? Parameter - - - - - - - - - - - - - - - - - About the Defaulted I/O? Parameter - - - - - - - - - - Tension Controller Configuration From the Web Page - - - - - - Instrument Setup - - - - - - - - - - - - - - - - - - - - - - - - Set Date/Clock Parameters- - - - - - - - - - - - - - - Process Setup - - - - - - - - - - - - - - - - - - - - - - - - - Analog Option Card Configuration - - - - - - - - - - - - - - - Analog Option Card Configuration from the Front Pane - - - Analog Output Option Card Configuration from the Web Page -
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HI 3300 Tension Controller
Service Manual
Chapter 5
Calibration - - - - - - - - - - - - - - - - - - - - - - - About Chapter 5 - - - - - - - - - - - - - - - - - - - - - Getting Started - - - - - - - - - - - - - - - - - - - - - - Binding - - - - - - - - - - - - - - - - - - - - - - - Traditional Calibration From the Front Panel - - - - - - - About Traditional Calibration - - - - - - - - - - - - - Mechanical Calibration Setup for Traditional Calibration Soft Calibration from the Front Panel - - - - - - - - - - - About Soft Calibration - - - - - - - - - - - - - - - - C2 Calibration From the Front Panel - - - - - - - - - - - C2 Calibration From the Web Page - - - - - - - - - - - - Traditional Calibration From the Web Page - - - - - - - - Soft Calibration from the Web Page- - - - - - - - - - - - Electrical Check Procedures - - - - - - - - - - - - - -
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Chapter 6
Mapping - - - - - - - - - - - - - - - - - - - - - - - - - - - - About Mapping - - - - - - - - - - - - - - - - - - - - - - - - - Mapping to a Network Output Table - - - - - - - - - - - - Selecting a Destination - - - - - - - - - - - - - - - - - - - Selecting a Source - - - - - - - - - - - - - - - - - - - - - Destinations: - - - - - - - - - - - - - - - - - - - - - - - - Sources: - - - - - - - - - - - - - - - - - - - - - - - - - - Example #2 Mapping an Alarm - - - - - - - - - - - - - - - Another Mapping Example - - - - - - - - - - - - - - - Mapping Multiple Sources - - - - - - - - - - - - - - - - - Simple Network Mapping - - - - - - - - - - - - - - - - - - Mapping to a Network Output- - - - - - - - - - - - - - Mapping a Network Input to a Local Output - - - - - - - A Definition of Mapping - - - - - - - - - - - - - - - - - - - - - Boolean Mapping - - - - - - - - - - - - - - - - - - - Analog Mapping - - - - - - - - - - - - - - - - - - - - Mixed Mapping- - - - - - - - - - - - - - - - - - - - - Special (Command) Mapping) - - - - - - - - - - - - - Command Interface - - - - - - - - - - - - - - - - - - - - - - Parameter Numbers, Code Explanations, Valid Ranges and
Default Settings - - - - - - - - - - - - - - - - - - - - - Getting the Parameter Information on the Web Browser - - - Mapping a Hardy Control-Link Network to a ControlNet/DeviceNet/
Profibus Network - - - - - - - - - - - - - - - - - - - - - - - -
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Chapter 7
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Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - About Chapter 7 - - - - - - - - - - - - - - - - - - - - - - - - - - Disassembly and Reassembly Notes and Cautions - - - - - - - - - Error Messages - - - - - - - - - - - - - - - - - - - - - - - - - - General Troubleshooting Flow Chart Index - - - - - - - - - - - - - A - Guidelines for Instabilities on Formerly Operating Systems- - - - B - Guidelines for Instabilities on Formerly Operating Systems (Cont’d)
B1 - Guidelines for Instabilities on Formerly Operating Systems:
Stability and Configuration Settings - - - - - - - - - - - - - - - - C - Guidelines for Instabilities on Formerly Operating Systems - - - F - Verify Individual Load Cell Milli-Volt Readings - - - - - - - - - - F(a) - Verify Individual Load Cell Readings Using Diagnostics - - - - G - A/D Failure Error - - - - - - - - - - - - - - - - - - - - - - - - H - Mechanical Inspection - - - - - - - - - - - - - - - - - - - - - J - Electrical Inspection - - - - - - - - - - - - - - - - - - - - - - - K - Load Sharing and Load Sensor Checkout - - - - - - - - - - - - M - Tension Reading Stops Incrementing - - - - - - - - - - - - - - -
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N - Blank Screen - - - - - - - - - - - - - - - - - - - - - - - - - - O - Display Stuck on a Screen - - - - - - - - - - - - - - - - - - - R - View Input States - - - - - - - - - - - - - - - - - - - - - - - - S - Forcing Outputs - - - - - - - - - - - - - - - - - - - - - - - - System Integrity Check and Fault Determination From the Front Panel
Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - About Diagnostics - - - - - - - - - - - - - - - - - - - - - Checking the Device Data List - - - - - - - - - - - - - - - Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - Voltage & Weight Displays - - - - - - - - - - - - - - - - - View Inputs - - - - - - - - - - - - - - - - - - - - - - - - View/Force Outputs - - - - - - - - - - - - - - - - - - - - Stability Test - - - - - - - - - - - - - - - - - - - - - - - - Weight and Voltage - - - - - - - - - - - - - - - - - - - - Factory Defaults - - - - - - - - - - - - - - - - - - - - - - System Integrity Check and Fault Determination From the
Web Browser - - - - - - - - - - - - - - - - - - - - - - - - Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - Troubleshooting The Network Connections and Configuration
with the "Ping" Tool - - - - - - - - - - - - - - - - - - - - - - - Selecting the module by number for Testing - - - - - - - - - - Exiting the Root Directory - - - - - - - - - - - - - - - - - - - About Solid State Relays With Light Loads - - - - - - - - - - - - - SCR SWITCHING LOAD CIRCUIT - - - - - - - - - - - - - - - General Policies and Information - - - - - - - - - - - - - - - - - - FOR FURTHER INFORMATION CONTACT: - - - - - - - - - - - - Ordering Replacement Parts - - - - - - - - - - - - - - - - - - - - System Support - - - - - - - - - - - - - - - - - - - - - - - - Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Glossary of Terms
Index
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Table of Illustrations
Table of Illustrations
Chapter 1
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
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Chapter 3
Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
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Chapter 4
UNWIND ZONE - - - - - - - - - - - - - - - - - - - - - - 2
REWIND ZONE - - - - - - - - - - - - - - - - - - - - - - - 2
MID-PROCESS ZONE - - - - - - - - - - - - - - - - - - - 2
REAR PANEL CLEARANCE REQUIREMENT - - - - - PANEL CUTOUT DIMENSIONS - - - - - - - - - - - PANEL MOUNT INSTALLATION - - - - - - - - - - - NEMA 4 GASKET FLUSH AGAINST THE FRONT
PANEL OF THE ENCLOSURE - - - - - - - - - - - INSTALLING THE SWIVEL MOUNT TO A HORIZONTAL
SURFACE - - - - - - - - - - - - - - - - - - - - - TENSION CONTROLLER INSTALLING IN A
SWIVEL MOUNT - - - - - - - - - - - - - - - - - - TENSION CONTROLLER INSTALLED IN A
SWIVEL MOUNT - - - - - - - - - - - - - - - - - - INSTALLING THE SWIVEL MOUNT TO A VERTICAL
SURFACE - - - - - - - - - - - - - - - - - - - - - TENSION CONTROLLER INSTALLING IN A
SWIVEL WALL MOUNT - - - - - - - - - - - - - - - TENSION CONTROLLER INSTALLED IN A
SWIVEL/WALL MOUNT - - - - - - - - - - - - - - - MAIN CONTROLLER BOARD INSTALLATION/LINING
UP BOARDS WITH THE SLOTS - - - - - - - - - - MAIN CONTROLLER BOARD INSTALLATION/SLIDING
THE BOARD INTO THE INSTRUMENT - - - - - - - MAIN CONTROLLER BOARD INSTALLED WITH
REAR PLATE - - - - - - - - - - - - - - - - - - - - POWER WIRING DIAGRAM - - - - - - - - - - - - - DC POWER SUPPLY CONNECTION - - - - - - - - - REAR PANEL/LOAD POINT CONNECTIONS - - - - - LVDT CONNECTIONS/COMPRESSION - - - - - - - LVDT CONNECTIONS/TENSION (REVERSE WRAP) - LVDT CONNECTIONS/HI 3300 REAR PANEL - - - - JUNCTION BOX CONNECTIONS - - - - - - - - - - - SECURE MEMORY MODULE (SMM) - - - - - - - - - INSTALLING THE SECURE MEMORY MODULE - - - -
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FRONT PANEL - - - - - - - - - - - - - - - - - - - - - DIRECTIONAL BUTTONS - - - - - - - - - - - - - - - LIST SELECTION/ENTER BUTTON - - - - - - - - - - FRONT PANEL/OPERATING MODE DISPLAY/STANDBY
FRONT PANEL/OPERATING MODE DISPLAY/MANUAL FRONT PANEL/OPERATING MODE DISPLAY/AUTO - - FRONT PANEL/OPERATING MODE DISPLAY/STOP - - PID PARAMETERS/SETTING PROPORTIONAL - - - - SETUP MENU - - - - - - - - - - - - - - - - - - - - - SETUP MENU/SELECTING INSTRUMENT SETUP - - - SETUP MENU/SELECTING CHANNEL NAME - - - - - INSTRUMENT ID/SETTING INSTRUMENT ID - - - - - -
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INSTRUMENT SETUP MENU/OPERATOR ID - - - - - - - 26
SETUP MENU/UNIT OF MEASURE - - - - - - - - - - - - - 26
SETUP MENU/DECIMAL POINT - - - - - - - - - - - - - - 26
INSTRUMENT SETUP MENU/AVERAGES - - - - - - - - - 27
INSTRUMENT SETUP MENU/WAVERSAVER - - - - - - - 27
INSTRUMENT SETUP MENU/MAXTENSION - - - - - - - - 28
INSTRUMENT SETUP MENU/SENSOR TYPE - - - - - - - 28
SETUP MENU/IR PORT - - - - - - - - - - - - - - - - - - 28
SETUP MENU/SET CLOCK - - - - - - - - - - - - - - - - - 29
CLOCK SETUP MENU/SET DATE - - - - - - - - - - - - - 29
CLOCK SETUP MENU/SET CLOCK - - - - - - - - - - - - 29
CLOCK SETUP MENU/SET GMT - - - - - - - - - - - - - - 30
SETUP MENU/ETHERNET - - - - - - - - - - - - - - - - - 31
ETHERNET MENU/IP ADDRESS WITH
DEFAULT IP ADDRESS - - - - - - - - - - - - - - - - - - 31
INSTRUMENT SETUP/ADJUSTING DISPLAY CONTRAST - 32
SETUP MENU/SELECTING PROCESS SETUP - - - - - - - 32
PROCESS SETUP DISPLAY - - - - - - - - - - - - - - - - 32
INSTRUMENT SETUP MENU/SELECTING A PRODUCT - - 33
PROCESS SETUP MENU/SETTING PROD 1
PARAMETERS - - - - - - - - - - - - - - - - - - - - - - 33
PROD1 MENU/SETTING PRODUCT 1 NAME - - - - - - - - 33
PROCESS SETUP MENU/SETTING PROD 2
PARAMETERS - - - - - - - - - - - - - - - - - - - - - - 33
PROD2 MENU/SETTING PRODUCT 2 NAME & SETPOINT - 34
INSTRUMENT SETUP MENU/SETTING PROD 3
PARAMETERS - - - - - - - - - - - - - - - - - - - - - - 34
PROD3 MENU/SETTING PRODUCT 3 NAME - - - - - - - - 34
PROCESS SETUP MENU/START LEVEL - - - - - - - - - - 35
PROCESS SETUP MENU/START TIME - - - - - - - - - - 35
PROCESS SETUP/SETTING START MULTIPLE - - - - - - 35
PROCESS SETUP MENU/STOP LEVEL - - - - - - - - - - 36
INSTRUMENT SETUP MENU/STOP TIME - - - - - - - - - 36
INSTRUMENT SETUP MENU/SETTING SPLICE LEVEL - - 36
INSTRUMENT SETUP MENU/SETTING THE HOLD LEVEL - 37
INSTRUMENT SETUP MENU/SETTING LOW ALARM - - - 37
INSTRUMENT SETUP MENU/SETTING LOW
ALARM DELAY - - - - - - - - - - - - - - - - - - - - - - 37
INSTRUMENT SETUP MENU/SETTING HIGH ALARM - - - 38
INSTRUMENT SETUP MENU/SETTING HIGH
ALARM DELAY - - - - - - - - - - - - - - - - - - - - - - 38
INSTRUMENT SETUP MENU/SETTING THE
PROPORTIONAL VALUE - - - - - - - - - - - - - - - - - 38
PROCESS SETUP MENU/SETTING THE INTEGRAL
VALUE - - - - - - - - - - - - - - - - - - - - - - - - - - 39
PROCESS SETUP MENU/SETTING THE DERIVATIVE
VALUE - - - - - - - - - - - - - - - - - - - - - - - - - - 39
PROCESS SETUP/SETTING AUTOGAIN - - - - - - - - - - 40
PROCESS SETUP MENU/SETTING THE TAPER
PERCENT - - - - - - - - - - - - - - - - - - - - - - - - - 40
PROCESS SETUP/SETTING WEB WIDTH - - - - - - - - - 40
PROCESS SETUP/SELECTING DEFAULTED I/P? - - - - - 41
TENSION CONTROLLER HOME PAGE/SELECTING
CONFIGURATION - - - - - - - - - - - - - - - - - - - - 41
CONFIGURATION PAGE/SELECTING INSTRUMENT
SETUP - - - - - - - - - - - - - - - - - - - - - - - - - - 41
CONFIGURATION - INSTRUMENT SETUP TENSION
II
III
Table of Illustrations
CONTROLLER PAGE - - - - - - - - - - - - - - - - - - - 42
FIG. 4-58 CONFIGURATION - INSTRUMENT SETUP TENSION
CONTROLLER PAGE/SELECTING UNIT OF MEASURE - 42
FIG. 4-59 INSTRUMENT SETUP MENU/SELECTING DECIMAL POINT 42
FIG. 4-60 INSTRUMENT SETUP PAGE/SELECTING WAVERSAVER
SETTING - - - - - - - - - - - - - - - - - - - - - - - - - 42
FIG. 4-61 INSTRUMENT SETUP PAGE/SELECTING SENSOR TYPE - 43
FIG. 4-62 INSTRUMENT SETUP/CLOCK SETUP - - - - - - - - - - - 43
FIG. 4-63 CONFIGURATION/SELECTING PROCESS SETUP - - - - - 43
FIG. 4-64 PROCESS SETUP/IMAGE 1 - - - - - - - - - - - - - - - - 44
FIG. 4-65 SELECTING PRODUCT CURRENTLY IN USE - - - - - - - 44
FIG. 4-66 BOTTOM SECTION OF PROCESS SETUP - - - - - - - - - 45
FIG. 4-67 SETUP DISPLAY/SELECTING OPTIONS - - - - - - - - - - 46
FIG. 4-68 OPTIONS DISPLAY/SELECTING ANALOG CARD SLOT 0 - 46
FIG. 4-69 ANALOG CARD SLOT 0/SELECTING MODE - - - - - - - - 46
FIG. 4-70 ANALOG CARD SLOT 0/CHAN 1 MODE SELECTION - - - 46
FIG. 4-71 2 ANALOG CARDS INSTALLED - - - - - - - - - - - - - - 46
FIG. 4-72 TENSION CONTROL HOME PAGE/SELECING
CONFIGURATION - - - - - - - - - - - - - - - - - - - - 47
FIG. 4-73 CONFIGURATION PAGE/SELECTING OPTIONS - - - - - - 47
FIG. 4-74 OPTIONS PAGE/SELECING ANALOG BOARD
CONFIGURATION (SLOT 0) - - - - - - - - - - - - - - - 47
FIG. 4-75 CONFIGURATION/SLOT 0/SETTING CHAN 0 MODE - - - - 47
FIG. 4-76 CONFIGURATION SLOT 0/SETING MODES - - - - - - - - 47
FIG. 4-77 OPTIONS/SELECTION ANALOG BOARD
CONFIGURATION (SLOT 1) - - - - - - - - - - - - - - - 48
FIG. 4-78 CONFIGURATION SLOT 1/SELECTING CHANNEL
MODES - - - - - - - - - - - - - - - - - - - - - - - - - - 48
FIG. 4-79 ANALOG CONFIG (SLOT 1) MODE CONFIGURATION
CHAN 0 AND CHAN 1 - - - - - - - - - - - - - - - - - - - 48
FIG. 4-80 CONFIGURATION PAGE/SLECTING MAPPING - - - - - - 48
FIG. 4-81 MAPPING PAGE/SELECTIN DESTINATION - - - - - - - - 49
FIG. 4-82 MAPPING DESTINATION/SELECTING ANALOG OUT
SLOT 0 CHAN 0 (HSO5) - - - - - - - - - - - - - - - - - 49
FIG. 4-83 SELECTING ANALOG OUT SLOT 0 (HSO5) - - - - - - - - 49
FIG. 4-84 DESTINATION ENTERED - - - - - - - - - - - - - - - - - 49
FIG. 4-85 SELECT SOURCE/SELECTING CONTROL DATA - - - - - 49
FIG. 4-86 CONTROL DATA/OPTIONS PULL DOWN MENU - - - - - - 49
FIG. 4-87 SELECTING THE SOURCE - - - - - - - - - - - - - - - - 49
FIG. 4-88 MAPPING CONTROL DATA TO ANALOG OUT SLOT 0 - - 50
FIG. 4-89 MAPPING LIST/CONTROL DATA MAPPED TO
ANALOG OUTPUT - - - - - - - - - - - - - - - - - - - - 50
FIG. 4-90 EXPANDED MAPPING DIALOG BOX - - - - - - - - - - - - 50
Chapter 5
Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - FIG. 5-1 CALIBRATION MECHANICAL SETUP - - - - - - - - - FIG. 5-2 SETUP MENU/SELECTING CALIBRATION - - - - - - - FIG. 5-3 CALIBRATION/SELECTING SENSOR TYPE - - - - - - FIG. 5-4 TRADITIONAL CALIBRATION/ZERO VALUE - - - - - - FIG. 5-5 CALIBRATION/C2 CAL - - - - - - - - - - - - - - - - - FIG. 5-6 CALIBRATION/SELECTING TRADITIONAL CALIBRATION
FIG. 5-7 CALIBRATION ENTERING REFERENCE WEIGHT - - - FIG. 5-8 CALIBRATION SETUP WITH NO WEIGHT - - - - - - - FIG. 5-9 DO TRADITIONAL CALIBRATION/ZERO - - - - - - - - FIG. 5-10 TRADITIONAL CALIBRATION/ENTERING SPAN WEIGHT
FIG. 5-11 SPAN CALIBRATION/SPAN WEIGHT - - - - - - - - - FIG. 5-12 TRADITIONAL CALIBRATION/SPAN CALIBRATION - - -
-
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HI 3300 Tension Controller
Service Manual
FIG. 5-13 CALIBRATION MENU/SELECTING SOFT CALIBRATION FIG. 5-14 SOFT CALIBRATION MENU/ENTERING REFERENCE
WEIGHT - - - - - - - - - - - - - - - - - - - - - - - FIG. 5-15 SOFT CALIBRATION MENU/ENTERING LOAD
SENSOR CAPACITY - - - - - - - - - - - - - - - - - FIG. 5-16 SOFT CALIBRATION MENU/ENTERING SENSITIVITY
OF THE LOAD CELLS - - - - - - - - - - - - - - - - - FIG. 5-17 TEST WEIGHT CONFIGURATION - - - - - - - - - - - FIG. 5-18 SOFT CALIBRATION MENU/ENTERING WRAP ANGLE 1
FIG. 5-19 SOFT CALIBRATION MENU/ENTERING WRAP ANGLE 2
FIG. 5-20 SOFT CALIBRATION/ENTERING FORCE FACTOR - - FIG. 5-21 SOFT CALIBRATION/DOING THE SOFT CALIBRATION FIG. 5-22 CONFIGURATION MENU/SELECTING SETUP - - - - - FIG. 5-23 CALIBRATION/SELECTING SENSOR TYPE - - - - - - FIG. 5-24 TRADITIONAL CALIBRATION/ZERO VALUE - - - - - - FIG. 5-25 CALIBRATION/ - - - - - - - - - - - - - - - - - - - - - FIG. 5-26 C2 CALIBRATION SUB-MENU - - - - - - - - - - - - - FIG. 5-27 ENTERING THE REFERENCE POINT - - - - - - - - - FIG. 5-28 C2 CAL/ENTERING WRAP ANGLE 1 - - - - - - - - - - FIG. 5-29 C2 CAL/ENTERING FORCE FACTOR - - - - - - - - - FIG. 5-30 C2 CALIBRATION - - - - - - - - - - - - - - - - - - - FIG. 5-31 CONFIGURATION MENU/SELECTING SETUP - - - - - FIG. 5-32 CONFIGURATION PAGE - - - - - - - - - - - - - - - - FIG. 5-33 METHOD 1: C2 CALIBRATION - - - - - - - - - - - - - FIG. 5-34 SETTING FORCE FACTOR - - - - - - - - - - - - - - - FIG. 5-35 CAL COMPLETED OK - - - - - - - - - - - - - - - - - FIG. 5-36 CONFIGURATION MENU/SELECTING SETUP - - - - - FIG. 5-37 CONFIGURATION PAGE/SELECTING CALIBRATION - FIG. 5-38 CALIBRATION SUB-MENU - - - - - - - - - - - - - - - FIG. 5-39 METHOD 2: CALIBRATION - ZERO CAL - - - - - - - - FIG. 5-40 CAL LOW COMPLETED OK - - - - - - - - - - - - - - FIG. 5-41 CAL COMPLETED OK - - - - - - - - - - - - - - - - - FIG. 5-42 HOME PAGE/SELECTING CONFIGURATION - - - - - FIG. 5-43 CONFIGURATION MENU/SELECTING CALIBRATION - FIG. 5-44 CALIBRATION PAGE/SOFT CALIBRATION - - - - - - - FIG. 5-45 SOFT CAL SUCCESSFUL - - - - - - - - - - - - - - - FIG. 5-46 PROPERLY INSTALLED LOAD CELL WITH NO BINDING
Chapter 6
Mapping
FIG. 6-1
FIG. 6-2
FIG. 6-3
FIG. 6-4
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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63
HOME PAGE/SELECTING CONFIGURATION - - - - - CONFIGURATION PAGE/SELECTING MAPPING SETUP
MAPPING PAGE - - - - - - - - - - - - - - - - - - - - SELECTING DESTINATION/NETWORK/CONTROL
LINK FLOAT OUT (EFO) - - - - - - - - - - - - - - - FIG. 6-5 DESTINATION/SELECTING CONTROL LINK FLOAT
OUT (EFO) WORD 2 - - - - - - - - - - - - - - - - - FIG. 6-6 “EFO2=” IS ENTERED IN THE MAP TEXTILES - - - - - FIG. 6-7 SELECT SOURCES/SELECTING STATUS - - - - - - - FIG. 6-8 STATUS SOURCE PULL DOWN MENU/SELECTING
HIGH TENSION ALARM (HI1.3) - - - - - - - - - - - - FIG. 6-9 SELECT SOURCES/SELECTING HIGH TENSION
ALARM (HI1.3) - - - - - - - - - - - - - - - - - - - - FIG. 6-10 MAPPING HIGH TENSION ALARM TO CONTROL
LINK FLOAT OUT - - - - - - - - - - - - - - - - - - - FIG. 6-11 HIGH TENSION ALARM IS MAPPED TO CONTROL
LINK FLOAT OUT - - - - - - - - - - - - - - - - - - - -
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IV
V
Table of Illustrations
FIG. 6-12
FIG. 6-13
FIG. 6-14
FIG. 6-15
FIG. 6-16
FIG. 6-17
FIG. 6-18
FIG. 6-19
FIG. 6-20
FIG. 6-21
FIG. 6-22
FIG. 6-23
FIG. 6-24
FIG. 6-25
FIG. 6-26
FIG. 6-27
FIG. 6-28
FIG. 6-29
FIG. 6-30
FIG. 6-31
FIG. 6-32
FIG. 6-33
FIG. 6-34
FIG. 6-35
FIG. 6-36
FIG. 6-37
FIG. 6-38
FIG. 6-39
FIG. 6-40
FIG. 6-41
FIG. 6-42
FIG. 6-43
FIG. 6-44
FIG. 6-45
Chapter 7
EXTENDED MAP DISPLAY - - - - - - - - - - - - - - - - - 65
DESTINATION/SEND EMAIL #0 (HO3.0) - - - - - - - - - - 67
SEND EMAIL #0 (HO3.0) SELECTED AS A DESTINATION - 67
SELECTING LOW TENSION ALARM ALARM - - - - - - - - 67
MAPPING/SELECTING LOW TENSION ALARM AS
THE SOURCE - - - - - - - - - - - - - - - - - - - - - - 67
LOW TENSION ALARM (HI1.2) IS MAPPED TO
SEND EMAIL #0 (HO3.0) - - - - - - - - - - - - - - - - - 67
OUTPUTS/SELECTING RELAYS - - - - - - - - - - - - - - 68
OUTPUT RELAYS/SELECTING RELAY 2 (HO0.1) - - - - - 68
OUTPUT RELAY 2 (HO0.1) APPEARS IN THE MAP FIELD - 68
SELECT SOURCES/LOCAL/SELECTING STATUS - - - - - 68
SELECT SOURCES/LOCAL/SELECTING HIGH
TENSION ALARM (HI1.3) - - - - - - - - - - - - - - - - - 69
HIGH TENSION ALARM (HI1.3) SOURCE ADDED - - - - - 69
HIGH TENSION ALARM (HI1.3) ADDED TO
THE MAP FIELD - - - - - - - - - - - - - - - - - - - - - 69
SETPOINTS/EXPANSION CHANNEL ALERT ALARMS - - - 69
LOW TENSION ALARM (HI1.2) ADDED AS THE
SECOND SOURCE TO THE ASSIGNMENT STATEMENT - 69
MULTIPLE SOURCE MAP - - - - - - - - - - - - - - - - - 69
DESTINATION/NETWORK/SELECTING DEVICENET
BOOLEAN OUT - - - - - - - - - - - - - - - - - - - - - - 70
NETWORK/SELECTING DEVICENET BOOLEAN
OUT (DO), WORD 2, BIT 2 - - - - - - - - - - - - - - - - 70
DEVICENET BOOLEAN OUT (DO2.2) SET
AS DESTINATION - - - - - - - - - - - - - - - - - - - - 70
SOURCE/CONTROL DATA/OUTPUT% (HFI1) - - - - - - - 70
ASSIGNMENT STATEMENT MAPPING OUTPUT% TO
DEVICENET BOOLEAN OUT, WORD 2, BIT 2 (DO2.2) - - 70
SIMPLE NETWORK MAP/OUTPUT% MAPPED TO
DEVICENET BOOLEAN OUT (DO2.2) - - - - - - - - - - - 70
OUTPUTS/ANALOG OUT - - - - - - - - - - - - - - - - - 71
DESTINATION SELECTING ANALOG OUT SLOT 0,
CHAN 0 - - - - - - - - - - - - - - - - - - - - - - - - - - 71
ANALOG OUT (HSO5) SLOT 0, CHAN 0 SET AS
DESTINATION - - - - - - - - - - - - - - - - - - - - - - 71
NETWORK/SELECTING DEVICENET FLOAT IN (DFI) - - - 71
ASSIGNMENT STATEMENT MAPPING DEVICENET
FLOAT IN (DFI) TO ANALOG OUT SLOT 1,
CHAN 0 (HSO9) - - - - - - - - - - - - - - - - - - - - - - 71
DEVICENET FLOAT IN ASSIGNED TO ANALOG OUT
SLOT 0, CHAN 0 - - - - - - - - - - - - - - - - - - - - - 71
MAPPING CONTROL LOST INPUT TO CONTROL
LINK BOOLEAN OUTPUT - - - - - - - - - - - - - - - - - 72
TENSION CONTROLLER HOME PAGE/SELECTING
OPERATION - - - - - - - - - - - - - - - - - - - - - - - 74
OPERATION PAGE/SELECTION DIAGNOSTICS - - - - - - 75
DIAGNOSTICS PAGE/SELECTING PARAMETERS - - - - - 75
PARAMETER DUMP - - - - - - - - - - - - - - - - - - - - 75
HARDY CONTROL-LINK NETWORK CONNECTED
TO A CONTROLNET/DEVICENET/PROFIBUS NETWORK 76
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
FIG. 7-1
TEST AND DATA MENU/SELECTING DEVICE
HI 3300 Tension Controller
Service Manual
FIG. 7-2
FIG. 7-3
FIG. 7-4
FIG. 7-5
FIG. 7-6
FIG. 7-7
FIG. 7-8
FIG. 7-9
FIG. 7-10
FIG. 7-11
FIG. 7-12
FIG. 7-13
FIG. 7-14
FIG. 7-15
FIG. 7-16
FIG. 7-17
FIG. 7-18
FIG. 7-19
FIG. 7-20
FIG. 7-21
FIG. 7-22
FIG. 7-23
FIG. 7-24
FIG. 7-25
FIG. 7-26
FIG. 7-27
FIG. 7-28
FIG. 7-29
FIG. 7-30
FIG. 7-31
FIG. 7-32
FIG. 7-33
FIG. 7-34
FIG. 7-35
FIG. 7-36
FIG. 7-37
FIG. 7-38
FIG. 7-39
FIG. 7-40
FIG. 7-41
FIG. 7-42
FIG. 7-43
DATA LIST - - - - - - - - - - - - - - - - - - - - - TEST DATA DISPLAY/INSTRUMENT ID - MODEL
NUMBER - S/N - - - - - - - - - - - - - - - - - - - TEST DATA DISPLAY/PART NUMBER/PROGRAM
VERSION - - - - - - - - - - - - - - - - - - - - - - TEST AND DATA MENU/SELECTING DIAGNOSTICS DIAGNOSTICS DISPLAY/SELECTING
VOLTAGE & WEIGHT - - - - - - - - - - - - - - - - DIAGNOSTIC MENU/VIEW INPUTS - - - - - - - - - INPUTS MENU - - - - - - - - - - - - - - - - - - - - DIAGNOSTICS VIEW/FORCE OUTPUTS - - - - - - - FORCE OUTPUTS MENU/READING OUTPUT 1234 - OUTPUT RELAY DISPLAY/SELECTING OUTPUT
RELAY #1 - - - - - - - - - - - - - - - - - - - - - - FORCE OUTPUTS MENU/SELECTING OUTPUT
RELAY #2/ON - - - - - - - - - - - - - - - - - - - - FORCE OUTPUTS/ENTRY ACCEPTED - - - - - - - OUTPUT RELAY #2 FORCED CLOSED DISPLAY - - DIAGNOSTICS DISPLAY/SELECTING STABILITY TEST
STABILITY TEST DISPLAY - - - - - - - - - - - - - - STABILITY TEST/TEST IN PROGRESS - - - - - - - SYSTEM STABILITY TEST DISPLAY/PASS - - - - - SYSTEM STABILITY TEST DISPLAY/FAIL - - - - - - DIAGNOSTICS DISPLAY/WEIGHT AND VOLTAGE - - WEIGHT AND VOLTAGE/TENSION READING - - - - TWO CHANNEL WEIGHT AND VOLTAGE DISPLAY - WEIGHT AND VOLTAGE MENU/CHANNEL 1 MV/V
DISPLAY - - - - - - - - - - - - - - - - - - - - - - DIAGNOSTICS MENU/FACTORY DEFAULTS - - - - FACTORY DEFAULTS DISPLAY - - - - - - - - - - - TENSION CONTROLLER HOME PAGE/SELECTING
OPERATION - - - - - - - - - - - - - - - - - - - - OPERATION PAGE/SELECTING DIAGNOSTICS - - - OPERATION/DIAGNOSTICS PAGE - - - - - - - - - DIAGNOSTICS/FACTORY DEFAULTS PAGE - - - - - HIGH SECURITY PASSWORD INVALID - - - - - - - FACTORY DEFAULTS SET - - - - - - - - - - - - - - COUNT OF UDP PACKETS RECEIVED FROM EACH
EXTERNAL NODE ON YOUR NETWORK - - - - - - DIAGNOSTICS/PARAMETER DUMP - - - - - - - - - DIAGNOSTICS/ALARM LOG - - - - - - - - - - - - - DIAGNOSTICS/STABILITY TEST - - - - - - - - - - - STABILITY TEST RESULTS PAGE - - - - - - - - - - DIAGNOSTICS PAGE/WEIGHTS AND VOLTAGE - - - DIAGNOSTIC PAGE/INPUT AND OUTPUT LIST
AND STATUS - - - - - - - - - - - - - - - - - - - - DIAGNOSTICS PAGE/C2 DATA - - - - - - - - - - - RUN/CMD ENTERED - - - - - - - - - - - - - - - - - COMMAND WINDOW - - - - - - - - - - - - - - - - ENTERING IP ADDRESS - - - - - - - - - - - - - - - SUCCESSFUL PING - - - - - - - - - - - - - - - - - SCR SWITCHING LOAD CIRCUIT - - - - - - - - - - -
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VI
1
CHAPTER 1
Overview
CHAPTER 1: OVERVIEW
General Introduction to the Hardy Tension
Controller HI 3300 Service Manual
This Service Manual provides the Technician with a complete description of installation, setup, calibration, mapping
and troubleshooting procedures for the HI 3300 Tension
Controller. To get the maximum service life from this product, technicians should use this instrument in accordance
with recommended practices either implied or expressed in
this manual. Before using the Tension Controller, all service
personnel should read and understand all cautions, warnings,
and safety procedures, referenced or explicitly stated in this
manual, to insure the safe operation and repair of this instrument. Hardy Instruments sincerely appreciates your business. We encourage input about the performance and
operation of our products from our customers. Should you
not understand any information in this manual or experience
any problems with this product, please contact our Technical
Support Department at:
Phone: (858) 278-2900
FAX: (858) 278-6700
E-Mail:
•
•
[email protected]
[email protected]
Or visit our web site at:
acters per line) and key pad or an HI 3300R, blind remote
stand-alone PID controller, swivel mounted with no display.
A remote 6 digit, 7 segment LED display is available as an
option for the HI 3300R. The standard version has a single
channel with a 2 channel option.
The HI 3300 Tension Controller is designed with output
alarms, for example:
•
•
•
•
The HI 3300 Tension Controller is field configurable for all
web tension applications including but not limited to, converting, printing, plastic film, textiles and other industries
where web tension is required. This instrument is a standalone PID closed loop controller which operates in auto or
manual modes for web tension process control. The display
keeps the user up to date as to the current tension value, output in percentage, operating status and tension setpoint for
the selected product. Output alarms warn the operator of
High tension, Low tension, Misalignment, etc. The Tension
Controller contains Hardy Instrument’s core features:
•
http://www.hardyinstruments.com
•
Our web site is full of useful information about our tension
control, process weighing and vibration analysis products.
You can also get the latest updates of the Tension Controller
Manual. The latest revised manuals are available FREE in
the Support Section of our Web Site. While you’re on the site
feel free to visit the other web pages which can provide
answers to your questions about, load sensors, brakes, vibration analysis or other Hardy instruments. Be sure to sign up
for the Hardy Newsletter to get the latest information on all
Hardy products and services. For answers to technical issues
and service problems check the Hardy Web Tech on our
Hardy Web Site. Most problems can be resolved by the
Hardy Web Tech, 365 days a year, 24 hours a day 7 days a
week. You can still contact a technician by phone during our
operating hours if necessary.
•
Description
The Hardy Instruments Tension Controller is part of a complete line of application specific web tension, process weighing and condition monitoring instruments. The Tension
Controller is available as a model HI 3300, a stand alone
closed loop, load cell based PID controller with a display
(Large font Tension Display with 4 additional lines; 20 char-
Low Tension
High Tension
Misalignment
Control Lost
WAVERSAVER® - Eliminates the effects
of vibration when measuring tension.
C2® Electronic Calibration - Calibration
without test weights.
SMM (Secure Memory Module) - Memory for manual transfer of configuration
data to another HI 3300 instrument(s).
All of Hardy’s 3000 Series instrumentation is loaded with
standard features like a selectable 10/100 BaseT Ethernet
port and an embedded web server to link performance diagnostics and setup data to and from your local Intranet, Extranet, VPN or via the Internet (World Wide Web). An IR (Infra
Red) port provides wireless connectivity to PDA devices for
easy configuration, loading and transfer of data. Optional
Devicenet®, ControNet®, Profibus®, Allen Bradley Remote
I/O®, Ethernet and Ethernet IP® (Coming Soon), Modbus®,
Analog and OPC interfaces allow multiple applications to be
viewed and controlled from one display and allows 3rd party
I/O to be easily added to the system. Mapped I/O saves you
wiring costs by distributing the I/O where you need it, at the
process or in the control room. The controllers act as a “Master” over Ethernet/IP (pending) and Devicenet communications while optional interfaces for Allen-Bradley Remote I/
O, Profibus® and Analog provide communications to PLC®
and DCS systems.
HI 3300 Tension Controller
Service Manual
NOTE:
All registered trademarks are the property of
their respective trade associations and corporations.
Built-in Diagnostics provide the ability to troubleshoot individual load cells. Alarms alert you to problems or potential
problems that can affect your process. The Tension Controller has Help dialogs that walk you through the instrument set
up while Web Site help files are just a key press away.
Typical Applications
•
•
•
•
PID Control for Unwinding Zone
PID Control for Mid-Process (intermediate) Zone.
PID Control for Rewinding Zone.
Web and Strand Tension Control
FIG. 1-2 REWIND ZONE
FIG. 1-1 UNWIND ZONE
FIG. 1-3 MID-PROCESS ZONE
2
3
CHAPTER 1
Overview
Hardy Web Tech
Setup Dialogs
Setup Dialogs enable the user to walk through the instrument
set up. On-board Help files are just a key press or click away.
Mapped I/O
Mapped I/O saves wiring costs by distributing the I/O where
you need it, at the process or in the control room. The controller is a DeviceNet Scanner and the DeviceNet Scan table
is configured using RS Networks®. Optional interfaces for
Allen-Bradley Remote I/O, Profibus and Analog provide
communications to PLC and DCS systems.
We have implemented Hardy Web Tech, our new Online
Tech Support Knowledge Base, to serve your tech support
needs better than ever before. Hardy Web Tech helps you
immediately find answers to your technical questions. Just
type in your question and see if your answer exists in our
knowledgebase, which is populated by interactions with customers like you.
You can also create your personalized support page, and
your own support section that you can access 24/7. You can
even view and update your entire call history, as well as
maintain your profile containing your product and system
information, so we can more effectively meet your needs.
Last, but not least, we invite all user feedback. Click on the
"Provide Feedback" link to let us know how we're doing!
What do you like about the product? What's missing? How
do you like our new support site? Anything! Your comments
are important and will help us shape the future direction of
our products.
Connectivity
All HI 3000 Series products enable the user to use the selectable 10/100 base T Ethernet port or use its embedded web
server to link performance, diagnostics and setup data to and
from your intranet, extranet, VPN or the internet. Receive
alarms via e-mail or over WAP enabled devices including
cellular phones and PDAs. A DeviceNet interface allows
multiple applications to be viewed and controlled from a display and additional 3rd party I/O can be easily added to the
tension control system. The HI 3300 includes a full line of
network interfaces, including:
•
•
•
•
•
•
•
ControlNet®
DeviceNet®
Allen Bradley Remote I/O
Profibus®
Modbus®
OPC (OLE Process Control)
Ethernet/IP (Pending)
WAVERSAVER®
Typically, mechanical noise (from other machinery in a plant
environment) is present in forces larger than the weight
forces trying to be detected. The HI 3300 is fitted with
WAVERSAVER® technology which eliminates the effects of
vibratory forces present in all industrial weight control and
measurement applications. By eliminating the factor of
vibratory forces the controller is capable of identifying the
actual weight data. WAVERSAVER® can be configured
from the front panel to ignore noise with frequencies as low
as 0.25 Hz. One of four higher additional cut off frequencies
may be selected to provide a faster instrument response time.
The default factory configuration is 0.50 Hz vibration frequency immunity.
C2® Calibration
C2® Second Generation Calibration enables a web tension
system to be calibrated electronically without using certified
test weights which equals the systems load capacity. A C2
weighing system consists of up to eight load sensors, a junction box, interconnect cable and an instrument with C2 capabilities, such as the Tension Controller. All Hardy
Instruments C2 certified load sensors contain digital information detailing its unique performance characteristics. The
Hardy Tension Controller reads the performance characteristics of each individual load sensor and detects the quantity of
load sensors in the system. Calibration is performed by simply adding a reference point from the front panel, PDA, or
via the Web Server. The reference can be zero (no weight on
the scale) or alternatively, a known weight on the scale. The
instrument is capable of performing traditional calibration
such as with the use of certified test weights.
NOTE:
WAVERSAVER® and C2® are registered trademarks of Hardy Instruments Inc.
On-Board Diagnostics
The HI 3300 has a built in diagnostics utility which enables
the operator to rapidly troubleshoot a tension zone from the
front panel of the controller or via the Web Server. Simply
press the Test button and scroll through several tests that will
HI 3300 Tension Controller
Service Manual
furnish the current state of each of the parameters that concern your application and the web tension system. Help is
just a click away in the event you should not understand the
information on the display or need a description of the
parameter.
-AC
Secure Memory Module (SMM)
-RIO
The Secure Memory Module stores critical configuration (up
to three product setpoints), calibration and setup data of the
HI 3300 Tension Controller, thereby protecting this information from corruption. During system operation when a new
parameter is entered, the SMM automatically updates the
value in its memory. Data stored in one HI 3300 can be
restored in another HI 3300 by physically transferring the
SMM to the new instrument. The SMM is conveniently
accessible from the instruments rear panel.
Allen-Bradley Remote I/O interface allows full instrument
capabilities to be communicated remotely to and from an
Allen-Bradley processor.
4
AC input power for the HI 3000 Series remote mount instrument to act as a booster power supply for multiple instruments on Devicenet.
-CN
ControlNet - Enables multiple controllers to control I/O on
the same wire and permits multicast of both inputs and peerto-peer data, reducing traffic on the wire and increasing system performance.
Relays
The HI 3300 is fitted with four (4) standard internal selectable 24 - 240 VAC or 5-60VDC Solid State electronic
(SPST) relays. The relays can be used to open or close
valves or gates, turn on/off motor, mixers, vibration equipment, heaters or coolers to name a few.
Analog Output
-MB
Swivel Mount including bracket and mounting hardware.
This mount enables the user to mount the instrument outside
an enclosure and rotate the HI 3300 for easier viewing.
Communication Options
NOTE:
The Analog Output enables the transmission of Tension as 05 VDC, 0-10 VDC, 0-20 mA or 4-20 mA (or the reverse of
these), and makes it possible to span these ranges over a portion of the weight data. Two analog option boards can be
installed in each instrument. Both voltage and current data
are available simultaneously.
Options
-2S
Dual Scale Input - Adds another channel to the standard
instrument enabling the user to add another load cell.
HI 3000-RC
Rear cap for the HI 3000 Series controllers. Upgrades the
entire assembly to a NEMA 4X rating by enclosing all the
rear panel connectors.
-PB
Profibus interface allows instrument capabilities to be communicated remotely to and from a Siemens or other Profibus
compatible processor.
For installation and configuration instructions
for all the Communication Options, please see
the HI 3000 Installation and Operation Manual
on this CD.
DeviceNet™
DeviceNet is a low-level network designed to connect the
Hardy HI 3000 Series Instruments to higher-level controllers
such as PCs, PLCs, or embedded controllers. The DeviceNet
Network is an open, global industry-standard communication network designed to provide an interface through a single cable from a programmable controller or PC directly to
all HI 3000 Series instruments as well as smart devices such
as sensors, push buttons, motor starters, simple operator
interfaces, drives and other weigh modules. With DeviceNet
the user can monitor or control multiple applications from
one display and allows 3rd party I/O to be easily added to
any system. You no longer have to hard-wire each device to
an I/O module or I/O block. The network also provides
access to the intelligence present in the instruments for superior diagnostics and troubleshooting to help increase system
up time. The DeviceNet network lets you monitor your
plant-floor devices from a central location and reconfigure
them as your needs change or service them as required. The
DeviceNet network's capabilities help reduce integration,
and reduce installation and wiring costs
5
CHAPTER 1
Overview
Remote I/O (RIO) Interface to the Allen Bradley Network
The RIO port allows bi-directional communications with
Allen-Bradley Programmable Logic Controllers (PLC) and
Small Logic Controllers (SLC). The HI 3300 represents a
selectable 1/4, 1/2, 3/4 or full rack of discrete I/O (32 bits in
the Logic Controllers output and input image files) to the
PLC Controller and supports both discrete and block transfers of data. It can support up to 230.4 Kbaud transfer rates.
PROFIBUS
Allows bi-directional communications to Profibus (ProcessFieldbus) 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.
OPC
OLE for Process Control (OPC) enables an HI 3300 module
to communicate with any device that supports OLE/COM.
The architecture is designed to utilize the Microsoft distributed OLE technology (DCOM) to facilitate clients interfacing to remote servers.
EtherNet/IP™
EtherNet/IP, short for Ethernet Industrial Protocol, is an
open industrial networking standard that takes advantage of
commercial, off-the-shelf Ethernet communication chips and
media. Ethernet technology, enables the user to access
device-level data from the Internet.The Ethernet/IP networking standard supports both implicit messaging (real-time I/O
messaging) and explicit messaging (message exchange).
EtherNet/IP is an open network that takes advantage of commercial technology that already exists.
TCP/IP is the transport and network layer protocol of the
Internet and is commonly linked with all Ethernet installations and the business world. TCP/IP provides a set of services that any two devices can use to share data. Because
Ethernet technology and standard protocol suites such as
TCP/IP have been published for public use, standardized
software tools and physical media have been mass-produced
and are readily available, offering you the benefits of known
technology and accessibility. The UDP/IP (User Datagram
Protocol) is also used in conjunction with the Ethernet network. UDP/IP provides fast, efficient data transport required
for real-time data exchange.
Modbus Over TCP/IP
Combining a versatile, scaleable, and ubiquitous physical
network (Ethernet) with a universal networking standard
(TCP/IP) and a vendor-neutral data representation (MOD-
BUS®) gives a truly open, accessible network for exchange
of process data. It is also extremely simple to implement for
any device that supports TCP/IP sockets.
Simplicity: MODBUS® TCP/IP simply takes the MODBUS® instruction set and wraps TCP/IP around it. If you
already have a MODBUS® driver and if you understand
Ethernet and TCP/IP sockets, you can in short period of
time, have a driver up and running and talking to a PC
ControlNet
ControlNet enables multiple controllers to control I/O on the
same wire and permits multicast of both inputs and peer-topeer data, reducing traffic on the wire and increasing system
performance.
HI 3300 Tension Controller
Service Manual
6
7
CHAPTER 2
Specifications
CHAPTER 2: SPECIFICATIONS
About Chapter 2
Chapter 2 lists the specifications for the HI 3300 Tension
Controller. Specifications are listed for the standard instrument and for instruments fitted with optional equipment. The
specifications listed are designed to assist in the installation,
operation and troubleshooting of the instrument. Service personnel should be familiar with this section before attempting
an installation or repair of the instrument.
Specifications for a Standard Instrument
•
Maximum Switch Current: .5 Amps
Maximum Switch Power: 120 Watts
Maximum Switch Voltage: .5 Amps @
240 VAC
Single Cycle Surge: 85 Amps (Peak)
Standard Electronic DC Relays:
•
•
•
•
•
Update Rate:
•
•
•
•
Wire Size: 12 AWG Maximum
Maximum Switch Current: .5 Amps
Maximum Switch Voltage: .5 Amps @ 60
VDC
Switch Voltage: 5-60 VDC
1 second surge: 5 Amps
55 updates per second
Non-Linearity:
Resolution:
•
•
•
Displayed: 1:985,000 (3 mV/V load cells)
Internal 1:1,048,5761
Excitation Voltage:
•
•
5 VDC
Drives up to 8 350 ohm load cells
•
1 to 250 - Sliding, User Selectable in Single Unit Increments
Averages:
Input:
•
•
•
Up to two (2) 350 ohm Full Wheatstone
Bridge, Strain Gauge Load Sensors/Cells
(5 volt excitation) on one vessel.
Up to two (2) LVDT Load Sensors
Signal Voltage Range ± 120mV/Volt (±
600 mV)
WAVERSAVER®:
•
•
•
•
•
•
Large font Tension (lbf/N) Display
4 line x 20 character backlit LCD
5 x 7 dot matrix
Display Increments (Graduations):
•
•
1,2,5,10,20,50,100,200,500 user selectable
Corresponding weight is dependent on the
decimal point location.
Standard Electronic AC Relays:
•
Wire Size: 12 AWG Maximum
Off
7.5 Hz
3.5 Hz
1.0 Hz
0.5 Hz
0.25 Hz
Calibration Techniques:
•
•
•
C2® - Second Generation: Electronic
Traditional - Calibration with test weights
Soft Calibration - Wrap Angles or Force
Factor
Standard Interfaces:
•
Display:
•
•
•
0.0015% of Full Scale
Ethernet - 10/100 Base T; embedded
server
Excitation Monitor:
•
Current less than 10%
Power and Utility Requirements:
Voltage - Universal Power Supply (50/60 Hz)
•
•
120-240 VAC ± 10%
12 - 24 VDC
Frequency
•
47-63 Hz
HI 3300 Tension Controller
Service Manual
8
Case Dimensions
Power:
•
•
10 Watts maximum with options
6.125"H x 8.56"W x 6.03"D (155.57mmH
x 217.42mmW x 1.53.16mmD)
Watts available for DeviceNet Power:
Front Panel Dimensions
•
15 Watts
•
Common Mode Voltage Range
•
7.686" H x 9.40" W x 0.625" D
(195.22mm H x 247.39mm W x
15.87mmD)
± 2.5 VDC
Panel Cutout Dimensions
Common Mode Rejection:
•
•
100dB @ 50-60Hz
Environmental Requirements:
Case Material
Operating Temperature Range:
•
6.75" H x 8.94" W (1775mm H x 227mm
W)
•
GE Cycolac Type KJW - Flame Retardant
ABS (Acrylanitrile Butadiene Styrene)
•
4.6 pounds (2.1 Kilograms)
•
Front Panel NEMA 4 Seal
-10º to 50º C (14º to 122º F)
Weight
Storage Temperature Range:
•
-20º to70º C (-4º to 158º F)
Rating
Temperature Coefficient:
•
Less than 0.005% of full scale per degree
C for zero and span.
Wall Mount (HI 3300-MB)
Humidity Range:
Base Dimensions
•
•
0-90% (non-condensing)
9.3” L x 4.0” W (236.22mm L x
101.60mm W)
Approvals:
•
•
•
CE
UL
CUL
Instrument Local I/O:
•
•
•
5 mappable inputs optically isolated
4 mappable outputs 48-240 VAC Form A
Electronic
3rd party mappable over DeviceNet
Physical Characteristics:
Panel Mount (Model # HI 3300-PM)
Depth
•
8.03" (203.96mm) Back of the Bezel to
rear cable clearance.
Overall Height with HI 3300 installed, as measured
from the base to the top of the front plate.
•
11.77” High (298.96mm H)
Swivel Material
•
304 Stainless Steel
Analog CCA
Resolution:
•
Output types:
•
•
•
•
16 bit resolution
0-5V
0-10V
4-20mA
0-20mA
9
CHAPTER 2
Specifications
Current Loop Power:
•
•
0-20, 4-20 mA output: Max Voltage - 12
volts
0-10 and 0-10V output: Max Current 5mA
ControlNet Option Board
Power Supply:
•
+5V max - 350mA
Operating Temperature:
Integral Nonlinearity:
•
•
0 - 70° C (32° - 158° F)
± 0.0045%
ControlNet Baud Rate:
Max Offset:
•
•
5 Mbit/second
± 0.04%
Max I/O Data Capacity:
Power Supply:
•
Minimum input: 60VAC
•
Maximum input: 120VAC RMS
•
•
ControlNet Supported Features:
•
•
Operating Temperature:
•
Input - 250 bytes
Output - 250 bytes
Redundant Media
Cyclic Messaging
0-50 Cº
EtherNet/IP™ Option Card (Pending)
Specifications for I/O Option Boards
Power Supply:
Profibus Option Board
•
+5V max 450mA
Power Supply:
Operating Temperature:
•
+5V max - 350mA
Operating Temperature:
•
0 - 70° C (32° - 158° F)
Profibus Services:
•
•
1003H with Standard GSD File (May
change if required)
0 - 70° C (32° - 158° F)
•
10/100 Mbit/s
•
2048 bytes
•
2048 bytes
I/O Input:
DP Services
ID Number and GSD Support:
•
Baud Rate:
I/O Output:
Application Interface:
Input Size:
•
•
Parallel
0-122 Words
Specification Rel. 2:
Output Size:
•
•
0-122 Words
Combined Input and Output Size:
•
Not exceed 208 Words
Functionality:
EtherNet/IP level 2 I/O Server CIP (ControlNet & DeviceNet)
HI 3300 Tension Controller
Service Manual
•
10/100Mbit MB/TCP +EtherNet/IP + IT
functions
•
•
RIO Option Board
Power Supply:
•
+5V max - 350mA
Operating Temperature:
•
0 - 70° C (32° - 158° F)
RIO Baud Rate:
•
57.6, 115, 225 Kbit/second
Max I/O Data Capacity:
•
•
•
•
Input - 63 bytes (Full Rack)
Output - 63 bytes (Full Rack)
15 Bytes Discrete
48 Bytes Block
RIO Supported Features:
•
•
•
Enclosure Ratings:
Block Transfer Data
IO Mode
1/4, 1/2, 3/4 and Full Rack
Control of the Rack_Size and Starting_Quarter Combinations
Starting Quarter
Valid Rack Sizes
First
For all Rack Sizes
Second
For 1/4, 1/2, 3/4 Racks
Third
For 1/4, 1/2 Racks
Fourth
Only for 1/4 Racks
Table 1: Quarter Combinations
Specifications for Peripherals/Systems
Components
HI 215JB-SS1 or PS1 Series:
Case Dimensions:
•
6.25"H x 6.25"W x 4.50D (158.75mmH x
158.75mmW x 114.3mmD)
•
5 pounds (2.27 Kilograms)
Weight
-SS1 Stainless Steel NEMA 4 & 4X
-PS1 Painted Carbon Steel NEMA 4
10
11
CHAPTER 3
Installation
CHAPTER 3: INSTALLATION
About Chapter 3
All information contained in Chapter 3 pertains to unpacking, cabling, interconnecting and installing the HI 3300 Tension Controller. Alternatives to any specifications contained
or implied in this section are not recommended. It is very
important that the user and service personnel be familiar
with the procedures contained in this chapter, before installing or operating the HI 3300 Tension Controller.
NOTE:
Ethernet and DeviceNet installation and setup
instructions are located in the HI 3000 Series
Operation and Installation Manual in the
Cabling Section. There are also installation
instructions in the Quick Installation Guide.
Disassembly and Reassembly Notes and
Cautions
•
WARNING: FAILURE TO DISCONNECT THE POWER CORD
BEFORE DISASSEMBLING MAY CAUSE PERSONAL INJURY
AND/OR PROPERTY DAMAGE.
WARNING: MAKE SURE THAT ALL PERSONNEL ARE
WEB TENSION MACHINERY BEFORE PUSHING THE START BUTTON. FAILURE TO DO SO MAY CAUSE
PERSONAL INJURY AND/OR PROPERTY DAMAGE.
CLEAR OF THE
•
Unpacking
Step 1. Before signing the packing slip, inspect the packing
for damage of any kind.
Step 2. Report any damage to the carrier company immediately.
Step 3. Check to see that everything in the package
matches the bill of lading. You should normally
have:
•
•
•
HI 3300 Panel Mount
•
•
•
(1) HI 3300 Tension Controller with mating
connectors and ordered options installed.
(1) Mounting Kit with a mounting bracket,
gasket and (4) RAF 8-32 captive screws.
CD containing User Guide and Service Manuals
Step 4. If any items are missing, damaged, or there are any
questions, please contact Customer Support at:
Hardy Instruments
9440 Carroll Park Drive, Suite 150
San Diego, CA 92121
Phone: (858) 278-2900
FAX: (858) 278-6700
Web Site: http//www.hardyinstruments.com
E-Mail: [email protected]
Step 5. 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.
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 the
instrument.
Place small fasteners, connectors and electrical parts in closed containers 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 Instruments,
Technical 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 component 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 immediately!
Always check to be sure that no loose
parts are sitting on printed circuit boards
or electrical connectors 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.
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
HI-3300 Tension Controller
Service Manual
•
WARNING:
of the printed circuit boards in the instrument.
Always follow proper safety procedures
when working on or around the instrument.
12
Dimensions of the panel cutout. (See Fig. 3-2)
•
•
8.94” ±.06 (227.076mm ± 1.52mm) Wide
6.625” ±.06 (171.45mm ± 1.52mm) High
8.94" (227.076)
IF A LITHIUM BATTERY IS REPLACED WITH AN
INCORRECT TYPE IT MAY CAUSE AN EXPLOSION WHICH
WILL CAUSE PROPERTY DAMAGE OR PERSONAL INJURY.
Mechanical Installation
Installing the HI 3300 in a Panel
6.625" (168.26)
Panel Cutout Specifications
Enclosure Size Requirements:
•
•
Overall depth of the enclosure must be a
minimum of 8.5" to allow for the 2" clearance between the rear panel of the HI 3300
Tension Controller and the inside surface of
the rear panel of the enclosure. (See Fig. 3-1)
There must be a 1" clearance completely
around the bezel and other installed units.
FIG. 3-2 PANEL CUTOUT DIMENSIONS
Installing the HI 3300 Tension Controller
Step 1. Make sure that all Electrostatic Discharge (ESD)
precautions are taken before and during installation.
Step 2. The Tension Controller comes with a NEMA 4 &
4X rated compression gasket. Slide the gasket over
the rear of the instrument until the gasket is flush
with the back side of the front panel. (See Fig. 3-3)
Panel Mount
Collar
W/Captive Screws
Panel Gasket
Enclosure
Front Panel
FIG. 3-3 PANEL MOUNT INSTALLATION
FIG. 3-1 REAR PANEL CLEARANCE REQUIREMENT
Step 3. Gently slide the Tension Controller with the gasket
into the cutout in the enclosure front panel or door
until the gasket is flush with the enclosure front
panel. (See Fig. 3-4) Be sure to secure the instrument with both hands when installing.
13
CHAPTER 3
Installation
Step 4. Line up the instrument’s tapped holes with the
through holes in the enclosure front panel.
CAUTION:
ONCE THE GASKET IS COMPRESSED IT
SHOULD NOT BE USED AGAIN. WHENEVER THE
TENSION
CONTROLLER IS REMOVED FROM THE PANEL, RE INSTALL
WITH A NEW GASKET.
mounted in the swivel which is fastened to a hard surface.
The mount not only supports the instrument but also allows
the Tension Controller to rotate for a better view of the display and more convenient access to the front panel key
board. The Swivel Mount also serves as a wall mount. Simply rotate the swivel mount 90 degrees and attach it to a wall.
The swivel allows the instrument to rotate several degrees,
even with cables and rear cover attached.
Step 1. Use four (4) 1/4 x 20 fasteners to fasten the swivel
mount to a horizontal surface. (See Fig. 3-5)
FIG. 3-5 INSTALLING THE SWIVEL MOUNT TO A
HORIZONTAL SURFACE
FIG. 3-4 NEMA 4 GASKET FLUSH AGAINST THE
FRONT PANEL OF THE ENCLOSURE
Step 5. Gently slide the Panel Mount Collar over the rear of
the instrument. (See Fig. 3-3)
Step 6. Push the captive screws through the holes in the
Enclosure Front Panel and install the screws into
the tapped holes on the instrument until the screws
are finger tight.
Step 7. Use a slotted head screwdriver and tighten each
screw until the instrument is snug and the compression gasket is tight against the Enclosure Front
Panel. DO NOT OVERTIGHTEN!
Step 8. The Panel Mount installation is complete.
Installing the HI 3300 in a Swivel/Wall Mount
About the Swivel/Wall Mount
The swivel mounts allows the Tension Controller to mount
on a horizontal or vertical surface. The instrument is
Step 2. Place the Tension Controller between the Swivel
Mount brackets so that the threaded holes in the
instrument are aligned with the slots in the Swivel
bracket. (See Fig. 3-6)
HI-3300 Tension Controller
Service Manual
14
Step 7. Use four (4) 1/4 x 20 fasteners to fasten the swivel
mount to a vertical surface. (See Fig. 3-8)
FIG. 3-6 TENSION CONTROLLER INSTALLING IN
A SWIVEL MOUNT
Step 3. Screw the two (2) fastener knobs into the threaded
holes on each side of the Tension Controller until
the brackets are snug against the instrument. (See
Fig. 3-6 & 3-7)
CAUTION: DO NOT OVERTIGHTEN.
Step 4. To rotate the instrument in the swivel mount, loosen
the two fastener knobs.
Step 5. Rotate the instrument to the position you want.
Step 6. Re-tighten the fastener knobs.
FIG. 3-7 TENSION CONTROLLER INSTALLED IN A
SWIVEL MOUNT
FIG. 3-8 INSTALLING THE SWIVEL MOUNT TO A
VERTICAL SURFACE
Step 8. Place the Tension Controller between the Swivel
Mount brackets so that the threaded holes in the
instrument are aligned with the slots in the Swivel
bracket. (See Fig. 3-9)
NOTE:
When wall mounted, the unit should support a 14
pound weight for one minute without coming
loose or damaging the equipment.
FIG. 3-9 TENSION CONTROLLER INSTALLING IN
A SWIVEL WALL MOUNT
15
CHAPTER 3
Installation
Step 9. Screw the two fastener knobs into the threaded
holes on each side of the Tension Controller until
the brackets are snug against the instrument. (See
Figs. 3-9 & 3-10)
Step 2. Gently slide the circuit board into the slots making
sure that the each side of the PC board is in the
proper slot. (See Fig. 3-12)
FIG. 3-12 MAIN CONTROLLER BOARD INSTALLATION/SLIDING THE BOARD INTO THE INSTRUMENT
FIG. 3-10 TENSION CONTROLLER INSTALLED IN
A SWIVEL/WALL MOUNT
Installing Printed Circuit Boards
Step 1. From the back of the instrument, align the PCB
board with the housing slots in the instrument so
that the backplane connector is facing the instrument. (See Fig. 3-11)
Step 3. Gently push the PC board all the way into the
instrument until the backplane connector is connected to the backplane.
Step 4. Install the Main Board rear plate. (See Fig. 3-13)
•
•
•
•
Place the Main Board rear plate so that the
threaded holes on each side of the instrument
chassis are aligned.
Screw a panhead screw (#4-40) into the
threaded hole on the instrument chassis. Do
not tighten.
Screw the panhead screws that attach the
rear plate to the Main Board until they are
finger tight.
Use a Phillips head screw driver and tighten
all the installed screws until snug.
CAUTION: DO NOT OVERTIGHTEN.
FIG. 3-11 MAIN CONTROLLER BOARD INSTALLATION/LINING UP BOARDS WITH THE SLOTS
HI-3300 Tension Controller
Service Manual
•
•
•
•
•
16
All cabling should be neatly bundled, tied,
and dressed.
Use a 6 inch service bend to relieve stress on
the connectors and to ease servicing the unit.
Make sure that all plugs are firmly in place.
Be sure to secure the power cord with the
two (2) captive screw-on clips.
All connections are made at the rear panel of
the Tension Controller.
AC Power Wiring
WARNING: DO NOT OPERATE WITH INCORRECT LINE
VOLTAGE. TO DO SO WILL RESULT IN PROPERTY DAMAGE
AND/OR PERSONAL INJURY. MAKE SURE THAT THE POWER
SOURCE DOES NOT EXCEED 240 VAC.
•
FIG. 3-13 MAIN CONTROLLER BOARD
INSTALLED WITH REAR PLATE
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.
(See Fig. 3-16)
Step 5. Installation of all the PC Boards used in any HI
3000 Series Instrument requires the same procedures.
Removing Printed Circuit Boards
Step 1. Unplug all the cables that are connected to the
instrument.
Step 2. Use a Phillips head screw driver and remove the
two (2) pan head screws that fasten the rear plate to
the instrument. You do not need to remove any of
the screws that fasten the rear panel to the PC
Board.
Step 3. Use your fingers to grasp the two (2) (knurled
knobs) that are mounted on the rear panels.
Step 4. Gently pull the knobs away from the instrument
until the PC Board is clear of the instrument slots.
Step 5. Store the circuit board in a secure and dry location,
free of any ESD.
Electrical Installation
Cabling and Interconnecting
Recommended Installation Procedures
•
Carefully plan the cable runs and wiring connections before routing, cutting and trimming cables and wires.
CAUTION: INSTRUMENT POWER AND RELAY
WIRES SHOULD BE ROUTED AWAY FROM ALL
OTHER SIGNAL CABLES TO AVOID ELECTRICAL
INTERFERENCE.
FIG. 3-14 POWER WIRING DIAGRAM
•
Power Input J1
J1-1 Neu (Low)
J1-2 Line (HI)
J1-3 Ground
Step 1. The HI 3000 Series instruments are configured with
a universal power supply rated from 120 to 240
VAC. The instruments can be powered by a 120 or
240 VAC power source and requires no switching
or jumper settings.
Step 2. Install a 3-wire, minimum 14 AWG power line to
the 3-pin terminal block connector. (See Fig. 3-16)
Step 3. The power and relay circuit card filters and conditions AC power. However, for noisy power lines,
external conditioning may be required.
-DC Power Wiring
WARNING: DO NOT OPERATE WITH INCORRECT LINE
VOLTAGE. TO DO SO WILL RESULT IN PROPERTY DAMAGE
AND/OR PERSONAL INJURY. MAKE SURE THAT THE POWER
SOURCE DOES NOT EXCEED 24 VDC.
•
The DC power should be supplied by a “clean” primary
line, directly from the DC power source.
17
CHAPTER 3
Installation
terminal block according to the cable color chart.
(See Below)
NOTE:
To purchase Hardy Load Cell cable, contact your
local Hardy Representative or Distributor.
Step 3. Plug the terminal block into the Channel 1 connector on the rear panel.
FIG. 3-15 DC POWER SUPPLY CONNECTION
Step 1. Connect your positive and negative DC voltage
lines to the Phoenix connector that plugs into the
DeviceNet Connector. (See Fig. 3-17)
Step 2. Plug the connector into the DeviceNet Connector at
the rear panel.
NOTE:
Non-C2 Load Point Connection
Cable color Code for Non-C2 Load Points:
•
•
•
•
•
•
•
•
•
Use DC power source when you have the -DC
option and do not have the DeviceNet Option.
The DeviceNet option has its own DC power
source.
Load Point Connections
FIG. 3-16 REAR PANEL/LOAD POINT CONNECTIONS
Shield
C2C2+
EXCSENSIGSIG+
SEN+
EXC+
Ground Wire
Not Used
Not Used
Black
Brown
White
Green
Blue
Red
Step 1. Remove the factory installed jumper from the terminal block if you have 6 wire load cell cable that
includes sense wires from the load cell or junction
box.
Step 2. Connect the cable (Recommended load cell cable:
Hardy Instruments Prt. # 6020-0001) wires to the J9
terminal block according to the Non-C2 cable color
chart.
Step 3. Plug the terminal block into the Channel 1 (J9) connector on the rear panel.
LVDT Tension Sensor - MB Series
Connection
C2® Load Point Connection
About LVDT Connections
Cable color Code for C2 Load Points (left to right facing the
rear panel):
•
•
•
•
•
•
•
•
•
Shield
C2C2+
EXCSENSIGSIG+
SEN+
EXC+
Ground Wire
Violet
Grey
Black
Brown
White
Green
BLUE
RED
Step 1. Remove the factory installed jumper from the terminal block if you are connecting an 8 wire cable
from the junction box.
Step 2. Connect the cable (Recommended load cell cable:
Hardy Instruments Prt. # 6020-0001) wires to the J9
The LVDT can be wired for compression applications and
for Tension applications. To convert from Compression to
Tension and back just reverse the SIG+ & SIG- wires (See
Figs. 3-19, 20).
Cable Color Code for MB Series LVDT load sensor connection:
•
•
•
•
Red
Black
Yellow
Green
EXC+
EXCSIGSIG+
HI-3300 Tension Controller
Service Manual
18
Junction Box Wiring
Yellow or White (SIG-)
Red (EXC+)
4
1
Compression
3
2
Black (EXC-)
FIG. 3-20 JUNCTION BOX CONNECTIONS
Green (SIG+)
FRONT VIEW OF CONNECTOR
FIG. 3-17 LVDT CONNECTIONS/COMPRESSION
Green (SIG+)
Red (EXC+)
4
1
NOTE:
Tension
3
Step 4. Connect the cable wires directly to the terminal
blocks according to the C2 or Non-C2 cable color
charts.
Step 5. Plug the terminal blocks into Channels 1 thru 4 connectors on the rear panel. Write down which load
cell is connected to Channel 1, Channel 2, Channel
3, Channel 4 for future reference.
2
Black (EXC-)
If you have one load point you must plug it into
Channel 1. If you have more than one load point
you must make sure that you plug one of the load
points into Channel 1.
Step 6. If you only have 3 load cells, do not use Channel 4.
Yellow or White (SIG-)
Network Option Card Installation
FRONT VIEW OF CONNECTOR
FIG. 3-18 LVDT CONNECTIONS/TENSION
(REVERSE WRAP)
1 2 3 4 5 6 7
+Exc
+Sen-
+Sig
Place jumpers in positions 4-5 and 8-9 (See
Fig. 3-19)
-Sig
-Sen
-Exc
+C2
-C2
Shield
•
Installation of Secure Memory Module
(SMM)
8 9
8 9
LINK
Line
Neu
V+
Txd
Rxd
Gnd
Iso
Gnd
+Exc
+Sen-
+Sig
-Sig
-Sen
-Exc
+C2
-C2
Shield
Channel 2
1 2 3 4 5 6 7
All Network Option Card installation and configuration
instructions can be found in the HI 3000 Manual which is
located on the Resource CD you received with your HI 3000
Series instrument. If you do not currently have the Resource
CD or an HI 3000 manual go to the Hardy Instruments Web
Site and download a free copy. For the Analog Option Card
Configuration please go to the Analog Option Card Configuration Section of Chapter 4 in this manual.
T/R
Channel 1
Printer/Display
Ethernet
SMM
Devicenet
FIG. 3-19 LVDT CONNECTIONS/HI 3300 REAR
PANEL
FIG. 3-21 SECURE MEMORY MODULE (SMM)
Step 7. Slide the module with the notch up into the module
housing at the rear panel. (See Fig. 3-20 & 21)
19
CHAPTER 3
Installation
FIG. 3-22 INSTALLING THE SECURE MEMORY
MODULE
Step 8. Press the module in until it stops. Do not force the
module, it should slide in easily.
Step 9. To remove the module pull the module straight out
of the housing. (See Fig. 3-22)
Transferring a Secure Memory Module
CAUTION: DO NOT REMOVE AN SMM WITH THE POWER
ON. ALWAYS DISCONNECT THE POWER CABLE FROM THE
INSTRUMENT BEFORE REMOVING OR INSTALLING THE
SECURE MEMORY MODULE.
Step 1. Disconnect the power cable from the Instrument.
Step 2. Remove the Secure Memory Module from the
instrument.
Step 3. Install the Secure Memory Module into the new
instrument.
Step 4. Power up the new instrument.
HI-3300 Tension Controller
Service Manual
20
21
CHAPTER 4
Configuration
CHAPTER 4: CONFIGURATION
About Chapter 4
Chapter 4 contains step-by-step instructions for configuring
the Hardy Instruments, HI 3300 Tension Controller. The procedures include complete instructions for configuring the
Tension Controller from the Front Panel, Remote I/O
(optional) ControlNet (optional), DeviceNet (Optional) and
Web Browser. We highly recommend reading the procedures
before configuring the Tension Controller. Being familiar
with the configuration procedures insures that the Controller
will provide trouble free service.
Operating the Tension Controller from the
Front Panel
Getting Started
Before operating the Hardy HI 3300 Tension Controller,
check to make sure the following procedures have been performed:
•
•
•
+
Power and Load Point cables properly
installed.
Communication cables properly installed.
Roll Weight and Load Sensors have been
Zeroed and Calibrated.
FIG. 4-1 FRONT PANEL
Front Panel Display
All the features of the Tension Controller operate the same
no matter what the interface. First let’s get familiar with configuring the HI 3300 from the front panel of the instrument.
(See Fig. 4-1)
The Front Panel Display has a large tension value display
with 4 line x 20 Alphanumeric character LCD. The screen
displays all the menus for Configuring, Calibrating and
Operating the HI 3300 Tension Controller.
Help
Button Functions
About Help
As you move through the setup/configuration menus you
may on occasion need assistance. If you need help, do the
following:
Step 1. Use the up and "-" arrows and move the cursor in
front of the Menu Item you want help on.
Step 2. Click the Help button either on the front Panel, or
Web Page and a Help Dialog appears. The help dialog tells you what the Menu Item is used for or
other descriptive information to help you enter the
right parameters for the current menu item.
Step 3. Push the Exit button to return to the current menu.
Start Button
The Start Button starts or restarts the tension process. Start
could also be a dual start where the Start Button will start the
process in the controller and send a signal to the VFD to
start.
WARNING: THE START BUTTON IS ACTIVE IN ANY MENU.
MAKE SURE THAT ALL PERSONNEL ARE CLEAR FROM ANY
AND ALL MACHINERY WHEN CONFIGURING THE TENSION
CONTROLLER. ACCIDENTALLY STARTING THE SYSTEM
WHEN IN THE CONFIGURATION OR CALIBRATION MENUS
COULD CAUSE PROPERTY DAMAGE AND/OR PERSONNEL
INJURY.
Stop Button
The Stop button stops or initiates a shutdown sequence for
the controller. The Stop could also provide a signal to a
remote station as well.
NOTE:
The Stop button is functional in all menus.
HI-3300 Tension Controller
Service Manual
22
Enter Button
Help Button
The Help button displays a Help message for the current
Menu item (the Menu item in front of the cursor) that is displayed. In Standby the Help button does not display a Help
message.
The Enter button enters the Alphanumeric value entered for
a menu item in the display. The Enter button also enters the
selections from a pick list. (See Fig. 4-3)
Auto/M Button
0.00
Enables you to enter or exit the manual or Auto mode of
operation. You also see “Auto” or “Manual” in the upper
right hand corner of the display telling you which mode you
are currently in. When in the Auto mode the PID control is
targeting the tension setpoint. In Manual mode if there is
ringing or oscillation it reflects the noise level in the system.
Product Button
The Product button opens the Product Menus which allows
the user to select among three preconfigured products. It also
enables the user to set or reset the Name of the Product and
the Tension Setpoint.
Left/Right Arrow, +/- Buttons
+
Sel ect Unit s using r ight or
l ef t ar r ow. Then pr ess ent er
> l bf
n
FIG. 4-3 LIST SELECTION/ENTER BUTTON
For example, when selecting units from a pick list, use the
left and right arrows to move the cursor in front of the unit
you want and press the Enter button.
Exit Button
The Exit button disregards the current value entry, restores
the previous value and moves the cursor to the previous
menu.
Clear Button
The Clear button clears the total Alpha/Numeric Entry and
repositions the cursor for the first entry.
Gain/1 Button
Enables you to change the System Gain (P) while in the
Operating Mode. Also enters the integer 1 in the display.
FIG. 4-2 DIRECTIONAL BUTTONS
The “+” and “-” buttons allow the operator to adjust the running tension up or down from the Operating Display when in
the Auto Mode. The “+” increases the running tension and
the “-” decreases the running tension. The “+” and “-” buttons enable the operator to adjust the output signal from the
Operating Display when in the Manual Mode.
When in a Sub-Menu, the +/- buttons move the cursor vertically allowing the user to scroll through each item of a menu.
The Left/Right arrow buttons move the cursor horizontally
left and right. The Left arrow button has an added backspace
function. For example if there are Alpha/Numeric characters
that appear in the display, as you press the left button it
erases the characters. The Right arrow button moves the cursor to the right in the display and does not erase an alphanumeric entry. The Left/Right arrow buttons also move the
cursor through a pick list. (See Fig. 4-2)
2/ABC Button
Enters the integer 2 in the display. Also enters the characters
A, B, C. Pushing the button once enters the integer 2.
NOTE:
For numeric entries only: Push the button and
the number on the button is entered.
NOTE:
For Alphanumeric entries only: Pushing the button once, the first letter on the button is entered in
uppercase, A, D, G, and so on. Push the button a
second time, the second letter is entered in uppercase, B, E, H, K and so on. Push the button a
third time, the third letter is entered in uppercase,
C, F, I, L, and so on. Push the button a fourth
time, the fourth letter is entered in uppercase, S,
Z. Push the button a fifth time the first letter is
entered in lowercase, a, d, g, and so on. After you
go through the lowercase letters, you can push
the button again for the number. You need to push
23
CHAPTER 4
Configuration
the buttons rapidly. If you delay too long the
instrument will accept the alphanumeric character and move the cursor to the left preparing for
the next alphanumeric entry. This is true for all
the Alphanumeric buttons. If this occurs use the
left arrow button to erase the current entry and
enter another.
Setup/3/DEF Button
This enables you to access the configuration and setup
menus. Also enters the number 3 and the letters D, E, F.
Taper/4/GHI
Enables you to change Taper percentage on the fly when
controller is in operating mode. Also enters the number 4
and the letters C, H, I.
5/JKL Button
Enters the integer 5 and the letters J, K, L.
Starting Up for the First Time
When the HI 3300 Tension Controller powers up after delivery from the factory, The Operating Mode Display appears
in the Front Panel Display with the controller on Standby.
(See Fig. 4-4) The Operating Display always indicates one
of the following modes of operation: (See Figs. 4-5, 6, 7)
•
•
•
•
Standby - Prepared and Waiting to Start
Auto - Instrument controlling the process
Manual - Operator controlling the process
Stop - Controller and Process are stopped.
You must press Start to Start or Restart the
Controller.
0.00
HI - Web
Out put : 25%
Set point : 5.00 l b
St andby
6/MNO Button
Enters the integer 6 and the letters M, N, O.
Calibrate/7/PQRS Button
Enables the user to calibrate (C2, Traditional Cal, Soft Cal)
the instrument when in the operating display. Also enters the
integer 7 and letters P, Q, R, S.
8/TUV Button
Enters the integer 8 and the letters T, U, V.
FIG. 4-4 FRONT PANEL/OPERATING MODE
DISPLAY/STANDBY
0.00
HI - Web
Out put : 25%
Set point : 5.00 l b
Manual
Test/9/WXYZ Button
Enables you to enter the self test or diagnostics mode. Also
enters the inter 9 and letters W, X, Y, Z.
FIG. 4-5 FRONT PANEL/OPERATING MODE
DISPLAY/MANUAL
User/./_/@ Button
Enables you to change the 3 digit user code while in the
standby mode. Also enters the period (.), underscore (_) and
@ symbols.
0/Char. Button
0.00
HI - Web
Out put : 25%
Set point : 5.00 l b
Aut o
Enters the integer 0 in the display. When you push the button
the second time a set of characters appears in the display.
Step 1. Using the “+” and "-" arrow buttons move the cursor in front of the character you want to display.
Step 2. Press the Enter Button to select the character.
Step 3. Press the Exit Button to return to the display. The
character should now appear next to the cursor.
FIG. 4-6 FRONT PANEL/OPERATING MODE
DISPLAY/AUTO
HI-3300 Tension Controller
Service Manual
0.00
HI - Web
Out put : 25%
Set point : 5.00 l b
St op
FIG. 4-7 FRONT PANEL/OPERATING MODE
DISPLAY/STOP
Let’s stop and look at the information on the Operating Display:
•
•
•
•
•
NOTE:
The large number at the top of the display
is the current tension in pounds force (lbf)
as measured by the load sensor.
The “HI - Web” is the Instrument ID.
“Standby, Auto, Manual or Stop” is the
current operational mode of the instrument.
Output is the percentage of the full Analog
output signal.
Setpoint is the Tension Setpoint Value
entered for the current product.
Proportional - More appropriately called “gain”, which is a
multiplier that increases the error signal to a value which is
useful as a correction signal. The correction signal is proportional to the original error and either increases or decreases
the tension to correct for the error signal from the load sensor.
Integral - More appropriately called “stability” provides a
correction to the PID algorithm that smooths or slows the
Controller output so that tensioning mechanisms don’t overreact, which adds stability to the system.
Derivative - More appropriately called “response” looks for
the rate at which the error rate changes. The derivative
accounts for and adjusts the output signal that corresponds to
the rate of change. D is different from P in that D responds
early to a rate of change and P only reacts to the absolute
error signal at any given point in time.
NOTE:
0.00
PID Par amet er s
Aut oGain
0.000
> Pr opor t ional
30
Int egr al
2.0
Tension Controller Configuration From the
Front Panel
Setting the P (Proportional) + I (Integral) + D
(Derivative) Parameters (PID)
About PID
A tension control process is a dynamic system which is
changing all the time. The actual tension changes from
moment to moment. Most often the actual tension will be
greater or less than the setpoint. The HI 3300 Tension Controller produces a correction signal that is sent to the tensioning mechanisms (clutch, motor, etc.) in order to maintain the
Setpoint Tension.
All entered values are for illustration purposes
only. Your requirements will vary.
Step 1. Press the Gain/1 button. The PID Parameters Display appears with the cursor in front of Proportional. (See Fig. 4-8)
The Setpoint displays lb, however it is measuring
pounds force (lbf).
The Tension Controller Configuration process sets up the
instrument to Maintain a Setpoint Tension via a PID Control
Algorithm. This includes setting WAVERSAVER®, Max
Tension, Units of Measure and other process and instrument
parameters required for your process. Here is where the permanent parameters are entered. All the parameters configured except the communications parameters, (IP Address
etc.) are stored in the Secure Memory Module (SMM).
24
FIG. 4-8 PID PARAMETERS/SETTING
PROPORTIONAL
Step 2. Use the alphanumeric key pad and enter the new
value.
NOTE:
An alternative is to first press the Clear button to
clear all entries. Then use the alphanumeric key
pad and enter the new value.
Step 3. Press the Enter button to save the entry.
Step 4. Press the “-” button until the cursor is in front of
“Integral”.
Step 5. Use the alphanumeric key pad and enter the new
value. Press the “-” button until the cursor is in
front of Derivative.
Step 6. Use the alphanumeric key pad and enter the new
value.
Step 7. Press the Enter button to save the entry.
Step 8. Press the Exit button to return to the Operational
Display.
25
CHAPTER 4
Configuration
Instrument Setup Procedures
Step 1. Press the Setup/3 button. The Setup Menu appears
with the cursor next to Process Setup. (See Fig. 4-9)
NOTE:
Note that there is a directional arrow on the right
side of the display in the Process Setup line. This
means that there are sub-menus that need to be
configured for this setup parameter. You can
press the Enter button to get to these displays.
Please refer to the HI 3300 Menu tree for assistance.
Set up
Opt ions
> Pr ocess Set up
Inst Set up
0.00
Inst Set up
Adj ust Cont r ast
> Inst r ument ID
Oper at or ID:
->
FIG. 4-11 SETUP MENU/SELECTING CHANNEL
NAME
Step 4. Press the Enter button. The “Instrument ID” display
appears. (See fig. 4-12)
0.00
->
Inst r ument ID:
0.00
> HI- Web
FIG. 4-9 SETUP MENU
Step 2. Press the - button until the cursor is in front of “Inst
Setup”. (See Fig. 4-10)
Set up
Pr ocess Set up
> Inst Set up
Cal ibr at ion
0.00
FIG. 4-12 INSTRUMENT ID/SETTING INSTRUMENT
ID
Instrument ID
PARAMETER:INSTRUMENT ID
RANGE: 19 CHARACTERS
DEFAULT: HI-WEB
->
FIG. 4-10 SETUP MENU/SELECTING INSTRUMENT
SETUP
Step 3. Press the Enter button. The Instrument Setup Menu
Appears with the cursor in front of “Instrument
ID:”. (See Fig. 4-11)
About Instrument ID
The Instrument ID parameter is used to provide specific
identification for a Tension Controller. This is extremely
important when using several Tension Controllers in a process. A unique Instrument ID allows you to identify one
instrument from another.
Step 1. Use the alphanumeric key pad to enter the new
Instrument ID. We entered “HI-Web” for Hardy
Instrument Web Tension. It is recommended that
you be brief and descriptive when entering the
Instrument ID. 8-10 characters should be good
enough.
Step 2. Press the Enter button to save the setting.
Step 3. Press Enter to return to the Setup Menu.
Step 4. Press the “-” button until the cursor is in front of
“Operator ID”. (See Fig. 4-13)
HI-3300 Tension Controller
Service Manual
Operator ID
PARAMETER:UNIT OF MEASURE
RANGE: LB, N, PLI
DEFAULT: LB
About Operator ID
The Operator ID is the ID of the user who is going to operate
the Tension Controller or service the instrument. Select three
letters or numbers or any combination of the two that adequately identifies the user. We have provided some examples
below for your assistance. The Operator ID is used in connection with the security level of the user.
Step 1. Press the "-" arrow button until the cursor is in front
of Unit of Measure. (See Fig. 4-14)
0.00
Inst Set up
Oper at or ID
> Unit s of Measur e
Decimal Point :
PARAMETER:OPERATOR ID
RANGE: 3 CHARACTERS
DEFAULT: BLANK
0.00
Inst Set up
Inst r ument ID
> Oper at or ID:
Unit s of Measur e
26
->
lb
lb
0
FIG. 4-14 SETUP MENU/UNIT OF MEASURE
Step 2. Press the right or left arrow buttons to make your
selection.
Step 3. Press the Enter button to save the setting.
Decimal Point Parameter
About the Decimal Point Parameter
FIG. 4-13 INSTRUMENT SETUP MENU/OPERATOR
ID
Step 1. Use the alphanumeric key pad to enter your Operator ID.
Step 2. An Operator ID is three (3) characters long and can
consist of alphanumeric characters.
Some examples of Operator IDs:
•
•
•
•
Joe
312
J15
JD7
Step 3. Press the Enter button to set the entry.
Unit of Measure Parameter
About Unit of Measure
The Unit of Measure Parameter sets the scale to either
English or Metric units. The Selections are:
•
•
•
NOTE:
Pounds Force (lb)
Newtons (N)
Pounds per Linear Inch (Pli)
Pounds (lb) are actually pounds force (lbf). It is
simpler to just think of this parameter as pounds
rather than pounds force.
The Decimal Point Parameter is set to determine the resolution you want for tension control. Here you set the location
of the decimal point for the tension resolution. The higher
the number the farther to the left the decimal point moves
and the higher the resolution of the scale..
PARAMETER:DECIMAL POINT
RANGE: 0-4
DEFAULT: 0
Step 1. Press the "-" arrow button until the cursor is in front
of Decimal Point. (See Fig. 4-15)
0.00
Inst Set up
Unit s of Measur e
> Decimal Point :
Aver ages:
lb
2
10
FIG. 4-15 SETUP MENU/DECIMAL POINT
Step 2. Press the right or left arrow buttons to make your
selection. The right arrow button increase the value.
The Left Arrow button decreases the value.
Step 3. Press the Enter button to set the entry.
27
CHAPTER 4
Configuration
Averages Parameter
About the Averages Parameter
This setting is to aid in ignoring the effects of disturbance. If
there is a lot of zone disturbance, tension fluctuations can be
seen. Applications requiring very quick tension readings
should reduce this setting to it’s minimum. If the tension is
unstable due to zone instability, increase the averages. This
sets the number of readings that will be used to compute the
Tension. The average is a sliding average so that a new average is available for display at every reading.
The Tension Controller does 55 updates per second which
translates to an update approximately every 20 milliseconds.
If you average enough tension readings the loss or gain
remains smooth. If you average the tension too much you
can cause an overreaction.
enables the Tension Controller to distinguish between actual
tension data and mechanical noise, both of which are typically transferred to the Tension Controller by the load cell
signal. WAVERSAVER® can be configured to ignore noise
with frequencies as low as 0.25 Hz. One of four higher additional cut off frequencies may be selected to provide a faster
instrument response time. The WAVERSAVER function is
user selectable and can be turned off.
PARAMETER:WAVERSAVER®
RANGE: .25 HZ, .50 HZ, 1.0 HZ, 3.50 HZ, 7.50 HZ,
OFF
DEFAULT: 1.00 HZ
Step 1. Press the "-" arrow button until the cursor is in front
of WAVERSAVER®. (See Fig. 4-17)
PARAMETER:AVERAGES
RANGE: 1-250
DEFAULT: 10
Inst Set up
Aver ages:
> WAVERSAVER
MaxTension
Step 1. Press the "-" arrow until the cursor is in front of
Averages. (See Fig. 4-16)
0.00
Inst Set up
Decimal Point :
> Aver ages:
WAVERSAVER
2
10
1.00 Hz
0.00
10
1.00 Hz
1000.0 l b
FIG. 4-17 INSTRUMENT SETUP MENU/
WAVERSAVER
Step 2. Press the right or left arrow buttons to select the setting or turn WAVERSAVER off.
Step 3. Press the Enter button to set the entry.
Step 4. Press the “-” arrow button until the cursor is in front
of “Capacity”. (See Fig. 4-29)
FIG. 4-16 INSTRUMENT SETUP MENU/AVERAGES
NOTE:
Step 2. Use the alphanumeric keypad and enter the value
for Averages.
Step 3. Press the Enter button to set the entry.
Step 4. Press the “-” arrow button until the cursor is in front
of “WAVERSAVER®”.
®
The WAVERSAVER Parameter
About the WAVERSAVER Parameter
Typically, mechanical noise (from other machinery in a plant
environment) is present in forces larger than the weight
forces trying to be detected. The Tension Controller is fitted
with WAVERSAVER® technology which eliminates the
effects of vibratory forces present in all industrial tension
control and measurement applications. By eliminating the
factor of vibratory forces the Tension Controller is capable
of identifying the actual tension data. WAVERSAVER®
When setting WAVERSAVER for higher speed
applications (>500 FPM) it is highly recommended to set WAVERSAVER to 1.00 Hz. If the
reaction time is too slow for your applications,
select OFF.
MaxTension Parameter
About the MaxTension Parameter
The Maxtension value should be any value between the tare
weight and maximum capacity of your combined load cells
that will not cause faults in your process or the largest value
of tension you expect to see. The HI 3300 tares or zeroes the
instrument when you set the reference weight in Traditional
Calibration or C2 Calibration. (See Chapter 5, Traditional
Calibration Procedures, C2 Calibration Procedures.) The
PID input is scaled by this value. Also when you press the
plus or minus buttons up or down to increase or decrease the
HI-3300 Tension Controller
Service Manual
28
setpoint, each time you push the button it increases or
decreases the setpoint by 1% of the Maxtension.
0.00
PARAMETER:CAPACITY
RANGE: .0001-99999.0
DEFAULT: 1000.0
Step 1. Press the "-" arrow button until the cursor is in front
of MaxTension. (See Fig. 4-18)
Inst Set up
WAVERSAVER
> MaxTension
Snsr Type
0.00
1.00 Hz
1000 l b
- / - 120mV/ V
FIG. 4-18 INSTRUMENT SETUP MENU/
MAXTENSION
Inst Set up
MaxTension
> Sensor Typ
Inf r ar ed Enabl e:
1000.0 l b
0- 120mV/ V
ON
FIG. 4-19 INSTRUMENT SETUP MENU/SENSOR
TYPE
Step 1. Press the left or right arrow button to toggle
between 0-120 and 0-3 sensitivity depending on the
what the sensitivity range of the load sensors on
your tension application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Infrared Enable”. (See Fig. 4-20)
Infra Red (IR) Port Parameter
Step 2. Use the alphanumeric key pad to enter the new total
Load Sensor Capacity value.
Step 3. Press the Enter button to set the entry.
Step 4. Press the “-” button until the cursor is in front of
“Sensor Typ”. (See Fig. 4-19)
Sensor Type Parameter
About the Sensor Type Parameter
The Sensor Type parameter enables the you to select four
load sensor sensitivity ranges. 0-120mV/V, +/-120mV/V, 03mV/V, +/-3mV/V, depending on the sensitivity range for
the load sensors used for your tension process and whether
the load sensors are in compression or tension. It is recommended that you select 0-120mV/V & 3mV/V for compression applications and +/- 120mV/V & +/-3mV/V for tension
applications.
PARAMETER:SENSOR TYP
RANGE: 0-120 mV/V, 0-3 mV/V, +/-120mV/V, +/-3mV/V
DEFAULT: 0-3 mV/V
About the IR Port Parameter
The Tension Controller IR Port enables wireless connectivity
to PDA devices for configuration and the loading and transfer of data. If your handheld uses Palm OS® 3.3, 3.5 or your
Pocket PC has the IrDA (Infrared Data Association) port
connection (normally COM3) its infrared (IR) port can perform wireless operations and connect to the IR Port of the
Tension Controller.
PARAMETER:IR PORT
RANGE: OFF/ON
DEFAULT: ON
0.00
Inst Set up
Sensor Typ
> Inf r ar ed Enabl e:
Cl ock Set up
0- 3mV/ V
ON
FIG. 4-20 SETUP MENU/IR PORT
Step 4. Use the right or left arrow buttons to toggle
between OFF or ON.
Step 5. Press the Enter button to set the entry.
Step 6. Press the “-” button until the cursor is in front of
“Clock Setup”. (See Fig. 4-21)
29
CHAPTER 4
Configuration
Set Clock Parameter
About Setting the Clock
You set the Hour, Minutes, Month, Day and Year parameters
here. These settings are the time stamps for the alarms.
PARAMETER:HOURS
RANGE: hh (0-23)
DEFAULT: NONE
PARAMETER:MINUTES
RANGE: mm (0-59)
DEFAULT: NONE
Cl ock Set up
Min- mm
> Year - yyyy
Mont h- mm
0.00
44
2004
9
FIG. 4-22 CLOCK SETUP MENU/SET DATE
Step 3. Use the alphanumeric key pad to change the Year
setting.
Step 4. Press the Enter button to set the entry.
Step 5. Press the “-” arrow button until the cursor is in front
of “Month”.
Step 6. Use the alphanumeric key pad to change the Month
setting.
Step 7. Press the Enter button to set the entry.
Step 8. Press the “-” arrow button until the cursor is in front
of “Day”.
Step 9. Use the alphanumeric key pad to change the Day
setting.
Step 10. Press the “-” button until the cursor is in front of
“Hour”. (See Fig. 4-23)
PARAMETER:MONTH
RANGE: 1-12
DEFAULT: NONE
PARAMETER:DAY
RANGE: dd (01-31)
DEFAULT: NONE
PARAMETER:YEAR
RANGE: yyyy (200 - 2099)
DEFAULT: NONE
PARAMETER:TIMEZONE
RANGE: -12 TO +12
DEFAULT: -8
Step 1. Press the "-" arrow button until the cursor is in front
of “Set Clock”. (See Fig. 4-40)
0.00
Inst Set up
Inf r ar ed Enabl e:
> Cl ock Set up
Et her net
ON
>>
FIG. 4-21 SETUP MENU/SET CLOCK
Step 2. Press the Enter button. The Clock Setup Menu
appears with the cursor in front of “Year”. (See Fig.
4-22)
Cl ock Set up
Day- dd
> Hour - hh
Min- mm
0.00
17
8
44
FIG. 4-23 CLOCK SETUP MENU/SET CLOCK
Step 11. Use the alphanumeric key pad to change the Hour
setting.
Step 12. Press the Enter button to set the entry.
Step 13. Press the “-” arrow button until the cursor is in front
of “Min”.
Step 14. Use the alphanumeric key pad to change the Minutes setting.
Step 15. Press the Enter button to set the entry.
Step 16. Press the "-" arrow button until the cursor is in front
of Timezone. (See Fig.4-24)
HI-3300 Tension Controller
Service Manual
GMT
Cl ock Set up
Min- mm
> Timezone
Year - yyyy
0.00
44
8
2004
Civilian Time Zones
+4
Cities
Abu Dhabi, UAE
Muscat
Tblisi
Volgograd
Kabul
+4:30
Afghanistan
+5
+5:30
FIG. 4-24 CLOCK SETUP MENU/SET GMT
30
India
+6
+6:30
Cocos Islands
About Timezones (Greenwich Mean Time)
+7
There are 25 integer World Time Zones from -12 through 0
(GMT) to +12. Each one is 15° of longitude as measured
East and West from the Prime Meridian of the World which
is at Greenwich, England. Some countries have adopted nonstandard time zones, usually a 30 minute offset.
+8
CCT: China Coast
Shanghai, China
Hong Kong, China
Beijing, China
+9
JST: Japan Standard
Tokyo, Japan
Osaka, Japan
Taipei, Taiwan
Each Time Zone is measured relative to Greenwich,
England. Civilian designations are typically three letter
abbreviations (e.g. EST) for most time zones. Below is a list
of the abbreviated time zones with the GMT time adjustment. You will see the time zone ranges in the e-mail header.
+9:30
Australian Central Standard
Darwin, Australia
Adelaide, Australia
+10
GST: Guam Standard
+10:30
Lord Howe Island
+11
+11:30
GMT
Civilian Time Zones
+12
GMT
GMT: Greenwich Mean
UT: Universal
UTC: Universal Co-ordinated
WET: Western Europe
Norfolk Island
Cities
London, England
Dublin, Ireland
Edinburgh, Scotland
Reykjavik, Iceland
Casablanca, Morocco
IDLE: International Date Line
East
NZST: New Zealand Standard
+13
Rawaki Island
+14
Line Islands
EAST OF GREENWICH
+1
+2
+3
+3:30
CET: Central Europe
EET: Eastern Europe
BT: Baghdad
Paris, France
Berlin, Germany
Amsterdam, Holland
Brussels, Belgium
Vienna, Austria
Madrid, Spain
Rome, Italy
Bern, Switzerland
Oslo, Norway
Athens, Greece
Helsinki, Finland
Istanbul, Turkey
Jerusalem, Israel
Harare, Zimbabwe
Kuwait
Nairobi, Kenya
Riyadh, Saudi Arabia
Moscow. Russia
Tehran, Iran
TABLE 4-1: GREENWICH TIME ZONES (GMT)
Wellington, NZ
Fiji
Marshall Islands
WEST OF GREENWICH
-1
WAT: West Africa
-2
AT: Azores
-3
Azores
Cape Verde Islands
Brasilia, Brazil
Buenos Aires, Agentina
Georgetown, Guyana
-3:30
Newfoundland
-4
AST: Atlantic Standard
Caracas, Venezuela
La Paz
-5
EST: Eastern Standard
Bogota, Colombia
Lima, Peru
New York, NY, USA
-6
CST: Central Standard
Chicago, Illinois, USA
Mexico City, Mexico
Saskatchewan, Canada
TABLE 4-1: GREENWICH TIME ZONES (GMT)
31
CHAPTER 4
Configuration
GMT
Civilian Time Zones
Cities
-7
MST: Mountain Standard
Phoenix, Arizona
Denver, Colorado
-8
Pacific Standard
Seattle, Washington
Portland, Oregon
San Francisco, CA
-9
YST: Yukon Standard
-10
AHST: Alaska-Hawaii Standard
CAT: Central Alaska
HST: Hawaii Standard
Anchorage, Alaska
Honolulu, Hawaii
-11
NT: Nome
Nome, Alaska
-12
IDLW: International Date Line
West
TABLE 4-1: GREENWICH TIME ZONES (GMT)
Step 17. Check Table 4-2 for the time zone you are in.
Step 18. Press the right or left arrow until the correct time
zone appears. For example Pacific Standard Time is
-8.
Step 19. Press the Enter button to set the entry.
Step 20. Press the Exit button to return to the SETUP
MENU.
Step 21. Press the “-” arrow until the cursor is in front of
“Ethernet”. (See Fig. 4-25)
Ethernet Parameters
About the Ethernet Parameters
All Tension Controllers are designed with a selectable 10/
100 base T Ethernet connection which links your PC to an
embedded server in the instrument. You can connect to an
instrument via the Internet, Intranet, Extranet, or VPN (Virtual Private Network). Your computer must have an ethernet
card and cable with an RJ45 connector to connect to the
instrument. Once connected you can, monitor, map and configure any of the instruments from your web browser from
any location in your plant or enterprise. Help Dialogs are
also available to assist when performing setup or troubleshooting of an instrument. In addition the browser connects
you to the Hardy Web Site which connects the user to a full
range of customer service and support. File downloads from
your control room are a snap. No more hauling devices to
download files to an instrument. Should you want to download a file or monitor the instrument from your laptop at the
site, simply connect a short cable from the lap top to the
Ethernet connect at the rear panel of the instrument to transfer files, monitor or configure the instrument. No matter
where you are, if you are connected to our instrument you
can configure and troubleshoot the HI 3300 Tension Controller.
About IP Addresses
An IP address consists of 32 bits. It is composed of two
parts:
•
•
The Network Number
The Host Number
By convention, the address is expressed as four decimal
numbers separated by periods, such as “200.1.2.3” representing the decimal value of each of the four bytes. Valid
addresses thus range from 0.0.0.0 to 255.255.255.255, a total
of about 4.3 billion addresses.
It is recommended that you leave the Mask, Gate and DNS
settings alone. Contact your Network Administrator if you
need to set these parameters.
PARAMETER:ETHERNET
RANGE: 0.0.0.0 - 255.255.255.255
DEFAULT: NONE
0.00
Inst Set up
Cl ock Set up
> Et her net
Adj ust Cont r ast
>>
FIG. 4-25 SETUP MENU/ETHERNET
Step 22. Press the Enter button. The Ethernet Menu appears
with the cursor in front of the IP Address. (See Fig.
4-26)
0.00
Et her net
DHCP 156.123.258.35
> IP:
156.123.258.35
Mask: 255.255.255.0
FIG. 4-26 ETHERNET MENU/IP ADDRESS WITH
DEFAULT IP ADDRESS
Step 23. Press the Clear button to clear the address.
Step 24. Use the alphanumeric key pad to enter the new
address. Remember there must be a period between
each part of the address. (e.g. 186.245.263.12)
HI-3300 Tension Controller
Service Manual
Step 25. This is the only parameter you need to change. If
you need to change the other parameters, contact
your Network Administrator for assistance.
Step 26. Press the Enter button to set the entry.
Step 27. Press the “-” arrow until the cursor is in front of
Adjust Contrast. (See Fig. 4-27)
Process Setup Procedures
Set up
Opt ions
> Pr ocess Set up
Inst Set up
Set LCD Contrast Parameter
About the Set LCD Contrast Parameter
The Set LCD Contrast Parameter is used to increase or
decrease the contrast on the display. Press the right arrow
button to increase the contrast. Press the left arrow to
decrease the contrast.
PARAMETER:ADJUST CONTRAST
RANGE: NONE
DEFAULT: NONE
Pr ocess Set up
Def ault ed I/ O?
> Set pnt In Use
Pr od 1
FIG. 4-27 INSTRUMENT SETUP/ADJUSTING
DISPLAY CONTRAST
If you don’t press the Enter button the Display
Contrast will return to the previous setting.
Step 3. Press the Exit button to return to the Setup Menu.
Step 4. Press the “+” or “-” button until the cursor is in
front of “Process Setup”. (See Fig. 4-28)
>>
Step 5. Press the Enter button. The Process Setup menu
appears with the cursor in front of “Setpnt in Use”.
(See Fig. 4-29)
0.00
NOTE:
0.00
FIG. 4-28 SETUP MENU/SELECTING PROCESS
SETUP
Inst Set up
Et her net
> Adj ust Cont r ast
Inst r ument ID:
Step 1. Press the left or right arrow button to increase or
decrease the contrast.
Step 2. Press the Enter button to set the adjustment.
32
0.00
NO
Pr od 1
FIG. 4-29 PROCESS SETUP DISPLAY
Setpoint in Use Parameter
About the Setpoint in Use Parameter
The Setpoint in Use Parameter allows the user to view and/or
select the Product that is currently being processed. There
are three selections, Prod 1, Prod 2, Prod 3. This parameter
also enables the user to setup three tension setpoints for three
different products in advance and select the setpoints at the
time of process.
•
NOTE:
For example, you can set up three setpoints for Polyethylene, Saran, and Polystyrene. Prod 1 (Polyethylene - 0.12 lb)
Prod 2 (Saran - 0.15 lb) and Prod 3 (Polystyrene-1.0 lb). As you process these webs
you simply select Prod 1, Prod 2, Prod 3
with the proper tension setpoints.
The tension setpoints are typical running tensions
yours may vary.
PARAMETER:SETPNT IN USE
RANGE: PROD 1, PROD 2, PROD 3
33
CHAPTER 4
Configuration
DEFAULT: PROD 1
Pr ocess Set up
Def ault ed I/ O?
> Set pnt In Use
Pr od 1
0.00
NO
Pr od 1
FIG. 4-30 INSTRUMENT SETUP MENU/SELECTING
A PRODUCT
Step 1. Press the left or right arrow buttons to select Prod 1,
Prod 2 or Prod 3.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Prod 1” (See Fig. 4-31)
Prod 1 Parameter
About the Prod 1 Parameter
This parameter menu allows the user to give the Process a
name and set the tension setpoint. The Name and tension setpoint of the Product is displayed on the Operational Display.
Prod 1 is also the default setpoint parameter if you do not
configure Prod 2 or Prod 3.
PARAMETER:PROD1
RANGE: NAME: 9 CHARACTERS, SETPOINT: 099999
DEFAULT: NONE
Pr ocess Set up
Set pnt In Use
> Pr od 1
Pr od 2
0.00
Pr od 1
->
FIG. 4-31 PROCESS SETUP MENU/SETTING PROD 1
PARAMETERS
Step 1. Press the Enter button. The Prod1 Menu appears.
(See Fig. 4-32)
Pr od1
> Set point
Pr odName
0.00
0.12 l b
Pol yet h
FIG. 4-32 PROD1 MENU/SETTING PRODUCT 1
NAME
Step 2. The cursor is now in front of “Setpoint”
Step 3. Use the alphanumeric key pad to enter the tension
setpoint you want for this product. We use 0.12 lb
which is a typical running tension for Polyethylene.
Yours may vary.
Step 4. Press the Enter button to set the entry.
Step 5. Use the alphanumeric key pad to type the Product
Name. In our example we used “Polyeth” for Polythylene. In order for the entire Product Name to
appear on the Operational Display try to use an
abbreviation of the product name.
Step 6. Press the Enter button to set the entry.
Step 7. Press the Exit button to return to the Instrument
Setup Menu.
Step 8. Press the “-” button until the cursor is in front of
“Prod 2” (See Fig. 4-32)
Prod 2 Parameter
About the Prod 2 Parameter
This parameter menu allows the user to give the Process a
name and set the tension setpoint. The Name and tension setpoint of the Product is displayed on the Operational Display.
PARAMETER:PROD2
RANGE: NAME: 9 CHARACTERS, SETPOINT: 099999
DEFAULT: NONE
Pr ocess Set up
Pr od 1
> Pr od 2
Pr od 3
0.00
->
FIG. 4-33 PROCESS SETUP MENU/SETTING PROD 2
PARAMETERS
HI-3300 Tension Controller
Service Manual
34
Step 1. Press the Enter button. The Prod1 Menu appears.
(See Fig. 4-34)
Pr od2
> Set point
Pr odName
0.00
0.15 l b
Sar an
Pr ocess Set up
Pr od 2
> Pr od 3
St ar t Level
0.00
->
25%
FIG. 4-35 INSTRUMENT SETUP MENU/SETTING
PROD 3 PARAMETERS
FIG. 4-34 PROD2 MENU/SETTING PRODUCT 2
NAME & SETPOINT
Step 2. The cursor is now in front of “Setpoint”
Step 3. Use the alphanumeric key pad to enter the tension
setpoint you want for this product. We used 0.15 lb
which is a typical running tension for Saran. Yours
may vary.
Step 4. Press the Enter button to set the entry.
Step 5. Use the alphanumeric key pad to type the Product
Name. In our example we used “Saran” (Polyvinylidene Chloride). In order for the Product Name
to appear on the Operational Display try to use an
abbreviation of the product name.
Step 6. Press the Enter button to set the entry.
Step 7. Press the Exit button to return to the Instrument
Setup Menu.
Step 8. Press the “-” button until the cursor is in front of
“Prod3” (See Fig. 4-35)
Prod 3 Parameter
About the Prod 3 Parameter
This parameter menu allows the user to give the Process a
name and set the tension setpoint. The Name and tension setpoint of the Product is displayed on the Operational Display.
PARAMETER:PROD3
RANGE: NAME: 9 CHARACTERS, SETPOINT: 099999
DEFAULT: NONE
Step 1. Press the Enter button. The Prod3 Menu appears.
(See Fig. 4-36)
Pr od3
> Set point
Pr odName
0.00
1.00 l b
Pol yst y
FIG. 4-36 PROD3 MENU/SETTING PRODUCT 3
NAME
Step 2. The cursor is now in front of “Setpoint”
Step 3. Use the alphanumeric key pad to enter the tension
setpoint you want for this product. We use 1.00 lb
which is a typical running tension for Polystyrene.
Yours may vary.
Step 4. Press the Enter button to set the entry.
Step 5. Use the alphanumeric key pad to type the Product
Name. In our example we used “Polysty” for Polystyrene. In order for the Product Name to appear on
the Operational Display try to use an abbreviation
of the product name.
Step 6. Press the Enter button to set the entry.
Step 7. Press the Exit button to return to the Instrument
Setup Menu.
Step 8. Press the “-” button until the cursor is in front of
“Start Level” (See Fig. 4-37)
Start Level Parameter
About Start Level Parameter
The Start Level Parameter setting applies a fixed percentage
output level when the controller is in Standby or when Starting. It is important that you set the Start Level to zero (0) for
Mid-process or Winding applications.
35
CHAPTER 4
Configuration
Start Multiple Parameter
PARAMETER:START LEVEL
RANGE: 0-100%
DEFAULT: 2%
Pr ocess Set up
Pr od 3
> St ar t Level
St ar t Time
About the Start Multiple Parameter
0.00
25%
0.00
FIG. 4-37 PROCESS SETUP MENU/START LEVEL
Step 1. Use the alphanumeric key pad to enter the Start
Level value for your applications.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Start Time” (See Fig. 4-38)
Start Time Parameter
The Start Level Multiplier allows for auto-adjusting start
levels in an application that has multiple start/stops. In an
unwind application, the output required at the start for a full
diameter roll is often much greater than the output required
when the roll is closer to its core diameter. By inputting a
Start Multiplier, each consecutive start will be based on the
output level of the last time the process was stopped. The
level of this next start output will be equal to [Start Multiplier] x [Output % at Last Stop]. Thus, if the output level was
50% at the last stopping point and the Start Multiplier is 0.5,
the output level at the next start will be 25%. The Autostart
routine is reset to the stored Start Level % upon receipt of the
Splice Input. Thus, in our example application, if the Start
Level % parameter is 80%, after a momentary receipt of the
Splice input, the output level at the subsequent Start will be
80%.
PARAMETER:START MULTIPLE
RANGE: 0.00-2.00
DEFAULT: 0.00
About The Start Time Parameter
The Start Time Parameter holds the Start Level output for the
length of time entered in the Start Time Parameter. The Start
Time should be set to time out immediately before the
machine reaches maximum speed. This allows the machine
to accelerate to full speed before the controller starts automatically controlling. It is important that you set the Start
Time to zero (0) for Mid-process or Rewinding applications.
PARAMETER:START TIME
RANGE: 0.00-100.0 SECONDS
DEFAULT: 1.0
Pr ocess Set up
St ar t Level
> St ar t Time
St ar t Mult ipl e
Pr ocess Set up
St ar t Time
> St ar t Mult ipl e
St op Level
0.00
0.35
0.00
2%
FIG. 4-39 PROCESS SETUP/SETTING START
MULTIPLE
0.00
25%
0.35
0.00
FIG. 4-38 PROCESS SETUP MENU/START TIME
Step 1. Use the alphanumeric key pad and enter the Start
Time you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Start Multiple” (See Fig. 4-39).
Step 1. Use the alphanumeric key pad to enter the Start
Multiple value for your applications.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Stop Level” (See Fig. 4-40)
Stop Level Parameter
About The Stop Level Parameter
WARNING: THIS PARAMETER IS NOT THE EMERGENCY STOP PARAMETER. STOP SHOULD NEVER BE
USED FOR EMERGENCY STOPS. TO DO SO MAY RESULT IN
PERSONAL INJURY AND/OR PROPERTY DAMAGE.
Stop Level increases the torque applied to a decelerating roll
to stop it. Make sure when setting the Stop Level you set it
high enough to stop a roll but avoid creating a slack web. It
HI-3300 Tension Controller
Service Manual
is important that you set the Stop Level to zero (0) for Midprocess or Rewinding applications.
Step 3. Press the “-” button until the cursor is in front of
“Splice Level” (See Fig. 4-42)
Splice Level Parameter
PARAMETER:STOP LEVEL
RANGE: 0 - 100%
DEFAULT: 100%
Pr ocess Set up
St ar t Mult ipl e
> St op Level
St op Time
36
About Splice The Level Parameter
0.00
0.00
10%
5.00
Splice Level Parameter is the output signal level you want
the controller to maintain when a flying transfer or flying
splice is made in the web. The Controller receives a Splice
input signal via Input #2 telling the controller to shift to the
Splice Level. The Splice Level is set as a percentage of the
full output signal.
PARAMETER:SPLICE LEVEL
RANGE: 0-100%
DEFAULT: 0%
FIG. 4-40 PROCESS SETUP MENU/STOP LEVEL
Step 1. Use the alphanumeric key pad and enter the Stop
Level you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Stop Time” (See Fig. 4-41)
Stop Time
Pr ocess Set up
St op Time
> Spl ice Level
Hol d Level
0.00
5.00
3%
0%
About The Stop Time Parameter
The Stop Time Parameter depends on the amount of time it
takes for a machine to decelerate from a run state to a complete stop. After the Stop Time times out the controller automatically resets to the Start Level ready to resume the
process. To restart the controller you need to press the Start
button. It is important that you set the Stop Time to zero (0)
for Mid-process or Rewinding applications.
Step 1. Use the alphanumeric key pad and enter the Splice
Level you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Hold Level” (See Fig. 4-43)
Hold Level Parameter
PARAMETER:STOP TIME
RANGE: 0.00 - 100.0 SECONDS
DEFAULT: 5.0
Pr ocess Set up
St op Level
> St op Time
Spl ice Level
FIG. 4-42 INSTRUMENT SETUP MENU/SETTING
SPLICE LEVEL
About The Hold Level Parameter
0.00
10%
5.00
0%
FIG. 4-41 INSTRUMENT SETUP MENU/STOP TIME
Step 1. Use the alphanumeric key pad and enter the Stop
Time you need for this application.
Step 2. Press the Enter button to set the entry.
The Hold Level is the output signal level (percentage) you
want the controller to maintain when the system is in a hold
state.
PARAMETER:HOLD LEVEL
RANGE: 0-100%
DEFAULT: 0%
37
CHAPTER 4
Configuration
Low Alarm Delay Parameter
Pr ocess Set up
Spl ice Level
> Hol d Level
Low Al r m
0.00
3%
5%
0.0 l b
FIG. 4-43 INSTRUMENT SETUP MENU/SETTING
THE HOLD LEVEL
Step 1. Use the alphanumeric key pad and enter the Splice
Level you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Low Alarm” (See Fig. 4-44)
Low Alarm Parameter
About The Low Alarm Parameter
The Low Alarm Level is set at the lowest tension level you
can allow in your system to prevent damage to the web (such
as bagging, slack tension, breaking, etc.). When the system
reaches the Low Alarm Level the controller activates an output relay which can be connected to any device including an
audio or visual alarm.
PARAMETER:LOW ALARM
RANGE: -99999.0 - +99999.0
DEFAULT: 0
About The Low Alarm Delay Parameter
Often the system will reach a low level for short periods of
time. These time periods are so short that they don’t have a
negative material effect. The Low Alarm Delay is a time
delay that occurs before the Low Level Alarm output signal
is triggered, to avoid false Low Alarm Level conditions. To
set this parameter most often you need to rely on the history
you have with your system and web material.
PARAMETER:LOW ALARM DELAY
RANGE: 0.00 - 100.0 SECONDS
DEFAULT: 0.00
Pr ocess Set up
Low Al ar mLevel
> Low Al ar mDel ay
High Al ar m
0.00
0.5
5
20.0
FIG. 4-45 INSTRUMENT SETUP MENU/SETTING
LOW ALARM DELAY
Step 1. Use the alphanumeric key pad and enter the Low
Alarm Delay you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“High Alarm” (See Fig. 4-46)
High Alarm Parameter
Pr ocess Set up
Hol d Level
> Low Al ar m
Low Al ar mDel ay
0.00
5%
0.5 l b
0
FIG. 4-44 INSTRUMENT SETUP MENU/SETTING
LOW ALARM
Step 1. Use the alphanumeric key pad and enter the Low
Alarm Level you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Low Alarm Delay” (See Fig. 4-45)
About The High Alarm Parameter
The High Alarm is set at the highest tension level you can
allow in your system to prevent damage to the web (such as
bagging, slack tension, breaking, etc.). When the system
reaches the High Alarm the controller activates an output
relay which can be connected to any device including an
audio or visual alarm.
PARAMETER:HIGH ALARM
RANGE: -99999.0 - +99999.0
DEFAULT: 100.0
HI-3300 Tension Controller
Service Manual
38
Misalignment Tolerance Parameter
0.00
Pr ocess Set up
Low Al ar mDel ay
> High Al ar m
High Al ar mDel ay
5
20.0
2
FIG. 4-46 INSTRUMENT SETUP MENU/SETTING
HIGH ALARM
Step 1. Use the alphanumeric key pad and enter the High
Alarm Level you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“High Alarm Delay” (See Fig. 4-47)
High Alarm Delay Parameter
About The High Alarm Delay Parameter
Often the system will reach a high level for short periods of
time. These time periods are so short that they don’t have a
negative material effect. The High Alarm Delay is a time
delay that occurs before the High Level Alarm output signal
is triggered, to avoid false High Alarm Level conditions. To
set this parameter most often you need to rely on the history
you have with your system and web material.
PARAMETER:HIGH ALARM DELAY
RANGE: 0.00 - 100.0 SECONDS
DEFAULT: 0
0.00
Pr ocess Set up
High Al ar m
> High Al ar mDel ay
Pr opor t ional
20.0
2
30
FIG. 4-47 INSTRUMENT SETUP MENU/SETTING
HIGH ALARM DELAY
Step 1. Use the alphanumeric key pad and enter the High
Alarm Level you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“AlignTol” (See Fig. 4-48)
About Misalignment Tolerance
There are occasions where the transducer is connected to a
roll that is misaligned. The misalignment will make the controller read the pounds force (lbf) or pounds per linear inch
(Pli) incorrectly. Misalignment is caused by one side of a
roller moving forward or backward. If that is the case you
need to provide for the misalignment by entering in a tolerance (offset) for the misalignment to achieve an accurate tension reading. Misalignment Tolerance Parameter only
applies to 2 channel load cell systems.
PARAMETER:MISALIGNMENT TOLERANCE
RANGE: 0.0001 - 99999.0
DEFAULT: 1000.0
Step 1. Use the alphanumeric key pad and enter the Misalignment Tolerance you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Proportional” (See Fig. 4-49)
Proportional Parameter
NOTE:
The PID values can also be modified by pushing
the Gain/1 button.
About Proportional Parameter
The Proportional Parameter more appropriately called
“gain”, which is a multiplier that increases the error signal to
a value which is useful as a correction signal. The correction
signal is proportional to the original error and either
increases or decreases the tension to correct for the error signal from the load sensor.
PARAMETER:PROPORTIONAL
RANGE: 0 - 1000.0
DEFAULT: 10
0.00
Pr ocess Set up
High Al ar mDel ay
> Pr opor t ional
Int egr al
2
30
2
FIG. 4-48 INSTRUMENT SETUP MENU/SETTING
THE PROPORTIONAL VALUE
39
CHAPTER 4
Configuration
Step 1. Use the alphanumeric key pad and enter the Proportional value you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Integral” (See Fig. 4-50)
Integral Parameter
About The Integral Parameter
The Integral parameter more appropriately called “stability”
and provides a correction to the PID algorithm that smooths
or slows the Controller output so that tensioning mechanisms
don’t overreact, which adds stability to the system.
0.00
2
1
0.000
FIG. 4-50 PROCESS SETUP MENU/SETTING THE
DERIVATIVE VALUE
Step 1. Use the alphanumeric key pad and enter the Derivative value you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“AutoGain” (See Fig. 4-52)
PARAMETER:INTEGRAL
RANGE: 0 - 1000.0
DEFAULT: 2.0
Pr ocess Set up
Pr opor t ional
> Int egr al
Der ivat ive
Pr ocess Set up
Int egr al
> Der ivat ive
Aut oGain
0.00
30
2
1
FIG. 4-49 PROCESS SETUP MENU/SETTING THE
INTEGRAL VALUE
Step 1. Use the alphanumeric key pad and enter the Integral
value you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Derivative” (See Fig. 4-51)
AutoGain Parameter
About the AutoGain Parameter
The response required in controlling winding or unwinding
of a large roll (whether web or strand) is different than that
for a small diameter roll. Due to the large inertia level of a
large roll, the controller will need to react more aggressively
than when controlling a small roll. This equates to braking
an 18 wheeler versus a pickup. The multiplier functions to
make the control more aggressive for a large diameter roll by
increasing the Gain parameter for an increased output level.
Keep in mind that the output level is directly proportional to
the Roll Diameter as expressed in the following formula:
•
New Gain = Gain + (Current Output% x
Multiplier)
•
If the stored Gain is 20 and the Gain multiplier is 0.5 and the Output Level is 80%,
the Adjusted Gain Level, therefore is:
For example:
Derivative Parameter
About the Derivative Parameter
The Derivative parameter more appropriately called
“response” looks for the rate at which the error rate changes.
The derivative accounts for and adjusts the output signal that
corresponds to the rate of change. D is different from P in
that D responds early to a rate of change and P only reacts to
the absolute error signal at any given point in time.
PARAMETER:DERIVATIVE
RANGE: 0.0 - 1000.0
DEFAULT: 0.0
Adjusted Gain Level = 20 + (80 x 0.5)
Adjusted Gain Level = 20 + 40
Adjusted Gain Level = 60
•
In our example the Gain (rate of change of
control) is three times greater at an 80%
output level than at a 0% output level.
PARAMETER:AUTOGAIN
RANGE: 0.000 - 2.000
DEFAULT: 0.000
HI-3300 Tension Controller
Service Manual
40
Web Width
Pr ocess Set up
Der ivat ive
> Aut oGain
Taper Per cent
0.00
1
0.000
0
FIG. 4-51 PROCESS SETUP/SETTING AUTOGAIN
Step 1. Use the alphanumeric key pad and enter the AutoGain value you want for this application. To shut
off the AutoGain enter zero (0).
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Taper Percent” (See Fig. 4-52)
Taper Percent Parameter (Rewind Only)
About Web Width
If you selected pounds per linear inch as you units of measure you will also have to enter the actual web width dimension parameter. If you selected pounds force or Newtons you
don’t have to enter a web width value.
PARAMETER:WEB WIDTH
RANGE: 0.01 - 99999.0
DEFAULT: 0
Pr ocess Set up
Taper Per cent
> Web Widt h
Def ault ed I/ O?
0.00
10
25
NO
About The Taper Percent Parameter
FIG. 4-53 PROCESS SETUP/SETTING WEB WIDTH
The Taper Percent is determined by the percentage difference between the diameter of a full roll, or the diameter of
the roll when starting a process and the diameter of the core
when the process is complete.
PARAMETER:TAPER PERCENT
RANGE: 0-100%
DEFAULT: 0%
Step 1. Use the alphanumeric key pad and enter the Web
Width value you need for this application. For
strand tension applications enter zero (0).
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Defaulted I/O?” (See Fig. 4-54)
Defaulted I/O? Parameter
Pr ocess Set up
Aut oGain
> Taper Per cent
Web Widt h
0.00
0.000
10
25
FIG. 4-52 PROCESS SETUP MENU/SETTING THE
TAPER PERCENT
Step 1. Use the alphanumeric key pad and enter the Taper
Percent value you want for this application.
Step 2. Press the Enter button to set the entry.
Step 3. Press the “-” button until the cursor is in front of
“Web Width” (See Fig. 4-53)
About the Defaulted I/O? Parameter
The Tension Controller has a default designation for the 5
inputs and 4 output relays. If you want to keep the defaults
select YES. If you want to reassign the inputs and outputs
select NO.
41
CHAPTER 4
Configuration
The Default I/Os are:
I/O
DEFAULT
Relay 1
Start/Stop Signal
Relay 2
Low Level Alarm
Relay 3
High Level Alarm
Relay 4
(Spare)
Input 1
Remote Start/Stop
Input 2
Splicing Input
Input 3
Hold Input
Input 4
Spare
Input 5
(Spare)
FIG. 4-55 TENSION CONTROLLER HOME PAGE/
SELECTING CONFIGURATION
TABLE 5: DEFAULT I/O
Instrument Setup
PARAMETER:DEFAULTED I/O?
RANGE: YES/NO
DEFAULT: YES
Pr ocess Set up
Web Widt h
> Def ault ed I/ O?
Set point In Use
0.00
25
NO
Pr od1
FIG. 4-54 PROCESS SETUP/SELECTING
DEFAULTED I/P?
Tension Controller Configuration From the
Web Page
NOTE:
For complete explanations of each of the parameters, please go to the Configuration From the
Front Panel Section of this manual or click on the
Help button at the top of the page.
Step 1. From the Tension Controller Home Page, click on
Configuration. (See Fig. 4-55) The Configuration
Page appears. (See fig. 4-56)
FIG. 4-56 CONFIGURATION PAGE/SELECTING
INSTRUMENT SETUP
Step 2. Click on Instrument Setup. The ConfigurationInstrument Setup Page appears. (See Fig. 4-57)
HI 3330 Tension Controller
Service Manual
42
FIG. 4-59 INSTRUMENT SETUP MENU/SELECTING
DECIMAL POINT
FIG. 4-57 CONFIGURATION - INSTRUMENT SETUP
TENSION CONTROLLER PAGE
Step 3. To create or change a Instrument ID, double click in
the text field next to Instrument ID.
Step 4. Type in the Instrument ID. There are only 19 characters so be brief but descriptive. We entered HIWeb (Hardy Instruments Web Tension)
Step 5. To create or change an Operator ID, double click in
the text field next to Operator ID.
Step 6. Type in the User ID. Remember you only have
three characters so be brief. We used “JD” (John
Doe).
Step 7. To select the Unit of measure, click on the Unit of
Measure pull down menu. (See Fig. 4-58)
Step 10. Click on the decimal place you want for this application. In our example we selected “2”.
Step 11. To set the Number of Averages, double click in the
text field next to Number of Averages.
Step 12. Type in the number of averages for the device connected to this instrument. In our example we
selected 10.
Step 13. To select the WAVERSAVER® setting, click on the
WAVERSAVER pull down menu. (See Fig. 4-60)
FIG. 4-60 INSTRUMENT SETUP PAGE/SELECTING
WAVERSAVER SETTING
FIG. 4-58 CONFIGURATION - INSTRUMENT SETUP
TENSION CONTROLLER PAGE/SELECTING UNIT
OF MEASURE
Step 8. Click on the Unit of measure you want for this
channel. In our example we selected “pli” (pounds
per linear inch).
Step 9. To set the Decimal point, click on the Decimal
Point pull down menu. (See Fig. 4-59)
Step 14. Click on the WAVERSAVER level you want for
this application. Remember the higher the frequency the more dampening occurs, however it can
slow the instrument somewhat. If instrument
response is critical try selecting a lower frequency
until the vibration dampening is suitable for your
application. In our example we selected “3.50 Hz”.
Step 15. To Set the Total Load Sensor Maximum Tension,
double click in the text field next to Maximum Tension.
Step 16. Type in the Total Capacity of the load sensors
attached to this instrument. In our example we
selected 1,000 lbs.
43
CHAPTER 4
Configuration
Step 17. To select the Load Sensor Type, click on the Sensor
Type pull down menu. (See Fig. 4-61)
FIG. 4-61 INSTRUMENT SETUP PAGE/SELECTING
SENSOR TYPE
Step 18. Click on the load sensor type that is connected to
the Tension Controller. In our example we selected
0-120mV/V. This is the sensitivity of the load sensor(s) that are connected to the controller.
Step 19. To turn ON the wireless infrared system, click in
the radio button next to YES.
Step 20. To turn OFF the wireless infrared system, click in
the radio button next to NO.
Step 21. Instrument Setup page appears. (See Fig. 4-62)
NOTE:
Set Date/Clock Parameters
Step 1. Double click in the Minute-mm field. Enter the current minutes. (See Fig. 4-100)
Step 2. Double click in the Hour-hh field. Enter the current
minutes.
Step 3. Double click in the Day-dd field. Enter the current
day.
Step 4. Double click in the Month-mm field. Enter the current month.
Step 5. Double click in the Year-yyyy field. Enter the Current year.
Step 6. Double click in the Timezone field. Check Table 42 Civilian Time Zones, GMT on page 40 for the
time zone you are in. Enter the correct Greenwich
Mean Time value. Don’t forget to enter the positive
(+) or negative (-) sign. For our example we used
the default time zone which is -8 or PST (Pacific
Standard Time).
Step 7. Click on the Save Parameters button to save the setting.
The Instrument Setup is complete.
Process Setup
You can click on the Save Parameters button anytime during this process. If you only change one
parameter, click on the Save Parameters button.
You must click on the Save Parameters button in
order for the changes to occur.
Step 22. Click on the right arrow at the bottom of the page.
The Clock Setup Page appears. (See Fig. 4-62)
FIG. 4-63 CONFIGURATION/SELECTING PROCESS
SETUP
Step 1. Click on Process Setup. The Configuration-Process
Setup Page appears. (See Fig. 4-64)
FIG. 4-62 INSTRUMENT SETUP/CLOCK SETUP
HI 3330 Tension Controller
Service Manual
•
•
44
Click in the setpoint field to the right.
Type in the Setpoint you want for this
product. In our example we entered 0.12
lb.
Step 5. To setup Prod2:
•
•
•
•
Double click in the text field next to
Prod2.
Type in the Product name. In our example
we selected Saran.
Click in the setpoint field to the right.
Type in the Setpoint you want for this
product. In our example we entered 0.15
lb.
Step 6. To setup Prod3:
•
•
•
•
FIG. 4-64 PROCESS SETUP/IMAGE 1
Step 2. To select the product currently being used (Product
1, Product 2, Product 3) click on the Setpoint in Use
pull down menu. (See Fig. 4-65)
FIG. 4-65 SELECTING PRODUCT CURRENTLY IN
USE
Step 3. Click on the Product currently in use. By selecting
the product, if you have preset the tension setpoints
for Prod1, Prod2, Prod3, it will automatically set
the tension setpoint for selected product. In our
example we selected Prod1 Polyethylene with a setpoint of 0.12 lb.
Step 4. To setup Prod1:
•
•
Double click in the text field next to
Prod1.
Type in the Product name. In our example
we selected Polyethylene (Polyeth).
Double click in the text field next to
Prod3.
Type in the Product name. In our example
we selected Polystyrene (Polystyr).
Click in the setpoint field to the right.
Type in the Setpoint you want for this
product. In our example we entered 1.00
lb.
Step 7. To set the Start Level, click in the text field next to
Start Level.
Step 8. Type in the Start Level you want for the product
you selected. In our example we set 25%.
Step 9. To set the Start Time, click in the text field next to
Start Time.
Step 10. Type in the Start Time you want for the product you
selected. In our example we set 5.00 seconds.
Step 11. To set the Auto Start Multiplier, double click in the
text field next to Auto Start Multiplier.
Step 12. Type in the multiplier you want to use for this application. In our example we used 3.
Step 13. To set the Stop Level, click in the text field next to
Stop Level.
Step 14. Type in the Stop Level you want for the product
you selected. In our example we set 10%.
Step 15. To set the Stop Time, click in the text field next to
Stop Time.
Step 16. Type in the Stop Time you want for the product you
selected. In our example we set 5 seconds.
Step 17. To set the Splice Level, click in the text field next to
Splice Level.
Step 18. Type in the Splice Level you want for the product
you selected. In our example we set 0%.
Step 19. To set the Hold Level, click in the text field next to
Hold Level.
Step 20. Type in the Hold Level you want for the product
you selected. In our example we set 0%.
45
CHAPTER 4
Configuration
Step 21. To set the Low Alarm Level, click in the text field
next to Low Alarm Level.
Step 22. Type in the Low Alarm Level you want for the
product you selected. In our example we set 0.11lb.
Step 23. To set the Low Alarm Delay, click in the text field
next to Low Alarm Delay.
Step 24. Type in the Low Alarm Delay you want for the
product you selected. In our example we set 0 seconds.
Step 25. To set the High Alarm Level, click in the text field
next to High Alarm Level.
Step 26. Type in the High Alarm Level you want for the
product you selected. In our example we set 100.00
lbs.
Step 27. To set the High Alarm Delay, click in the text field
next to High Alarm Delay.
Step 28. Type in the High Alarm Delay you want for the
product you selected. In our example we set 0 seconds.
Step 29. To set the Misalignment Tolerance, click in the text
field
Step 30. To set the Proportional, click in the text field next to
Proportional.
Step 31. Type in the Proportional value you want for the
product you selected. In our example we set 30.
Step 32. To set the Integral, click in the text field next to
Integral.
Step 33. Type in the Integral value you want for the product
you selected. In our example we set 2.
Step 34. To set the Derivative, click in the text field next to
Derivative.
Step 35. Type in the Derivative value you want for the product you selected. In our example we set 1.
Step 36. To set the Auto Gain Adjust, click in the text field
next to Auto Gain Adjust.
Step 37. Type in the Auto Gain Adjust value you want for
the product you selected. In our example we set
0.00.
Step 38. Scroll down to the bottom section of the Second
Page Instrument Parameters list. (See Fig. 4-66)
Step 40. Type in the Auto Gain Adjustment you want to use
for this application. In our example we are not
using the Auto Gain Adjustment so we typed in
0.000.
Step 41. To set the Taper Percent, click in the text field next
to Taper Percent.
Step 42. Type in the Taper Percent value you want for the
product you selected. In our example we set 50.
Step 43. To set the Web Width parameter, click in the text
field next to Web Width.
Step 44. Enter the width of the web for this application. In
our example we entered 50 inches.
Step 45. To select whether you want to use the Default
inputs, click in the radio button next to ON or the
radio button next to OFF.
•
•
ON = Yes I want to use the default inputs.
OFF = No I don’t want to use the defaults
inputs, I will set them up on my own.
Step 46. To save the parameters at this point you can click
on the Save Parameters button. This can be done at
anytime in the process.
The Process Setup is Complete
Analog Option Card Configuration
The Analog Output Option card can be configured from the
Front Panel and the Web Page. You need to configure the
instrument for each Analog Output Option Card Slot (0 or 1)
and for each channel (0 or 1) on each Slot. Make sure when
configuring an Analog Output Option Card Slot that the configuration mode selection matches the Option Card wiring
selection. For example if you have wired your output card
for voltage configure it for voltage, DO NOT configure it for
current.
PARAMETER:ANALOG CARD SLOT 0 OR 1
RANGE: 0-5 V, 0-10 V, 0-20 MILLIAMPS, 4-20
MILLIAMPS
DEFAULT: 0-10 V
Analog Option Card Configuration from the Front
Panel
Step 1. From the Operating Mode Display Press the Setup/
3 button. The Setup Display appears. (See Fig. 467)
FIG. 4-66 BOTTOM SECTION OF PROCESS SETUP
Step 39. To set the Auto Gain Adjust, click in the text field
next to Auto Gain Adjust.
HI 3330 Tension Controller
Service Manual
Setup
Secur ity
> Options
Pr ocess Setup
0.00
46
Step 8. Press the - button until the cursor is in front of Chan
1 Mode. (See Fig. 4-70)
Step 9. Press the right or left button to select the mode that
matches the Analog Card Output wiring for Channel 1. In our example we selected 0-10 V for Channel 1. (See Fig. 4-70)
->
0.00
FIG. 4-67 SETUP DISPLAY/SELECTING OPTIONS
Step 2.
Press the + or - buttons until the cursor is in front of
Options.
Step 3. Press the Enter button. The Options Display
appears. (See Fig. 4-68)
Anal og Car d Sl ot 0
Chan 0 Mode
> Chan 1Mode
4-20 mA
0- 10 V
FIG. 4-70 ANALOG CARD SLOT 0/CHAN 1 MODE
SELECTION
Options
0.00
> Anal og Car d Sl ot 0
->
DeviceNet
FIG. 4-68 OPTIONS DISPLAY/SELECTING ANALOG
CARD SLOT 0
Step 4. Press the + or - button until the cursor is in front of
“Analog Card Slot 0” or Analog Card Slot 1”
Step 5. Press the Enter button. the Analog Card Slot 0 or 1
display appeares. (See Fig. 4-69) In our example
we selected Analog Card Slot 0.
0.00
Anal og Car d Sl ot 0
> Chan 0 Mode
Chan 1Mode
4-20 mA
0- 10 V
Step 10. Press the Enter button to save the configuration.
Step 11. If you have an Analog Card installed in Slot 1 the
Options Display will list Analog Card Slot 1.
Repeat Steps 1-9 above to configure the Analog
Card Slot 1.
Step 12. If you have an Analog Card installed in Slot 0 and
Slot 1 the Options display will list both the Analog
Card Slot 0 and Analog Card Slot 1. (See Fig. 471)
Options
0.00
> Anal og Car d Sl ot 0
->
Anal og Car d Sl ot 1
DeviceNet
FIG. 4-71 2 ANALOG CARDS INSTALLED
Step 13. Press the Exit button to return to the Operating
Mode display.
Analog Output Option Card Configuration from the
Web Page
FIG. 4-69 ANALOG CARD SLOT 0/SELECTING
MODE
Step 6. Press the Enter button to save the configuration.
Step 7. Press the right or left buttons to select the mode that
matches the Analog Card Output wiring. In our
example we selected 4-20 mA for Channel 0.
Step 1. From the Tension Control. Home Page click on
Configuration. (See Fig. 4-72) The Configuration
page appears. (See Fig. 4-73)
47
CHAPTER 4
Configuration
NOTE:
If only one Analog Option Board is installed, only
one card will appear in the Options page.
Step 3. Click on the Analog Option Board you want to configure. The Analog Option Board Configuration
page appears. (See Fig. 4-75) In our example we
selected Analog Board (Slot 0).
FIG. 4-72 TENSION CONTROL HOME PAGE/
SELECING CONFIGURATION
FIG. 4-75 CONFIGURATION/SLOT 0/SETTING
CHAN 0 MODE
FIG. 4-73 CONFIGURATION PAGE/SELECTING
OPTIONS
Step 2. Click on Options. The Options page appears. (See
Fig. 4-74)
Step 4. Click on the Chan0 Mode pull down list.
Step 5. Click on the Mode that matches the installed wiring. For example if you wired the Analog Board
for current select a current mode. If you wired the
Analog Board for voltage select a voltage mode. In
our example we selected 0-20 mA.
Step 6. Click on the Chan 1 Mode pull down list.
Step 7. Click on the Mode that matches the installed wiring
for Channel 1. Our example, 0-10V.
FIG. 4-74 OPTIONS PAGE/SELECING ANALOG
BOARD CONFIGURATION (SLOT 0)
FIG. 4-76 CONFIGURATION SLOT 0/SETING
MODES
HI 3330 Tension Controller
Service Manual
48
Step 8. Click on the Set Modes button to save the settings.
Step 9. To Configure the Analog Board in Slot 1, from the
Options Page click on Analog Board Configuration
(Slot 1). See Fig. 4-77)
FIG. 4-79 ANALOG CONFIG (SLOT 1) MODE
CONFIGURATION CHAN 0 AND CHAN 1
FIG. 4-77 OPTIONS/SELECTION ANALOG BOARD
CONFIGURATION (SLOT 1)
Step 11. From the Configuration page click on Mapping.
(See Fig. 4-80) The Mapping page appears. (See
Fig. 4-81)
Step 10. Repeat Steps 4-8. (See Fig. 4-78 & 4-79)
FIG. 4-78 CONFIGURATION SLOT 1/SELECTING
CHANNEL MODES
FIG. 4-80 CONFIGURATION PAGE/SLECTING
MAPPING
49
CHAPTER 4
Configuration
Step 16. To select a Source click on the Local pull down list.
(See Fig. 4-85)
FIG. 4-81 MAPPING PAGE/SELECTIN
DESTINATION
Step 12. Click on the Output pull down list.
Step 13. Click on Analog Out. A pull down list with all the
installed Analog Option Boards. (See Fig. 4-82)
FIG. 4-82 MAPPING DESTINATION/SELECTING
ANALOG OUT SLOT 0 CHAN 0 (HSO5)
FIG. 4-85 SELECT SOURCE/SELECTING CONTROL
DATA
Step 17. Click on the Local Source you want for your application. In our example we selected Control Data.
The Control Data options pull down list appears to
the right. (See Fig. 4-86)
FIG. 4-86 CONTROL DATA/OPTIONS PULL DOWN
MENU
Step 14. Click on the Analog Output you want to map. In
our example we selected Analog Out Slot 0, Channel 0 (HSO5)
Step 18. Click on either Tension or Output%. In our example we selected Tension.
FIG. 4-83 SELECTING ANALOG OUT SLOT 0
(HSO5)
FIG. 4-87 SELECTING THE SOURCE
Step 15. Click on the Select button. The Analog Out Slot 0
Chan 0 symbol (HSO5) appears to the left of the
equals sign in the mapping text field. (See Fig. 484)
FIG. 4-84 DESTINATION ENTERED
Step 19. Click on the Select button. The Source Symbol
(HF10) appears to the right of the equals sign in the
Mapping text field.
HI 3330 Tension Controller
Service Manual
FIG. 4-88 MAPPING CONTROL DATA TO ANALOG
OUT SLOT 0
Step 20. Click on the Map button. The mapping assignment
statement appears in the Mapping list. (See Fig. 489) Control Data is now mapped to the selected
Analog Output table.
FIG. 4-89 MAPPING LIST/CONTROL DATA
MAPPED TO ANALOG OUTPUT
Step 21. To see a more detailed listing of the mappings click
on “Click here for an expanded map”. The
expanded mapping dialog box appears with all the
mappings listed including the latest analog output
mapping. (See Fig. 4-90)
FIG. 4-90 EXPANDED MAPPING DIALOG BOX
Step 22. This completes the Analog Output Board configuration for Slot 0. To configure the Analog Output
Board for Slot 1 repeat all the steps above.
50
51
CHAPTER 5
Calibration
CHAPTER 5: CALIBRATION
About Chapter 5
Chapter 5 pertains to the calibration procedures for the
HI 3300 Tension Controller. Alternatives to any procedures
implied or explicitly contained in this chapter are not recommended. In order for the Tension Controller to work properly, it must be calibrated prior to operation. Be sure to
follow all the procedures completely to insure that the
weights read by the Tension Controller are accurate. It is
very important that the user and service personnel be familiar with the procedures contained in this chapter, before
installing or operating the HI 3300 Tension Controller.
COULD CAUSE PROPERTY DAMAGE AND/OR PERSONNEL
INJURY.
About Traditional Calibration
Traditional Calibration is the method of calibration that uses
test weights. We recommend that the test weights total 25%
to 100% of the Maximum Tension for your application.
Make sure you know the exact weight. See Fig. 5-1 for the
proper mechanical configuration for a Hard Cal.
Mechanical Calibration Setup for Traditional Calibration
Getting Started
Process Wrap Angles
The HI 3300 Tension Controller can be calibrated three
ways. The first is the Hardy C2® Second Generation calibration which requires no test weights. Hardy C2® Calibration
is one of the Core Technologies. The second calibration technique is called traditional calibration which requires certified
test weights. It is important to note that the procedures contained in this section either explicitly stated or implied
should be followed to guarantee the performance of the
instrument. The third is Soft Calibration which does not
require any test weights. Alternatives to the procedures listed
here are not recommended.
Before you can calibrate the instrument you first need to
check to see if the system is ready to be calibrated.
Binding
Step 1. Due a visual check to see if the load sensors have
been installed so that nothing is binding the load
cell or other parts of the web tension system. Make
sure that nothing is draped over the rolls or sheaves,
such as a cable, electrical cord or other objects. You
want to be sure that you are able to zero or tare the
instrument to compensate for the tare weight (deadload).
Step 2. Make sure that all cables are properly connected
between the load sensors, junction boxes, drive and
the Tension Controller.
Step 3. That the cord and weight are installed correctly and
that the known weight is suspended freely with
nothing touching it. (See Fig. 5-1)
Traditional Calibration From the Front
Panel
T
Idler Roll
Idler Roll
Transducer Roll
W
Known Weight
FIG. 5-1 CALIBRATION MECHANICAL SETUP
Step 1. You can press the Calibration/7 button to get
directly to the Calibration Menu.
Step 2. An alternative is to Press the Setup/3 button. The
Setup Menu appears. (See Fig. 5-2)
Set up
Inst Set up
> Cal ibr at ion
Secur it y
0.00
->
FIG. 5-2 SETUP MENU/SELECTING CALIBRATION
WARNING: THE START BUTTON IS ACTIVE IN ANY MENU.
MAKE SURE THAT ALL PERSONNEL ARE CLEAR FROM ANY
AND ALL MACHINERY WHEN CALIBRATING THE TENSION
CONTROLLER. ACCIDENTALLY STARTING THE SYSTEM
WHEN IN THE CONFIGURATION OR CALIBRATION MENUS
Step 3. Press the “-” button until the cursor is in front of
“Calibration”. (See Fig. 5-2)
HI-3300 Tension Controller
Service Manual
Step 4. Press the Enter button. The CALIBRATION Menu
appears with the cursor next to “Snsr Type”. (See
Fig. 5-3)
Cal ibr at ion
Sof t Cal
> Snsr Type
Capacit y
0.00
0- 3mV/ V
200 l bs
FIG. 5-3 CALIBRATION/SELECTING SENSOR TYPE
Step 5. Press the Right or Left arrow buttons to select the
sensor type. The sensor types are categorized by the
sensitivity of the Load Cell type which is posted on
the load cell or with the load cell documentation.
Step 6. Press the Enter Button to set the entry.
Step 7. Press the “-” button until the cursor is in front of
“Capacity”. (See Fig. 5-4)
Set up
Snsr Type
> Capacit y
C2 Cal
0.00
0- 3mV/ V
200 l bs
Cal ibr at ion
Capacit y
> C2 Cal
Tr ad Cal
0.00
200 l bs
->
FIG. 5-5 CALIBRATION/C2 CAL
Step 11. Press the “-” button until the cursor is in front of
“Trad Cal”. (See Fig. 5-6)
Cal ibr at ion
C2 Cal
> Tr ad Cal
Sof t Cal
0.00
->
FIG. 5-6 CALIBRATION/SELECTING
TRADITIONAL CALIBRATION
Step 12. Press the Enter button. The “Trad Cal” menu
appears, with the cursor pointing to “Ref Wgt.”
(See Fig. 5-7)
FIG. 5-4 TRADITIONAL CALIBRATION/ZERO
VALUE
Step 8. Use the alphanumeric key pad and enter the total
capacity of all the load sensors used for your application. For example if you are using two load sensors that are rated at 100 lbs each, you enter 200 lbs.
(100 x 2 = Maximum Capacity)
Step 9. Press the Enter button to set the entry.
Step 10. Press the Enter Button to set the entry. Press the “-”
button until the cursor is in front of “C2Cal”. See
Fig. 5-5)
52
Tr ad Cal
Do Cal Span?
> Ref Wgt
Do Cal Low?
0.00
0.00 l b
FIG. 5-7 CALIBRATION ENTERING REFERENCE
WEIGHT
Step 13. Traditional Calibration requires a zero point and the
physical placement of test weights on the scale. To
Set the Reference Weight:
•
•
Remove all weight from the end of the
cable or cord. (See Fig. 5-8) The Reference weight should almost always be 0.00.
Use the alphanumeric key pad and enter
0.00.
53
CHAPTER 5
Calibration
•
Press the Enter button to set the entry.
Step 14. Press the “-” button until the cursor is in front of
“Do Cal Low?”. (See Fig. 5-9)
Tr ad Cal
Do Cal Low?
> Span Wgt
Do Cal Span?
Process Wrap Angles
T
0.00
10.00 l b
Idler Roll
FIG. 5-10 TRADITIONAL CALIBRATION/
ENTERING SPAN WEIGHT
Idler Roll
•
Transducer Roll
•
No Weight
FIG. 5-8 CALIBRATION SETUP WITH NO WEIGHT
Tr ad Cal
Ref Wgt
> Do Cal Low?
Span Wgt
Place the certified test weight on the end
of the cable or cord. (See Fig. 5-11)
Use the alphanumeric key pad to enter the
value of the test weight. (If a 10 lb.weight
is used, enter 10).
Process Wrap Angle
0.00
T
0.00 l b
->
10.00 l b
Idler Roll
Idler Roll
Transducer Roll
FIG. 5-9 DO TRADITIONAL CALIBRATION/ZERO
Step 15. Press the Enter button to do the Cal Low (Zero)
Calibration.
•
•
If “Function OK” appears the Zero Calibration is complete.
If an “ERR” appears go to Chapter 7,
Troubleshooting for more information.
W
Known Weight
FIG. 5-11 SPAN CALIBRATION/SPAN WEIGHT
Step 17. Press the Down arrow button until the cursor is in
front of the Do Span Cal?. (See Fig. 5-12)
Step 16. Press the Down arrow button until the cursor is in
front of Span Wgt. (See Fig. 5-10) To Set the Span
Value:
Tr ad Cal
Span Wgt
> Do Cal Span?
Ref Wgt
0.00
10.00 l b
->
0.00
FIG. 5-12 TRADITIONAL CALIBRATION/SPAN
CALIBRATION
Step 18. Press the Enter button to do the Span Calibration.
HI-3300 Tension Controller
Service Manual
•
•
If “Function OK” appears the Span Calibration is complete
If an “ERR” number appears go to Chapter
7, Troubleshooting for more information.
Step 3. Use the alphanumeric key pad and enter 0.00 if the
current setting is not 0.00.
Step 4. Press the Enter button to set the entry.
Step 5. Press on the “-” button until the cursor is in front of
“Capacity”. (See Fig. 5-15)
Step 19. End of Traditional Calibration.
Step 20. Remove the rope and weight from the rollers or
sheaves.
Soft Calibration from the Front Panel
About Soft Calibration
Soft Calibration does not require you disassemble your web
zone or process to do another hard calibration. By entering a
few calibration parameters you used during Traditional Calibration you can do a Soft Calibration which resets the Tension Controller to the original Traditional Calibration. This
eliminates the necessity of using the Test Weights over and
over again. Simply enter the calibration values and do the
Soft Cal and you are back in calibration.
Step 1. In the Calibration Menu press the “-” button until
the cursor is in front of Soft Cal. (See Fig. 5-13)
Cal ibr at ion
Tr ad Cal
> Sof t Cal
Snsr Type
FIG. 5-13 CALIBRATION MENU/SELECTING SOFT
CALIBRATION
Step 2. Press the Enter button. The Soft Cal Sub-Menu
appears with the cursor in front of “Ref Wgt”. (See
Fig. 5-14)
SOFT CAL
Do Sof t Cal ?
> Ref Wgt
Capacit y
SOFT CAL
Ref Wgt
> Capacit y
Sensit ivit y
0.00
0.00
200 l b
FIG. 5-14 SOFT CALIBRATION MENU/ENTERING
REFERENCE WEIGHT
0.00
0.00
200 l b
.268
FIG. 5-15 SOFT CALIBRATION MENU/ENTERING
LOAD SENSOR CAPACITY
Step 6. Use the alphanumeric key pad and enter the combined Maximum capacity of the load cells on your
system.
Step 7. Press the Enter button to set the entry.
Step 8. Press on the “-” button until the cursor is in front of
“Sensitivity”. (See Fig. 5-16)
0.00
->
0- 3mV/ V
54
SOFT CAL
Capacit y
> Sensit ivit y
Wr ap Angl e 1
0.00
200 l b
.268
30.0
FIG. 5-16 SOFT CALIBRATION MENU/ENTERING
SENSITIVITY OF THE LOAD CELLS
Step 9. Use the alphanumeric key pad and enter the Sensitivity of the load cells on your system.
Step 10. If you do not know the sensitivity of your load cell
do the following:
•
•
With no tension on the roller, record the
millivolt reading (X1) using either a digital
multimeter or the Diagnostics function
located in the Test Menu. (See Chapter 7,
Diagnostics for instructions)
Apply a known test weight to the roller or
sheave. (See Fig. 5-17)
55
CHAPTER 5
Calibration
SOFT CAL
Sensit ivit y
> Wr ap Angl e 1
Wr ap Angl e 2
Load Cell
0.00
.268
30.0
30.0
FIG. 5-18 SOFT CALIBRATION MENU/ENTERING
WRAP ANGLE 1
10 lbs
Step 13. Use the alphanumeric key pad and enter Wrap
Angle #1 for your application.
Step 14. Press the Enter button to set the entry.
Step 15. Press on the “-” button until the cursor is in front of
Wrap Angle 2”. (See Fig. 5-19)
SOFT CAL
Wr ap Angl e 1
> Wr ap Angl e 2
For ce Fact or
FIG. 5-17 TEST WEIGHT CONFIGURATION
•
•
Record the millivolt reading (X2).
Formula:
Sensitivity = X2 - X1/ Excitation Voltage
Capacity = Reference Weight
Example:
Reference Weight = 10 lbs
mV when no wrap applied = 50mV = X2
10 lbs applied = 100mV = X1
Sensitivity = (X2-X1)/Excitation
Sensitivity = (100mV-50mV)/5V
Sensitivity = (50mV)/5V
Sensitivity = 10mV/V
•
0.00
30.0
30.0
0.1736
FIG. 5-19 SOFT CALIBRATION MENU/ENTERING
WRAP ANGLE 2
Step 16. Use the alphanumeric key pad and enter Wrap
Angle #2 for your application.
Step 17. Press the Enter button to set the entry.
Step 18. Press on the “-” button until the cursor is in front of
“Force Factor”. (See Fig. 5-20)
Use the above for the sensitivity value.
SOFT CAL
Wr ap Angl e 2
> For ce Fact or
Do Sof t Cal ?
Step 11. Press the Enter button to set the entry.
Step 12. Press on the “-” button until the cursor is in front of
Wrap Angle 1”. (See Fig. 5-18)
0.00
30.0
0.1736
FIG. 5-20 SOFT CALIBRATION/ENTERING FORCE
FACTOR
NOTE:
If you do not know Wrap Angle 1 or Wrap Angle 2
enter the Force Factor value.
HI-3300 Tension Controller
Service Manual
Step 19. Use the alphanumeric key pad and enter the Force
Factor for your application.
Step 20. Press the Enter button to set the entry.
Step 21. Press on the “-” button until the cursor is in front of
“Do Soft Cal?”. (See Fig. 5-21)
SOFT CAL
For ce Fact or
> Do Sof t Cal ?
Ref Wgt
0.00
0.1736
Step 22. Press the Enter button to do the Span Calibration.
•
C2 Calibration From the Front Panel
Step 2.
Press the Setup/3 button. The Setup Menu
appears.
Press the “-” button until the cursor is in front of
Calibration. (See Fig. 5-22)
Set up
Inst Set up
> Cal ibr at ion
Secur it y
0- 3mV/ V
200 l bs
FIG. 5-23 CALIBRATION/SELECTING SENSOR
TYPE
Step 4. Press the Right or Left arrow buttons to select the
sensor type. The sensor types are categorized by the
sensitivity of the Load Cell type which is posted on
the load cell or with the load cell documentation.
Step 5. Press the Enter Button to set the entry. Press the “-”
button until the cursor is in front of “Capacity”.
(See Fig. 5-24).
If “Cal Completed OK” appears the Soft
Calibration is complete.
If an “ERR number” appears go to Chapter
7, Troubleshooting for more information.
Step 23. End of Soft Calibration.
Step 24. Press the Exit button to return to the Operating
Menu.
Step 1.
0.00
0.00
FIG. 5-21 SOFT CALIBRATION/DOING THE SOFT
CALIBRATION
•
Cal ibr at ion
Sof t Cal
> Snsr Type
Capacit y
56
0.00
->
FIG. 5-22 CONFIGURATION MENU/SELECTING
SETUP
Step 3. Press the Enter button. The Calibration Menu
appears with the cursor next to Snsr Type. (See Fig.
5-23)
Set up
Snsr Type
> Capacit y
C2 Cal
0.00
0- 3mV/ V
200 l bs
FIG. 5-24 TRADITIONAL CALIBRATION/ZERO
VALUE
Step 6. Use the alphanumeric key pad and enter the total
capacity of all the load sensors used for your application. For example if you are using two load sensors that are rated at 100 lbs each, you enter 200 lbs.
(100 x 2 = Maximum Capacity)
Step 7. Press the Enter button to set the entry. Press the “-”
button until the cursor is in front of “C2 Cal”. See
Fig. 5-25)
Cal ibr at ion
Capacit y
> C2 Cal
Tr ad Cal
0.00
200 l bs
->
FIG. 5-25 CALIBRATION/
57
CHAPTER 5
Calibration
Step 8. Press the Enter button. The C2 CAL Sub-menu
appears with the cursor in front of “Load Sensor
Num”. (See Fig. 5-26)
0.00
C2 CAL
Do C2 Cal ?
> Load Sensor Num
Ref wgt
Step 15. Press the “-” button to move the cursor in front of
“Wrap Angle 2”.
Step 16. Use the alphanumeric key pad and enter Wrap
Angle 2.
Step 17. Press the Enter button to set the entry.
Step 18. Press the “-” button to move the cursor in front of
“Force Factor”. (See Fig. 5-29)
NOTE:
2
0.00 l b
FIG. 5-26 C2 CALIBRATION SUB-MENU
Step 9.
Step 10.
The Load Sensor number is a read only field. It
tells you how many load sensors are connected to
the instrument.
Press the down arrow button to move the cursor
in front of the “Ref Wgt”. (See Fig. 5-27)
C2 CAL
Wr ap Angl e 2
> For ce Fact or
Do C2 Cal ?
0.00
C2 CAL
Load Sensor Num
> Ref wgt
Wr ap Angl e 1
2
0.00 l b
60.0
FIG. 5-27 ENTERING THE REFERENCE POINT
Step 11.
Step 12.
The Reference Weight should be 0.00 if it is not
use the alphanumeric keypad and enter 0.00 lb.
Press the “-” arrow button to move the cursor in
front of “Wrap Angle 1”. (See Fig. 5-28)
C2 CAL
Ref wgt
> Wr ap Angl e 1
Wr ap Angl e 2
0.00
60.0
0.998
FIG. 5-29 C2 CAL/ENTERING FORCE FACTOR
Step 19. Use the alphanumeric key pad and enter the Force
Factor for your application.
Step 20. Press the down arrow button to move the cursor in
front of “Do C2 Calibration”. (See Fig. 5-30)
Step 21. Wait 15 seconds for the scale to settle.
Step 22. Press the Enter button to complete the Calibration.
0.00
0.00
C2 CAL
For ce Fact or
> Do C2 Cal ?
Load Sensor Num
0.00 l b
60.0
60.0
0.998
2
FIG. 5-30 C2 CALIBRATION
FIG. 5-28 C2 CAL/ENTERING WRAP ANGLE 1
Step 13. Use the alphanumeric key pad and enter Wrap
Angle 1.
Step 14. Press the Enter button to set the entry.
If you did not enter values for Wrap Angle 1 or
Wrap Angle 2 you enter the Force Factor if you
know what it is. If you entered values for Wrap
Angle 1 and Wrap Angle 2 the force factor (Force
Factor = (cos Wrap Angle 1) + (cos Wrap Angle
2) is calculated for you and stored in non-volatile
memory. If you don’t know either wrap angles or
the force factor, the force factor is calculated
when you do a traditional calibration and saved
in non-volatile memory.
Step 23.
A “Cal Completed OK” momentarily appears on
the screen indicating the calibration was successful
HI-3300 Tension Controller
Service Manual
•
•
Step 24.
Step 25.
58
A message that says “Function Error” means
that the calibration was not successful.
Check Chapter 7 - Troubleshooting of this
manual for corrective action.
Another message may occur which is: Security Violation. This means that the User does
not have the security level required to do a
calibration.
Press the Exit button until you return to the
Standby display.
C2 calibration is complete.
C2 Calibration From the Web Page
Step 1.
On the Tension Controller Home Page click on
Configuration. (See Fig. 5-31) The Configuration page appears. (See Fig. 5-32)
FIG. 5-32 CONFIGURATION PAGE
Step 2.
Click on Calibration. The Calibration Sub-menu
appears. (See Figs. 5-33)
FIG. 5-31 CONFIGURATION MENU/SELECTING
SETUP
FIG. 5-33 METHOD 1: C2 CALIBRATION
Step 3.
Step 4.
Step 5.
NOTE:
The Load Sensor number is a read only field. It
tells you how many load sensors are connected to
the instrument. If this number does not reflect the
actual number of load sensors go to Chapter 7 Troubleshooting.
Double click in the Weight text field to enter the
Reference Weight or click in the Reference
Weight text field. (See Fig. 5-33) Type in the reference weight which should in almost all cases be
0.00.
Double click in the Wrap Angle 1 text field.
If you do not know the wrap angle and know the
Force Factor, enter the Force Factor instead.
(See Fig. 5-34)
59
CHAPTER 5
Calibration
FIG. 5-34 SETTING FORCE FACTOR
Step 6.
Step 7.
Step 8.
Step 9.
Step 10.
Enter the Wrap Angle 1 value.
Double click in the Wrap Angle 2 text field.
Enter the Wrap Angle 2 value.
Click on the Do C2 Calibration button.
A page appears telling you that the C2 Calibration
completed OK. (See Fig. 5-35)
FIG. 5-36 CONFIGURATION MENU/SELECTING
SETUP
FIG. 5-35 CAL COMPLETED OK
Step 11. Click on “Back” to return to the Calibration page.
Step 12. Click on “Home” to return to the Tension Controller Home page.
Step 13. C2 calibration is complete.
Traditional Calibration From the Web Page
Step 1.
On the Tension Controller Home Page Click on
Configuration. (See Fig. 5-36) The Configuration page appears. (See Fig. 5-37)
FIG. 5-37 CONFIGURATION PAGE/SELECTING
CALIBRATION
Step 2.
Click on Calibration. The Calibration Sub-menu
appears. (See Figs. 5-38 & 39)
HI-3300 Tension Controller
Service Manual
Step 7.
60
A page telling you that the Cal Completed OK
appears. (See Fig. 5-40)
FIG. 5-40 CAL LOW COMPLETED OK
FIG. 5-38 CALIBRATION SUB-MENU
Step 8. Click on “Back” to return to the Calibration page.
Step 9. Place a certified test weight on the rope or cord, this
is your span weight.
Step 10. To enter the Span Weight double click in the Span
Weight field. (See Fig. 5-39)
Step 11. Use your keyboard to type in the new Span Weight
value. In our example we entered 10.00 lbs. (See
Fig. 5-39)
Step 12. Click in the Sensitivity text field. Use your keyboard and enter the rated sensitivity of the Load
Sensor.
Step 13. Click in the Capacity text field. (See Fig. 5-39)
Type in the combined Maximum capacity of the
load cells on your system.
Step 14. Click on the Do Cal High button.
Step 15. A page telling you that the Do Cal High Calibration
completed OK. (See Fig. 5-41)
FIG. 5-41 CAL COMPLETED OK
Step 16. Click on “Home” to return to the Tension Controller Home page.
Step 17. Traditional calibration is complete.
FIG. 5-39 METHOD 2: CALIBRATION - ZERO CAL
Step 3.
Step 4.
Step 5.
Step 6.
If the Method 2: Calibration - Zero Cal reference
weight is any value other than 0.0 go to Step 4
otherwise go to Step 10.
To clear the entry, press the left mouse button and
hold while moving the cursor over the current
Reference Weight which highlights the weight
value.
Use your keyboard to type in 0.00 (See Fig. 5-39)
Click on the Do Cal Low button.
Soft Calibration from the Web Page
Step 1. From the Home Page Click on Configuration. (See
Fig. 5-42) The Configuration Page appears. (See
Fig. 5-43)
61
CHAPTER 5
Calibration
FIG. 5-44 CALIBRATION PAGE/SOFT
CALIBRATION
FIG. 5-42 HOME PAGE/SELECTING
CONFIGURATION
Step 3. Click in the Sensitivity text field.
Step 4. Enter the sensitivity of the load sensors you are
using for this application.
Step 5. Click in the Wrap Angle 1 text field.
Step 6. Enter Wrap Angle 1.
Step 7. Click in the Wrap Angle 2 text field.
Step 8. Enter Wrap Angle 2.
Step 9. Click in the Capacity text field.
Step 10. Enter the Total Load Cell capacity.
Step 11. Click in the Ref Wgt text field.
Step 12. Enter the Reference Weight, 0.00.
Step 13. Click on the Do Soft Cal.
Step 14. If the Soft Calibration was successful, a message
page appears with “Cal completed OK”. (See Fig.
5-45)
Step 15. Soft Calibration Complete.
FIG. 5-45 SOFT CAL SUCCESSFUL
FIG. 5-43 CONFIGURATION MENU/SELECTING
CALIBRATION
Step 2. Click on Calibration. The Calibration page appears.
Scroll down to Method 3: Calibration - Soft Cal
(See Fig. 44)
CAUTION:
BINDING ON A ROLL OR LOAD SENSOR DOES
NOT ALLOW THE LOAD SENSOR FREE MOVEMENT AND MAY
PREVENT THE INSTRUMENT FROM RETURNING TO THE
ORIGINAL ZERO REFERENCE POINT.
Step 16.
Check to see that the load cell is mounted so that
100% of the load vertically passes through the
load cell. (See Fig. 5-46)
HI-3300 Tension Controller
Service Manual
FIG. 5-46 PROPERLY INSTALLED LOAD CELL
WITH NO BINDING
Electrical Check Procedures
Step 1.
Check to see that there is power to the controller.
a.
b.
Step 2.
If there is power to the controller The front
panel display should be lit.
If the display appears with a value the unit is
ready for calibration.
Check to see that all communication and power
cables are securely fastened to the connectors on
the rear panel.
62
63
CHAPTER 6
Mapping
CHAPTER 6: MAPPING
About Mapping
Mapping is a simple process where you connect input (called
a “Source”) to an output (called a “Destination”). In addition
you can map any of the parameters to the outputs and Inputs.
The benefit of Mapping is that it requires no programming
whatsoever. Simply select a Destination and a Source and
your in business.
Mapping to a Network Output Table
In English we might say: “Connect High Tension Alarm to
(Control Link Float Out)”.
•
•
Control Link Float Out is the Destination.
High Tension Alarm is the Source
In Assignment Statement form this mapping would look like
this:
•
•
Destination = Source or
Control Link Float Out = High Tension
Alarm
FIG. 6-2 CONFIGURATION PAGE/SELECTING
MAPPING SETUP
Selecting a Destination
From the Web Browser lets go through the process:
Step 1. From the Tension Control Home Page click on
Configuration. (See Fig. 6-1) The Configuration
Page appears. (See Fig. 6-2)
FIG. 6-3 MAPPING PAGE
Step 3. Under Destination, click on the Network Pull Down
Menu. (See Fig. 6-4)
FIG. 6-1 HOME PAGE/SELECTING
CONFIGURATION
Step 2. Click on Mapping. (See Fig. 6-2) The Configuration Mapping Page appears. All the pull down
menus include all the Destinations and Sources for
the HI 3300. (See Fig. 6-3)
HI 3300 Tension Controller
Service Manual
64
Step 8. Click on Status. (See Fig. 6-7) Status appears in the
Local Pull Down Menu with an additional pull
down menu to the right and a Select button.
FIG. 6-4 SELECTING DESTINATION/NETWORK/
CONTROL LINK FLOAT OUT (EFO)
Step 4. Click on “Control Link Float Out (EFO)”. Control
Link Float Out (EFO) appears in the text field and a
Word selection appears. (See Fig. 6-5)
FIG. 6-7 SELECT SOURCES/SELECTING STATUS
Step 9. Click on pull down menu.
Step 10. Click on High Tension Alarm (HI1.3) (See Fig. 6-8)
FIG. 6-8 STATUS SOURCE PULL DOWN MENU/
SELECTING HIGH TENSION ALARM (HI1.3)
FIG. 6-5 DESTINATION/SELECTING CONTROL
LINK FLOAT OUT (EFO) WORD 2
Step 11. High Tension Alarm appears in the pull down
menu. (See Fig. 6-9)
Step 5. Click in the Word text field and type in the word
you want. We selected Word 2.
Step 6. Click on the Select button. The Destination is
entered in the Map field. (See Fig. 6-6)
FIG. 6-6 “EFO2=” IS ENTERED IN THE MAP TEXTILES
Selecting a Source
Step 7. Under Source, click on the Local Pull Down Menu.
FIG. 6-9 SELECT SOURCES/SELECTING HIGH
TENSION ALARM (HI1.3)
Step 12. Click on the Select button. The source appears to
the right of the equal (=) sign. (See Fig. 6-10)
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CHAPTER 6
Mapping
15.
16.
17.
18.
•
Start Time (HFO18)
Stop time (HFO19)
Taper Adjustment (HFO20)
Command Interface (CMD0)
Outputs: Include the following:
19. Relays
FIG. 6-10 MAPPING HIGH TENSION ALARM TO
CONTROL LINK FLOAT OUT
a.
b.
c.
d.
e.
Step 13. Click on the Map button. The new map appears in
the list of mappings. (See Fig. 6-11)
1.
Analog Out
a.
b.
FIG. 6-11 HIGH TENSION ALARM IS MAPPED TO
CONTROL LINK FLOAT OUT
•
Step 14. To see the expanded map click on the blue underlined here. The Map dialog box appears with the
mappings extended. (See Fig. 6-12)
Analog Out Slot 0 Chan 0 (HSO5)
Analog Out Slot 0 Chan 1 (HSO6)
Scratchpad which are empty registers you
can do whatever you want with. Scratchpad includes the following:
1.
2.
3.
4.
5.
6.
7.
8.
•
All Relays (HSO0)
Relay 1 (HO0.0)
Relay 2 (HO0.1)
Relay 3 (HO0.2)
Relay 4 (HO0.3)
Float Variable 0 (HFO0)
Float Variable 1 (HFO1)
Float Variable 2 (HFO2)
Float Variable 3 (HFO3)
Float Variable 4 (HFO4)
Float Variable 5 (HFO5)
Float Variable 6 (HFO6)
Float Variable 7 (HFO7)
E-Mail includes E-Mail Outputs such as:
FIG. 6-12 EXTENDED MAP DISPLAY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Step 15. Now let’s take a moment to take a look at the Mapping page.
Destinations:
•
Control: Include the following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Start/Stop (HO4.0)
Splice/Splice Stop (HO4.1)
Hold/Hold Stop (HO4.2)
Start (HO4.3)
Stop (HO4.4)
Setpoint 1 (HFO9)
Setpoint 2 (HFO10)
Setpoint 3 (HFO11)
PID P (HFO12)
PID I (HFO13)
PID D (HFO14)
Start Level (HFO15)
Stop Level (HFO16)
Splice Level (HFO17)
•
Send email #0 (HO3.0)
Send email #1 (HO3.1)
Send email #2 (HO3.2)
Send email #3 (HO3.3)
Send email #4 (HO3.4)
Send email #5 (HO3.5)
Send email #6 (HO3.6)
Send email #7 (HO3.7)
Send email #8 (HO3.8)
Send email #9 (HO3.9)
Network: Includes the following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
DeviceNet Boolean Out (DO)
DeviceNet Short Out (DSO)
DeviceNet Int Out (DIO)
DeviceNet Float Out (DFO)
Control Link Boolean Out (EO)
Control Link Short Out (ESO)
Control Link Int Out (EIO)
Control Link Float Out (EFO)
Comm. Network Boolean Out (CO)
HI 3300 Tension Controller
Service Manual
10.
11.
12.
13.
14.
15.
16.
b.
Comm. Network Short Out (CSO)
Comm. Network Int Out (CIO)
Comm. Network Float Out (CFO)
Modbus Boolean Out (MO)
Modbus Short Out (MSO)
Modbus Int Out (MIO)
Modbus Float Out (MFO)
c.
d.
•
NOTE:
Communication (Comm.) is used when a ControlNet or Profibus Option Card is installed.
Sources:
•
1.
Control Data
a.
b.
2.
Relay State
a.
b.
c.
d.
e.
3.
Status Word (HSI1)
Operating Mode (HSI3)
A/D Conversion Error (HI1.0)
A/D Failure (HI1.1)
Low Tension Alarm (HI1.2)
High Tension Alarm (HI1.3)
Control Loss (HI1.4)
Clock Failure (HI1.5)
Misalignment Alarm (HI1.6)
NVR Failure (HI1.8)
Infrared Failure (HI1.9)
Status=Started (HI2.0)
Discrete Input (HSI0)
Discrete Input 0 (HSI0.0)
Discrete Input 1 (HSI0.1)
Discrete Input 2 (HSI0.2)
Discrete Input 3 (HSI0.3)
Discrete Input 4 (HSI0.4)
DeviceNet Status
a.
DeviceNet status, node 0-15
(HSI40)
•
Float Variable 0 (HFO0)
Float Variable 1 (HFO1)
Float Variable 2 (HFO2)
Float Variable 3 (HFO3)
Float Variable 4 (HFO4)
Float Variable 5 (HFO5)
Float Variable 6 (HFO6)
Float Variable 7 (HFO7)
Networks include the following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
All Relays (HSO0)
Relay 1 (HO0.0)
Relay 2 (HO0.1)
Relay 3 (HO0.2)
Relay 4 (HO0.3)
Discrete Inputs
a.
b.
c.
d.
e.
f.
5.
•
Status
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
4.
Tension (HFI0)
Output% (HFI1)
DeviceNet status, nodes 16-31
(HSI41)
DeviceNet status, nodes 32-47
(HSI42)
DeviceNet status, nodes 48-63
(HSI43)
Scratchpad which are empty registers you
can do whatever you want with. Scratchpad
includes the following:
1.
2.
3.
4.
5.
6.
7.
8.
Local Inputs include the following:
66
DeviceNet Boolean In (DI)
DeviceNet Short In (DSI)
DeviceNet Int In (DII)
DeviceNet Float In (DFI)
Comm. Network Boolean In (CI)
Comm. Network Short In (CSI)
Comm. Network Int In (CII)
Comm. Network Float In (CFI)
Modbus Boolean In (MI)
Modbus Short In (MSI)
Modbus Int In (MII)
Modbus Float In (MFI)
Control Link enables you to select the Node
Address and the type of value and word
number and includes the following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Node 0 (0)
Node 1 (1)
Node 2 (2)
Node 3 (3)
Node 4 (4)
Node 5 (5)
Node 6 (6)
Node 7 (7)
Node 8 (8)
Node 9 (9)
Node 10 (U)
Node 11 (V)
Node 12 (W)
Node 13 (X)
Node 14 (Y)
Node 15 (Z)
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CHAPTER 6
Mapping
NOTE:
For a complete description of nodes please go to
the HI 3000 Manual, Installation Section, ControlNet and Profibus Installation, subchapters.
Example #2 Mapping an Alarm
Commonly an alarm is mapped (assigned) to an e-Mail Output. Lets say we want to map a source such as the Low Tension Alarm to an e-Mail destination. Our Assignment
Statement is:
•
•
NOTE:
Destination = Source
Sending e-mail #0 = Low Tension Alarm
(HI1.2)
To set up E-mail go to the HI 3000 Manual, EMail Chapter.
Step 1. On the Mapping Setup Page click on the Email pull
down menu. (See Fig. 6-13)
FIG. 6-15 SELECTING LOW TENSION ALARM
ALARM
Step 8. Click on the Select button. The Low Tension Alarm
Source (HI1.2) appears on the right side of the
equals sign. (See Fig. 6-16)
FIG. 6-16 MAPPING/SELECTING LOW TENSION
ALARM AS THE SOURCE
Step 9. Click on the Map button.
Step 10. The Mapping Assignment Statement is complete.
(See Fig. 6-17) Send email #0(HO3.0) = Low Tension Alarm (HI1.2) (See Fig. 6-17)
FIG. 6-13 DESTINATION/SEND EMAIL #0 (HO3.0)
Step 2. Click on Send email #0 (HO3.0). A Select button
appears. (See Fig. 6-13)
Step 3. Click on the Select button. (See Fig. 6-13) The
Send email #0 appears in the mapping text box.
(See Fig. 6-14)
FIG. 6-17 LOW TENSION ALARM (HI1.2) IS
MAPPED TO SEND EMAIL #0 (HO3.0)
Another Mapping Example
FIG. 6-14 SEND EMAIL #0 (HO3.0) SELECTED AS A
DESTINATION
Step 4.
Step 5.
Step 6.
Step 7.
Click on the Local pull down menu.
Click on Status.
Scroll down until you see Low Tension Alarm.
Click on Low Tension Alarm. A Select button
appears to the right. (See Fig. 6-15)
Step 1. Map Tension (HFI0) to DeviceNet Float Out (DFO)
Step 2. Under Destination, click on the Network pull down
menu.
Step 3. Click on DeviceNet Float Out.
Step 4. Network DeviceNet Float Out appears with Word
selection to the right.
Step 5. Accept the default word “0”.
Step 6. Click on Select. The Destination appears in the
Mapping text field.
Step 7. Under Sources, click on the Local pull down menu.
Step 8. Click on Control Data. A pull down menu appears
to the right with Tension (HFI0) in the field.
Step 9. Click on the Select button to select the Tension
source.
Step 10. In the Map field you will see DFO0=HFI0.
Step 11. Click on the Map button.
HI 3300 Tension Controller
Service Manual
68
Step 12. You have now mapped the Tension value located in
the input table to the DeviceNet Float out located in
the output table. The Tension value is now available
for the DeviceNet scanner when it polls the output
table of the HI 3300. The Tension reading can be
sent to a PLC or other Master device in your
DeviceNet Network.
Mapping Multiple Sources
Now that you know how to map (assign) a single source to a
destination we can move onto multiple sources mapping.
Lets say you want the High Tension Alarm and Low Tension
Alarm mapped to a single relay output. We want to select
relay output 2 in this case.
Our Assignment Statement looks like this:
Destination = Source 1 + Source 2
FIG. 6-19 OUTPUT RELAYS/SELECTING RELAY 2
(HO0.1)
Step 3. Click on Relay 2 (HO0.1).
Step 4. Click on the Select button. Relay 2 (HO0.1) appears
in the Map field. (See Fig. 6-20)
Relay 2 = High Tension Alarm + Low Tension
Alarm
In this Assignment Statement we use a boolean operator. “+”
which in boolean Assignment Statements means “or”. This
means that one or the other alarms will activate output relay
2 depending on the tension reading.
Here’s the process:
Step 1. From the Mapping Page/Destination click on the
Outputs pull down menu and select Relays. (See
Fig. 6-18)
FIG. 6-18 OUTPUTS/SELECTING RELAYS
Step 2. Relays appears in the Output Menu with the Output
Relays pull down menu to the right. (See Fig. 6-19)
FIG. 6-20 OUTPUT RELAY 2 (HO0.1) APPEARS IN
THE MAP FIELD
Step 5. Under Select Sources, Click on the Local pull down
menu and select Status. (See Fig. 6-21) A Status
pull down menu appears to the right of the Status.
FIG. 6-21 SELECT SOURCES/LOCAL/SELECTING
STATUS
Step 6. Click on the Status Pull Down menu.
Step 7. Click on High Tension Alarm (HI1.3). (See Fig. 622)
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CHAPTER 6
Mapping
Step 14. Click on the Select button to the right of the Local
fields to add the “Low Tension Alarm (HI1.2)” to
the Assignment Statement. (See Fig. 6-20)
FIG. 6-22 SELECT SOURCES/LOCAL/SELECTING
HIGH TENSION ALARM (HI1.3)
Step 8. Click on the Select button. “HI1.3” appears to the
right of the equals (=) sign. (See Fig. 6-23)
FIG. 6-23 HIGH TENSION ALARM (HI1.3) SOURCE
ADDED
Step 9. To add another Source to the Assignment Statement
and make it a Boolean “or” Statement, click on the
“or” button above the Assignment Statement. (See
Fig. 6-24) A “+” plus sign appears to the right of
the High Tension Alarm (HI1.3). (See Fig. 6-25)
FIG. 6-26 LOW TENSION ALARM (HI1.2) ADDED AS
THE SECOND SOURCE TO THE ASSIGNMENT
STATEMENT
Step 15. Click on the Map button to save the mapping. The
multiple source map appears in the Current Mappings listing. (See Fig. 6-21)
FIG. 6-27 MULTIPLE SOURCE MAP
Step 16. You have now mapped multiple sources to a single
destination.
Simple Network Mapping
Mapping to a Network Output
If you want to send data to a PLC from the HI 3300 you need
to map the data to a network output. Here is the process:
Step 1. From the Mapping Page, Destination Section, click
on the Network pull down menu and select
DeviceNet Boolean Out. (See Fig. 6-28)
FIG. 6-24 HIGH TENSION ALARM (HI1.3) ADDED
TO THE MAP FIELD
FIG. 6-25 SETPOINTS/EXPANSION CHANNEL
ALERT ALARMS
Step 10.
Step 11.
Step 12.
Step 13.
Click on the Local pull down menu. (See Fig. 6-22)
Click on Status.
Click on the Status Pull Down menu.
Click on Low Tension Alarm.
HI 3300 Tension Controller
Service Manual
70
FIG. 6-31 SOURCE/CONTROL DATA/OUTPUT%
(HFI1)
Step 7. Click on the pull down menu and click on Output%
(HFI1).
Step 8. Click on the Select button to enter Output% as the
source of the Assignment Statement.
Step 9. The Output% (HFI1) appears on the right side of
the Assignment Statement. (See Fig. 6-32)
FIG. 6-28 DESTINATION/NETWORK/SELECTING
DEVICENET BOOLEAN OUT
FIG. 6-29 NETWORK/SELECTING DEVICENET
BOOLEAN OUT (DO), WORD 2, BIT 2
Step 2. Double click in the Word text box and type in the
number 2.
Step 3. Double click in the Bit text box and type in the
number 2.
Step 4. Click on the Select button to set the Destination.
The “DeviceNet Boolean Out” address appears on
the left side of the Assignment Statement. (See Fig.
6-30)
FIG. 6-32 ASSIGNMENT STATEMENT MAPPING
OUTPUT% TO DEVICENET BOOLEAN OUT,
WORD 2, BIT 2 (DO2.2)
Step 10. Click on the Map button.
Step 11. Output% is now available to the PLC via the
DeviceNet Scanner. (See Fig. 6-33)
FIG. 6-33 SIMPLE NETWORK MAP/OUTPUT%
MAPPED TO DEVICENET BOOLEAN OUT (DO2.2)
Mapping a Network Input to a Local Output
FIG. 6-30 DEVICENET BOOLEAN OUT (DO2.2) SET
AS DESTINATION
NOTE:
The DeviceNet Boolean Out address DO2.2
means the following. DO = DeviceNet Out. 2.2 =
Word 2, Bit 2.
Step 5. In the Select Source Section of the Mapping Page
click on the Local Pull Down Menu.
Step 6. Click on Control Data. A second pull down menu
appears. (See Fig. 6-31)
If you want a Controller to send instructions to an HI 3300
you will have to map the local Output to a network input.
Here is the process:
NOTE:
Keep in mind that the network input on the HI
3300 will now be the source for the PLC output.
This enables the Controller to send instructions
to the network input table of the HI 3300 and in
turn to the HI 3300 output table.
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CHAPTER 6
Mapping
Step 1. From the Mapping Page, click on the Network pull
down menu and select Analog Out, Slot 1, Chan 0
(See Fig. 6-27)
FIG. 6-37 NETWORK/SELECTING DEVICENET
FLOAT IN (DFI)
FIG. 6-34 OUTPUTS/ANALOG OUT
Step 2. Click on the Analog Out Slot 0 Chan 0 (HSO5).
(See Fig. 6-35)
Step 5. Click on “DeviceNet Float In (DFI)” to select it as
the Source for the Assignment Statement. (See Fig.
6-37)
Step 6. Click in the Word text box and type in the number
“2”.
Step 7. Click on the Select button to enter the source.
FIG. 6-38 ASSIGNMENT STATEMENT MAPPING
DEVICENET FLOAT IN (DFI) TO ANALOG OUT
SLOT 1, CHAN 0 (HSO9)
FIG. 6-35 DESTINATION SELECTING ANALOG
OUT SLOT 0, CHAN 0
Step 8. Now whatever is sent to Devicenet Float In (DFI2)
from the Network Controller will be sent to Analog
Out Channel 0 (HSO5).
Step 3. Click on the Select button to select Analog Out as
the Destination for the left side of the Assignment
Statement. (See Fig. 6-36)
FIG. 6-39 DEVICENET FLOAT IN ASSIGNED TO
ANALOG OUT SLOT 0, CHAN 0
FIG. 6-36 ANALOG OUT (HSO5) SLOT 0, CHAN 0
SET AS DESTINATION
Step 4. Under Select Sources, Click on the Network: pull
down menu. (See Fig. 6-37)
A Definition of Mapping
Mapping (Addressing I/O) is the same as using an Assignment Statement. The Destination is located on the left hand
side of the equals (=) sign and is a memory address (variable). The Source is the data located on the right hand side of
the equals (=) sign at a memory address. So when you refer
to the right hand side of the Assignment Statement you are
referring to the data only and not the address even though the
address is listed.
•
Memory Address (Variable) = Data (Values, states)
The equals (=) sign assigns the data stored at the Memory
Address on the right side of the Assignment Statement to the
HI 3300 Tension Controller
Service Manual
Memory Address on the left side of the Assignment Statement.
72
HI 3300
This is exactly what you are doing when you map a source to
a destination.
Input
To PLC
The things that can be mapped are organized into Input
Image Tables and Output Image Tables, which are arrays of
variables (i.e. memory locations of a certain size based on
the type assigned to the variable) with addresses where data
is stored.
0
1
1
2
2
3
3
4
Output Image
Table
Control Link
Boolean (EO1.0)
Desired State 1
Input
Input Image
Table
0
1
2
Hardy Boolean Out
Control Lost
(HI1.4)
3
4
A table is called an “output” image table if the items in the
table are permitted to be on the left hand side of an Assignment Statement. The Output variables are also further identified by the first two letters of the variable:
•
•
•
NOTE:
HO - Hardy Output Image Table
DO - DeviceNet Output Image Table
CO - ControlNet Output Image Table or
Profibus Output Image Table.
You won’t use ControlNet and Profibus at the
same time so they can both use the same tables.
EO1=HI1.4
FIG. 6-40 MAPPING CONTROL LOST INPUT TO
CONTROL LINK BOOLEAN OUTPUT
Boolean Mapping
A Boolean variable is a variable that can have the value 0
(FALSE) or 1 (TRUE). In the HI 3300 Tension Controller
there are 3 boolean operations supported:
•
If the items in the table are only permitted on the right hand
side of an Assignment Statement, we call it an “input” image
table:
•
•
•
HI - Hardy Input Image Table
DI - DeviceNet Input Image Table
CI - ControlNet Input Image Table or
Profibus Output Image Table.
For example, the digital inputs on the Tension Controller are
found in an input image table, as are the items in the
DeviceNet input image table.
•
•
AND - The symbol for “AND” in a Boolean Assignment Statement is “*”.
OR - The symbol for “OR” in a Boolean
Assignment Statement is “+”.
NOT - the symbol for “NOT” in a Boolean
Assignment Statement is “~”.
The Boolean image tables are arrays of short (2 byte) integers. An individual Boolean variable in the image table is
located by its word offset and its bit offset. Boolean image
tables are given 2 letter names as follows:
•
•
The HI 3300 scans through the I/O image tables 55 times a
second and reads any values that are contained in the tables.
If there is nothing stored in the tables the controller does
nothing with it. If there are state values or other values stored
in the tables, the firmware processes the data and outputs it
to an output device or the screen.
•
•
•
•
DI
DO
table.
HI
HO
RI
RO
is the DeviceNet input image table.
is the DeviceNet output image
is the Hardy input image table.
is the Hardy output image table.
is RIO input image table.
is RIO output image table.
The RIO input and output images tables are mapped to physical external devices using RSLogix. DeviceNet and ControlNet input and output image tables are mapped to physical
external devices using Rockwell Software’s RS NetWorx.
The Hardy input and output image tables have pre-defined
meanings for certain bits within the tables.
NOTE:
Make sure you use RS NetWorx for DeviceNet
and RS NetWorx for ControlNet. They are two
different applications.
A Boolean variable is addressed with the syntax below:
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CHAPTER 6
Mapping
[tablename][word offset].[bit offset]
Example:
DI0.3 is bit #3 in the DeviceNet input table, word #0.
Analog Mapping
An analog variable is one that can have many different values. The HI 3300 Tension Controller supports float, 16 bit
integer, and 32 bit integer analog variable types.
There are three (3) analog operations supported. The symbols are the same as the Boolean operations, but with different meanings.
A Boolean variable in an analog equation is converted to 1.0
or 0.0.
An Analog variable in a Boolean equation is TRUE if it is
greater than zero (0) and FALSE if it is less than or equal to
zero (0).
Example:
•
•
DO1.0=HFI0
Explanation - DeviceNet Output Word 1,
Bit 0 = Tension
Special (Command) Mapping)
Command Interface consists of:
•
•
•
Multiply - The symbol for “Multiply” is
“*”.
Add - The symbol for “Add” is “+”.
Negate - the symbol for “Negate” is “~”.
•
•
•
•
16 bit words
Word 0
Command #
Word 1
Parameter ID
Words 2&3 Data.
Analog tables are given 3 letter names as follows:
The commands defined are the following:
DFI, DFO, DSI, DSO, DII, DIO all refer to DeviceNet
tables, where the item is a float, a short integer, or a 32 bit
integer depending on the first letter in the table name. HFI is
a table of Hardy defined floating point numbers.
An analog variable is address with the syntax below:
[tablename][offset]
WRITEINTEGER, command number 0x1000
The WRITEINTEGER command is used to set the value of
integer valued parameters.
Command data:
2 bytes: PARAMETER NUMBER: the number (PARAMID)
of the parameter to write.
4 bytes: PARAMETER VALUE: what to set the parameter
to.
Example:
•
•
DFO2=HFI0
Explanation - DeviceNet Float Output
Word 2 = Gross Weight
The offset is an offset in words in the case of the DeviceNet
tables. The offsets in Hardy tables have various predefined
meanings.
•
•
•
HFI0 - is Gross Weight
HFI1 - is Net Weight
. . . . other offsets to be determined.
When an analog equation is evaluated, all terms get converted to float. The final result is then converted to the type
of the LHS (Left Hand Side).
Mixed Mapping
It is permissible to have analog variables appear in Boolean
equations and to have Boolean variables in analog equations.
(We call a mixed equation “Boolean” if its LHS is a Boolean
term, and “Analog” if its LHS is an analog term) The interpretation is the following:
Data returned by the HI 3300: 8 bytes, echoing the
WRITEINTEGER command.
WRITEFLOAT, command number 0x1001
The WRITEFLOAT command is used to set the value of
float valued parameters.
Command data:
2 bytes: PARAMETER NUMBER: the number (PARAMID)
of the parameter to write.
4 bytes: PARAMETER VALUE: what to set the parameter
to.
Data returned by the HI 3300: 8 bytes, echoing the WRITEFLOAT command.
WRITESTRING, command number0x1002
The WRITESTRING command can be used to set the value
of any parameter.
Command data:
2 bytes: PARAMETER NUMBER: the number (PARAMID)
of the parameter to write.
Variable number of bytes: a zero terminated ASCII string,
giving the value to set the parameter to.
HI 3300 Tension Controller
Service Manual
Command in DeviceNet input word 0; return
DeviceNet out word 4
Data returned by the HI 3300: 8 bytes, echoing the first 8
bytes of the WRITESTRING command.
READINTEGER 0x2000
READFLOAT 0x2001
These commands are used to read the value of integer or
float parameters.
Command data:
2 bytes: PARAMETER NUMBER: the number (PARAMID)
of the parameter to read.
Data returned by the HI 3300: 8 bytes. The first 4 bytes echo
the command, and the next 4 contain the value of the parameter.
Setting up the command interface in mapping:
Use an equation of the form
CMD0 = (in_table)*(out_table)
In_table is an input table, defining where the command is
written.
Out_table defines where the reply data is written.
74
Command Interface
Parameter Numbers, Code Explanations, Valid
Ranges and Default Settings
CAUTION: THESE VALUES AND EXPLANATIONS CAN
CHANGE. ALWAYS CHECK ON THE HARDY WEB SITE FOR
THE NEWEST COMMAND INTERFACE LIST BEFORE USING
THE COMMAND INTERFACE.
NOTE:
The default parameter values are marked by
DEF and bold type.
Getting the Parameter Information on the Web
Browser
Step 1. From the Tension Controller Home Page, click on
Operation. (See Fig. 6-41) The Operation Page
appears. (See Fig. 6-42)
Example:
CMD0*DOO0
This equation says the command will be written to the
DeviceNet input table, at word offset 0, and the reply data is
written to the DeviceNet output table, at word offset zero.
It is legal to omit the Out_table.
Example:
CMD0=DSI3
This equation says that the command will be written to the
DeviceNet input table, at word offset 3, but no reply data
will be written.
Command (CMD) Interface can be used for different tables,
or multiple locations in one table. Example:
CMD0=DSI0*DSO0+RSI0*RSO0+RSI8*RSO8
Which says a command can show up in DeviceNet input
table word 0; Return in DeviceNet Out Table Word 0 or RIO
input table word 0; Return in RIO out table word 0 or RIO
input table word 8; return RIO out table word 8.
Input and output do not need to start at the same word:
Example: CMO0=DSI0*DSO4
FIG. 6-41 TENSION CONTROLLER HOME PAGE/
SELECTING OPERATION
Step 2. Click on Diagnostics. (See Fig. 6-42) The Diagnostics Page appears. (See Fig. 6-43)
75
CHAPTER 6
Mapping
FIG. 6-42 OPERATION PAGE/SELECTION DIAGNOSTICS
Step 3. Click on Parameters. (See Fig. 6-43) A complete
list of the Parameters with settings appears. (See
Fig. 6-44)
FIG. 6-43 DIAGNOSTICS PAGE/SELECTING
PARAMETERS
FIG. 6-44 PARAMETER DUMP
HI 3300 Tension Controller
Service Manual
76
Mapping a Hardy Control-Link Network to
a ControlNet/DeviceNet/Profibus Network
ControlNet Interface
Profibus Interface
DeviceNet Interface
HI-3300
Machine Monitor
With Network Option
Card
Hardy Control-Link Network
FIG. 6-45 HARDY CONTROL-LINK NETWORK CONNECTED TO A CONTROLNET/DEVICENET/PROFIBUS
NETWORK
The Hardy HI 3300 Tension Controllers are designed to save
you money. To connect a Hardy Control-Link Network to a
ControlNet/DeviceNet/Profibus Network simply purchase
one of the Hardy HI 3300 Series Network Interface Option
Cards and install it in the instrument that you want to directly
connect to the other network. You can map to this instrument
from all the other instruments on the Hardy Control-Link
Network, rather than buy a separate network card for each
instrument. (See Fig. 6-36)
Step 1. Determine into which Instrument you want to
install the Network option card.
Step 2. To install the network card. See the HI 3000 Installation and Operation manual, Cabling and Installation Section.
Step 3. Connect the network cables from the designated HI
3000 Series Instrument and begin mapping to that
instrument from either the Hardy Control-Link Network or the ControlNet/DeviceNet/Profibus Network.
77
CHAPTER 7
Troubleshooting
CHAPTER 7: TROUBLESHOOTING
About Chapter 7
Chapter 7 consists of all the procedures for troubleshooting
the electrical, mechanical and firmware elements of the HI
3300 Tension Controller in the event of a malfunction.
Included in Chapter 7 is a comprehensive flow chart to provide a road map for troubleshooting an entire Tension Controller system, including load cells and cabling.
Disassembly and Reassembly Notes and
Cautions
•
Always disconnect the power cord before
disassembling.
WARNING: FAILURE TO DISCONNECT THE POWER CORD
BEFORE DISASSEMBLING MAY CAUSE PERSONAL INJURY
AND/OR PROPERTY DAMAGE.
•
•
•
•
•
•
•
•
•
•
Any repairs should be made by an authorized trained technician.
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 the
Tension Controller.
Place small fasteners, connectors and electrical parts in closed containers 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 Instruments,
Technical 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 component 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 immediately!
Always check to be sure that no loose
parts are sitting on printed circuit boards
or electrical connectors 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.
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 Tension
Controller.
Always follow proper safety procedures
when working on or around the Tension
Controller.
Error Messages
!A/D Failure Error! - Internal Electronics Error, Retry.
!A/D Conversion Error! - Load Cells input out of range.
!Low Tension Alarm! - Tension below the Low Tension Setting.
!High Tension Alarm! - Tension above the High Tension Setting.
!Error in Option Slot 0! - Card in that slot is not functioning.
!Error in Option Slot 1! - Card in that slot is not functioning.
!C2 Cal Error! - Error occurred during calibration,
re-calibrate.
!Misalignment Alarm! - Roller is misaligned causing incorrect load sensor readings.
!Nonvolatile Memory Failure! - SMM failure or chipset failure.
!Control Lost! - Out of PID control.
!No C2 Sensor! - Instrument did not detect a C2 Load Sensor
!CAL Failed! - Not enough counts between Zero and Span.
(Traditional Calibration)
!CAL Failed! - ADC Error (Soft Calibration)
DeviceNet communications status for nodes 0-63. A '1' indicates that communication with the node has failed.
HI-3300 Tension Controller
Service Manual
General Troubleshooting Flow Chart Index
Drifting or unstable weight readings
A
Electrical, Mechanical and Configuration
reviews for Stable Readings
B
Instabilities on Formerly Operating
System
C
Verify individual load sensor operation
F
Trad. Cal - A/D Failure Error
G
Mechanical Inspection
H
Electrical Inspection
J
Load Sensor Installation
K
Weight Display Stops Incrementing
M
Blank Display
N
Display Stuck on a Screen
O
View Input States
R
Forcing Outputs
S
78
79
CHAPTER 7
Troubleshooting
A - Guidelines for Instabilities on Formerly
Operating Systems
A - STABILITY TEST
A
Confirms the Health of the
internal A/D converter
circuits.
Enter
Diagnostics
STABILITY
TEST
Activate the
test for each
channel
review the
results.
PASS
No
There isn’t a port
defined or enabled
The internal A/D
convert has a
hardware problem
Yes
Continue
checking for
mechanical
problems.
B
H
Check
Configuration
settings under
options
B
Cycle power and re-run
the test. If the second
test fails contact:
Hardy Instruments
Technical Support
HI-3300 Tension Controller
Service Manual
B - Guidelines for Instabilities on Formerly Operating Systems (Cont’d)
B
Check for
Electrical Stability
OK
J
Check for
Mechanical Stability
OK
H
Check Configuration
settings for
stability
OK
B1
80
81
CHAPTER 7
Troubleshooting
B1 - Guidelines for Instabilities on Formerly Operating Systems: Stability and
Configuration Settings
B1
Running
Condition
OK
No
Check MaxTension: Problem might be a ringing effect
resulting from an incorrect MaxTension setting. Adjust
the MaxTension until the ringing stops.
Verify that the PID settings are correct for your
application.
Yes
Static
Condition
OK
Yes
Return to
A
I.T. Diagnostics
No
C
HI-3300 Tension Controller
Service Manual
C - Guidelines for Instabilities on Formerly Operating Systems
C
Record load sensor for
comparison and stability
Check individual load sensors output by using the
Integrated Technician
Read and record the Millivolt
readings
A load sensor output can be considered stable if
the readings only vary +- 0.01mv. Applying
weight and releasing the weight should show a
very rapid Millivolt change. A slow Millivolt
change can indicate a damages strain gauge.
Repeat for each sensor
Inspect the Wiring Terminations for
contamination or damage, and replace if
necessary
Stable?
No
Yes
Stable?
Yes
No
Test
Complete
Insure the problem is not
mechanical (Review Section B)
No
Yes
Stable?
F
No
If you are unable to isolate the
problem, contact Hardy Technical
Support: 800-821-5831
Remove and replace any load
sensor determined to be unstable
82
83
CHAPTER 7
Troubleshooting
F - Verify Individual Load Cell Milli-Volt
Readings
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 3 mV/V. A scale capacity of 1,000 lbs with 100 lbs
of dead load at empty the load point mV reading should equal 1.5 mV
F
Using a Multimeter
MV
readings
acceptable?
Physically lift the
signal leads to read
each load cell’s
output.
Check individual
load sensor
output mV
readings.
MV
readings
acceptable?
1) No dead load.
Apply load and re-test.
2) Wiring error.
Verify color code using the
load cell certificate.
3) Open bridge circuit.
Disconnect power and verify
load point bridge resistance
reading with an Ohmmeter.
1) Stressed load cell, remove
all load and re-test.
2) Excessive loading.
For additional
testing go to:
H
NO
Check load sensor
NEXT
MV
readings
acceptable?
K
MV
readings
acceptable?
A
Record load
sensor mV
output level for
comparison.
Repeat for all load
sensors
Defective load cell?
Replace and repeat
Test F
MV
readings
acceptable?
YES
TEST COMPLETE
If you were unable to determine the
Milli-volt readings. Go to
K load sharing
or
Contact Technical Support
HI-3300 Tension Controller
Service Manual
F(a) - Verify Individual Load Cell Readings
Using Diagnostics
The top mV/V range is -120 to +120 mV/V
Your acceptable millivolt range is dependent
on the load cell certificate and your Instrument
setup. Diagnostics enables the operator to rapidly
troubleshoot a Tension Zone from the front panel
or web browser of the HI 3300. You can read each
individual load cell in mV, mV/V and tension to
determine if the load sensor is malfunctioning
or not connected. The configuration settings change
the allowable millivolt range.
F(a)
Enter
Diagnostics
Voltage &
Weight
Read and record
each load cell’s
signal output
Activate the test
and review the
results.
Yes
Unstable mV
reading?
Pass
No
All signal levels fall within -615 mV
to +615 mV range for LVDT load
cells. Verify acceptable range on
the load cell certificate. You must
verify all load cells millivolt readings
are changing in the same direction.
Millivolt reading is slow or
0.0 mV. It may be a
negative reading. Use a
multimeter to confirm
The Millivolt range is
outside the mV range
Check
Wiring
Apply force and
insure all signal
voltages increased
the same amount
No
K
Replace the load cell if the
unit signal readings are
out of tolerance
Check for mechanical
reasons, or replace load cell
Pass
B
84
85
CHAPTER 7
Troubleshooting
G - A/D Failure Error
Traditional Calibration
A/D Failure Error
The difference between Cal Low and span is less than +100 counts
G
ON Dual Channel (2 load cells) instruments both load cells must be operational
There are two places during Traditional Calibration where an error can occur
CAL LOW and SPAN
SPAN
ZERO
The new Cal Low is larger than the
original Span (FSCNT)
The milli-volt signal reading is not moving in the correct
direction
(1) Press the Cal/7 button.
(2) Press the “-“ button until the
cursor is in front of Span.
(3) Add the test weight to the
roller.
(4) Press the “-“ button until the
cursor is in front of Do Span
Cal?
(5) Press the Enter button. If
“Function OK” appears go
back Reference weight.
(6) Remove the test weight from
the roller.
(7) At the Reference Weight enter
0.0
(8) Repeat steps 1 - 6
(9) Continue with the calibration.
Note: Load Cells in Suspension can output negative mV
signal.
(1)
(2)
(3)
(4)
Use the multimeter in Diagnostics to verify mV levels.
Mechanical binding restricts the load cell.
Load Cell wires disconnected or improperly wired.
Improper load sharing or mechanical loading on the
load cell(s).
The Span Weight is too small.
(1) 1000 ocunts out of 985,000 is very small
(10,000 lb tension requires 11 lbs.)
(2) Mechanical binding can mask tension reading.
A/D
Error?
Yes
Contact Technical
Support
No
Proceed with
Calibration
HI-3300 Tension Controller
Service Manual
H - Mechanical Inspection
H
1)
2)
3)
4)
5)
Keep flexures on the horizontal
Vertical flexures should be avoided
Do not use flexures to correct for misaligning 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 its diameter.
6) Pipe flexure lengths should be a ratio of 6 times it’s diameter
7) Feed and discharge piping flexed
8) Are the flex joints on the correct side of the valve?
(a) You weigh the output valve, not the input valve
(b) Does the weigh scale see all the product to be weighed?
(C) If the product applies a force to a valve or pipe so that
pipe or valve must be included in the weigh vessel.
(d) Proper positioning of the flexures are key.
(E) Your vessel must seem to float.
H1
All pipes and conduits
flexible?
H2
Mechanically Isolated
from ladders and
connecting structures?
H3
Are the load cells
properly mounted?
1)
2)
3)
4)
H4
Are Check Rods
installed to dampen
vessel movement?
1) Protects the load cells from overload and impact forces
2) Limits the movement of the vessel.
3) Rods must be loose and not interacting with the vessel.
H5
Are cables routed
properly?
H6
Housekeeping
To
Verify Electrical
Go to
J
1) Floors or structures do not interact.
2) Local traffic does not interact.
3) Protected from forklifts and adjacent processing equipment
Level, solid mounting base
The load cell is mounted right side up.
All load cell bolts installed using anti-seize compounds.
Mechanically aligned to compensate for expansion and contraction.
1)
2)
3)
4)
5)
Separate conduit for low and high voltage cables.
Do not bundle low voltage with high voltage cables.
Maintain at least 3 inches of separation.
Maintain 14” separation from magnetic fields and 440 VAC.
Cables are in conduit or tied up and protected from damage.
1)
2)
3)
4)
Product, tools and production aids are off the vessel.
No workers are physically on the scale.
Must protect equipment from environmental damage
Make sure openings are sealed to keep water and environmental
contaminates from damaging:
(a) Instrument Cabinet or Enclosure
(b) Summing Card
(c) Load Cells
(d) Conduit Runs
(e) Covers are properly installed
86
87
CHAPTER 7
Troubleshooting
J - Electrical Inspection
J
1)
J1
Verify the proper
voltage level has
been supplied.
J2
Apply power to the
controller only if supply
voltage is correct.
J3
Does the instrument
reflect a Tension
Change?
2)
3)
4)
5)
6)
7)
1)
2)
3)
Cabling
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.
Apply the weight on the roller.
1)
Does the Tension increase or decrease in the correct
direction.
2)
Is the Tension reading repeatable?
3)
The Tension value will not be correct until a proper
calibration is complete.
1)
J4
DO NOT POWER UP THE CONTROLLER UNTIL
INPUT VOLTAGES CAN BE VERIFIED.
Check the specification label attached to the Tension
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.
a.
Keep ground cable runs as short as possible
b.
Excessive ground cable runs can act as an antenna
for AC noise
c.
Install grounding straps around load cells to direct
static away from the load cell and directly to ground.
d.
Install ground straps on the input and discharge
piping, and the vessel to a common earth ground.
2)
c)
3)
To Verify Proper Load Cell
Operations Go to
K
4)
Use the load cell certificates to verify color code Input is
excitation, Output is signal.
Shielding
a)
Grounded only at the tension controller
b)
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.
HI-3300 Tension Controller
Service Manual
K - Load Sharing and Load Sensor Checkout
K
1) Verify that the mV signal moves in the correct direction when applying a
load on the roll or sheave.
2) If the mV signal is moving in the wrong direction, check if the
load cell is mounted properly.
Verify the proper voltage
level has been supplied
a) The arrow goes in the direction of the force.
b) If there isn’t an arrow, you must manually verify movement in the
correct direction.
c) If you are still receiving a signal in the wrong direction verify the
load cell wiring color code.
Rule of thumb: You should not operate in tension ranges that are less than
10% or greater than 90% of a load cell’s capacity.
1) Verify the reading from both load cells using a multimeter.
2) Record the mV reading and compare each load cell for proper load sharing
Apply power to the Tension Controller
only if supply voltage is correct.
Monitor the system for
proper operation
Check out complete
No
A
a) Proper load sharing should only see a difference of 10%.
b) Use a level (spirit, laser) and verify that the roller is level side to side top
to bottom.
c) If the roller is misaligned, make the correct adjustments.
d) Check the mV reading again to see if the adjustments equalized the load
sharing. If the readings are within 10% of each other the problem is
fixed.
e) If the problem continues you probably have a bad load cell. Replace the
load cell immediately.
88
89
CHAPTER 7
Troubleshooting
M - Tension Reading Stops Incrementing
Tension Reading is Frozen at Zero or a High Tension Reading.
M
The load sensor output signal has exceeded the millivolt limits
set in Configuration and/or the internal factory setting.
Channel not enabled during configuration.
1) Verify that the signal wires are properly connected.
a) Verify the load cell cable color code.
(1) Load Cell Certificate
(2) Service Manual
(3) Cable marking strips
b) Broken signal wires act as antennas for EMI/RFI
c) Load cell cable shields must be grounded only at the controller to dampen EMI/RFI signals
2) The load cell output signal voltage has exceeded mV/V capacity.
a) Use a multimeter to verify mV levels
b) Verify individual load cell mV signals.
(1) An individual load cell may be over-ranged and exhibit high milli-volt readings.
(2) Possible physical damage to the load cell.
(3) Moisture in the load cell cable or body.
3) The load exceeds the Calibration Capacity Setting.
a) Under Calibration verify the Capacity setting.
c) You have exceeded the capacity of your load cell(s) such that the output signal is no longer able to
increase, the tension controller longer responds. This does not effect calibration.
4) Load exceeds the load cell capacity.
d) Mechanical forces or product acting on the sensed roller overloads the load cells.
e) Use a multimeter to verify the milli-volt levels.
5) Review Mechanical and Electrical Flow charts for additional tips. B
Verify Channel is enabled
in Configuration
ERROR?
No
Yes
Contact Technical
Support
No
Setup
Proceed with
Calibration
HI-3300 Tension Controller
Service Manual
N - Blank Screen
N
Measure AC or DC Power or 24V DC
power or 24V DC power DeviceNet
Connector V- & V+
1) Check for proper power at the
source connection.
2) check the circuit breaker at the
source
No
Measure the excitation voltage at J1
Check the power fuse located inside the controller case.
No
5VDC?
OK?
Yes
No
Disconnect all the
connectors from the
back panel except
power.
Contact Hardy Instrument
Service 800–821-5831
Replace the 2.5 amp sloblow fuse and supply power.
Measure the Excitation voltage
at J1
Does the fuse blow out
again?
5 VDC?
Yes
No
Yes
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
No
Monitor system for proper
operation
Check out complete
Contact Technical Service
90
91
CHAPTER 7
Troubleshooting
O - Display Stuck on a Screen
O
Power down the power up
Able to Change
Screen
Yes
Remove all connectors
Other than the power connector
Able to Change
Screen
Yes
Disconnect the power cable
Remove the back plate with the printed circuit
boards. Reseat the board.
Able to Change
Screen
Yes
No
Contact Technical Service
1-800-821-5831
Monitor system for proper
operation
Check out complete
HI-3300 Tension Controller
Service Manual
R - View Input States
R
The input States display shows
whether or not the instrument has
any inputs activated. This provides
a way of testing the inputs before
actually starting the process.
Enter
Diagnostics
STABILITY
Test
View Inputs
A
Activate the test
and review the
results.
These are dry contact closures.
Allowing 110 VAC in the input
will damage the instrument.
Verify contact is
being made
between the
connector
common to the
input desired.
No
Pass
Yes
Contact Hardy Technical
Support for repair.
Us a jumper to
physically make the
connection and verify
operation
Test Complete
Repeat for each
Input
A
92
93
CHAPTER 7
Troubleshooting
S - Forcing Outputs
S
Enter
Diagnostics
View Force
Outputs
A
Activate the test
and review the
results
These are Opto isolated solidstate relays, switching 110-240
VAC. They will not work as a dry
contact closure
Verify voltage is being provided.
The controller will not supply the
switching voltage
Contact Hardy
Technical Support
Use an AC meter to physically
verify operation
The relay will activate.
Therefore activating any
machinery attached.
Repeat for each
output
A
No
PASS
Yes
HI-3300 Tension Controller
Service Manual
94
System Integrity Check and Fault Determination From the Front Panel
To determine if an instrument or cabling problem exists, verify the basic operation of the system by performing the following system checks.
Diagnostics
About Diagnostics
The Diagnostics menus enable the technician to get a more
complete view of how the Tension Control system is working. For example you can check to see the last Calibration,
the type of calibration and when the last Calibration was performed. You can view the Data List Display for the Serial
Number assigned to the instrument or Program Part Number.
You can also check the last graduation size, Units selected,
Operator ID, Analog Options and more information about
the configuration of the instrument you are checking. You
can get information about the Load Sensors such as Output
Sensitivity, Hysteresis, Sensitivity of each individual Load
Sensor. The Diagnostic Menus allow you to perform a Self
Test which provides the total scale input to the instrument
such as mV and Force, mV/V and Force and mV/V for the
units selected (i.e. lbs, kg, oz, g).
Checking the Device Data List
The Device Data List is a list of all the parameters that were
set for the ingredient you are currently using and the instrument parameters that have been set for this instrument.
Step 1. From the Standby Display press the Test/9 button.
The Test and Data Menu appears with the cursor in
front of Device Data List. (See Fig. 7-1)
0.00
TESTAND DATA MENU
> Device Dat a List
Diagnost ics
Dat a List
> Ser ial : 1234
ID: HI- Web
Model : HI- 3300
FIG. 7-2 TEST DATA DISPLAY/INSTRUMENT ID MODEL NUMBER - S/N
Step 3. Here you can view the Instrument ID, Model Number and Serial Number of the instrument. This is a
read only display. To change any of the parameters
you will have to go to the Instrument Setup Menu/
Instrument ID.
Step 4. Press the down arrow button until the next three
parameters appears. (See Fig. 7-3)
0.00
Dat a List
> PP: 0650- 0140- 01
Ver sion: 2.4.000F
Ser ial : 1234
FIG. 7-3 TEST DATA DISPLAY/PART NUMBER/
PROGRAM VERSION
Step 5. These are read only displays. The information is
important:
•
->
•
FIG. 7-1 TEST AND DATA MENU/SELECTING
DEVICE DATA LIST
Step 2. Press the Enter button. The Device Data List Display appears with the cursor in front of Instrument
ID. (See Fig. 7-2)
0.00
PP# = Program Part Number. This is the
part number of the firmware. To order
additional copies of the firmware you will
need this number. This is also additional
information available to a service technician for troubleshooting.
Often a technician needs to know the program version to determine if the correct
version is being used. A Hardy Technical
Support Technician will ask what version
of software you are currently using to
determine the source of a problem. You
can find the version here.
Step 6. Press the Exit button to return to the Test and Data
Menu.
Step 7. Press on the “-” button until the cursor is in front of
95
CHAPTER 7
Troubleshooting
Diagnostics
Voltage & Weight Displays
Step 1. Press the down arrow until the cursor is in front of
Diagnostics. (See Fig. 7-4)
0.00
0.00
Diagnost ic
Cont r ol Net
> View Input s
View/ For ce Out put s
->
TESTAND DATA MENU
> Diagnost ics
->
Dat a List
FIG. 7-6 DIAGNOSTIC MENU/VIEW INPUTS
Step 4. To see the current state of each input press the Enter
button. The View Inputs menu appears. (See Fig. 77)
FIG. 7-4 TEST AND DATA MENU/SELECTING
DIAGNOSTICS
Step 2. Press the Enter button. The Diagnostics Display
appears with the cursor in front of Network Card.
This is a read only display and indicates the network card that is currently installed. In this case the
installed Network Card is the ControlNet Network
card. If there is no network card installed it will
read “No Network Card”. (See Fig. 7-5)
View Input s
0.00
> Input
12 34 5
St at us 1 1 1 1 1
FIG. 7-7 INPUTS MENU
Diagnost ic
St at us 2
> Cont r ol Net
View Input s
0.00
Step 5. The input status is a 1 or 0.
•
•
1 = Active
0 = Inactive
View/Force Outputs
WARNING: FORCING THE OUTPUT RELAY MAY CAUSE
MAKE ABSOLUTELY SURE
DAMAGE OR PERSONAL INJURY.
FIG. 7-5 DIAGNOSTICS DISPLAY/SELECTING
VOLTAGE & WEIGHT
THAT YOU KNOW WHAT THE RELAY IS CONNECTED TO
BEFORE ACTIVATING. IF NECESSARY DO A PHYSICAL
CHECK TO DETERMINE WHAT THE SELECTED OUTPUT
Step 3. Press the “-” button until the cursor is in front of
View Inputs. (See Fig. 7-6)
View Inputs
The View Inputs enables the user to view the status of each
of the 5 inputs to the instrument to see which ones are active
or inactive.
RELAY IS CONNECTED TO BEFORE ACTIVATING.
The Force Outputs function individually activates each of
the 4 Output relays in the instrument. Useful in pre-startup to
determine if all the relays are connected to the correct auxiliary devices.
Step 1. Press the up or down arrow buttons until the cursor
is in front of View/Force Outputs. (See Fig. 7-8)
HI-3300 Tension Controller
Service Manual
0.00
Diagnost ic
View Input s
> View/ For ce Out put s
St abil it y Test
->
FIG. 7-8 DIAGNOSTICS VIEW/FORCE OUTPUTS
Step 2. Press the Enter button. The Force Outputs menu
appears with the cursor in front of the Output Relay
list. The Output Relay List is a read only list. (See
Fig. 7-9)
•
•
The State list indicates if the Output Relay
is activated or not.
All the output relays on the instrument are
Normally Open so activation will close the
relay.
0.00
For ce Out put s
For ce
Rel ay 1 ON
> Out put
12 3 4
St at e
10 0 1
96
Step 4. To select another Output Relay, press the left or
right arrow buttons until you have selected the Output Relay and state you want. (See Fig. 7-10)
0.00
For ce Out put s
St at e
10 0 1
> For ce
Rel ay 2 ON
Out put
12 3 4
FIG. 7-11 FORCE OUTPUTS MENU/SELECTING
OUTPUT RELAY #2/ON
Step 5. Press the Enter button to activate the output relay
you have chosen. “Entry Accepted” briefly, (See
Fig. 7-12) than the State for Output 2 changes to
“1”. (See Fig. 7-13)
0.00
For ce Out put s
St at e
10 0 1
> Ent r y Accept ed
Out put
12 3 4
FIG. 7-12 FORCE OUTPUTS/ENTRY ACCEPTED
FIG. 7-9 FORCE OUTPUTS MENU/READING OUTPUT 1234
Step 3. Press the “-” button until the cursor is in front of
“Force
Relay 1 ON”. (See Fig. 7-10)
0.00
For ce Out put s
St at e
10 0 1
> For ce
Rel ay 1 ON
Out put
12 3 4
FIG. 7-10 OUTPUT RELAY DISPLAY/SELECTING
OUTPUT RELAY #1
0.00
For ce Out put s
St at e
110 1
> For ce
Rel ay 2 ON
Out put
12 3 4
FIG. 7-13 OUTPUT RELAY #2 FORCED CLOSED
DISPLAY
Step 6. Press the Exit button to return to the Diagnostics
Menu.
Stability Test
The Stability Test switches a fixed signal into the analog to
digital convertor, and calculates the mean squared variation
from the average reading, using 100 samples.
97
CHAPTER 7
Troubleshooting
The test passes if the mean squared variation is less than 5.0,
and the average reading is between 30237 and 36955.
Step 1. Press the”-” button until the cursor is in front of
Stability Test. (See Fig.7-14)
0.00
Diagnost ics
View/ For ce Out put s
> St abil it y Test
Weight and Volt age
->
! ! !DANGER! ! !
Test in Pr ogr ess
FIG. 7-16 STABILITY TEST/TEST IN PROGRESS
•
FIG. 7-14 DIAGNOSTICS DISPLAY/SELECTING
STABILITY TEST
If the instrument passes the Stability Test
the Pass display appears. (See Fig. 7-17)
This means that the Mean Squared Variation is less than 5.0 and the average reading is between 30237 and 36955. In short
the instrument is working fine.
Step 2. Press the Enter button. The Information display
appears with a “!!!DANGER!!! warning you. (See
Fig. 7-15)
WARNING: DO NOT PERFORM THE STABILITY TEST
WITH PRODUCT ON THE ROLLER OR SHEAVE OR WHILE THE
TO DO SO CAN RESULT IN PROPERTY
DAMAGE, PRODUCT DAMAGE AND/OR PERSONAL INJURY.
MAKE SURE THE SYSTEM IS COMPLETELY STOPPED
BEFORE PERFORMING THE STABILITY TEST.
0.00
! ! !DANGER! ! !
0.00
SYSTEM IS RUNNING.
! ! !DANGER! ! !
> Test Chan1
0.00
->
FIG. 7-15 STABILITY TEST DISPLAY
Step 3. WHEN YOU ARE COMPLETELY SURE THE
PROCESS IS STOPPED, press the ENTER button to perform the stability test. The display indicates that the Test is in Progress. (See Fig. 7-16)
The results of the Stability Test are displayed. (See
Figs. 7-17 & 18)
PASS St abil it y
FIG. 7-17 SYSTEM STABILITY TEST DISPLAY/
PASS
•
If the instrument does not pass the Stability Test the Fail display appears. (See Fig.
7-18) This means that the Mean Squared
Variation is greater than 5.0 and/or the
average reading is not between 30237 and
36955. This test examines the internal
electronics and not the load cells input signal.
! ! !DANGER! ! !
0.00
FAIL St abil it y
FIG. 7-18 SYSTEM STABILITY TEST DISPLAY/FAIL
HI-3300 Tension Controller
Service Manual
1.
2.
3.
Disconnect the power cord and reconnect the power cord to cycle power to
the instrument.
Repeat the Stability test.
If the instrument Fails the Stability
Test again, contact Hardy Instruments
Inc., Technical Support for assistance.
Step 4. Press the Exit button to return to the Diagnostics
display.
Step 5. Press the “-” button until the cursor is in front of
Weight and Voltage. (See Fig. 7-19)
Tension Controller is 0-15 mV. If you are
getting a reading outside this range the
problem is probably the load cell (electrical). If you are getting a reading between
0-15 mV the reading is normal.
Step 3. If you are using both channels the display will show
each channel weight reading, mV reading, mV/V
reading and so on. (See Fig. 7-21)
Weight and Voltage
0.00
Weight and Volt age
Chan2 count s
> Chan1Tension
Chan2Tension
0.00
Diagnost ics
St abil it y Test
> Weight and Volt age
Fact or y Def ault s
98
16776960
1276.2 l b
1276.2 l b
->
FIG. 7-19 DIAGNOSTICS DISPLAY/WEIGHT AND
VOLTAGE
Step 1. Press the Enter button. The Weight and Voltage
Menu appears with the cursor in front of Channel 1
Tension. (See Fig. 7-20)
0.00
Weight and Volt age
Chan1 count s
16776960
> Chan1Tension
1276.2 l b
Ch1 mV
3.1
FIG. 7-21 TWO CHANNEL WEIGHT AND VOLTAGE
DISPLAY
Step 4. Press the up or down arrow buttons until the cursor
is in front of Chan1mV/V.
Step 5. The mV/V and Weight Display appears. (See Fig.
7-22)
0.00
Weight and Volt age
Ch1 mV
3.1
> Ch1 mv/ V
3.199
Ch1 count s
176952201
FIG. 7-22 WEIGHT AND VOLTAGE MENU/CHANNEL 1 MV/V DISPLAY
FIG. 7-20 WEIGHT AND VOLTAGE/TENSION
READING
•
Step 2. Press on the “+” or “-” buttons to move to the item
you want to see.
•
•
•
The mV is a coarser reading than the mV/
V. However the reading is sufficient to
balance the load share between the two
load cells.
Additionally, this reading allows you to
determine if the problem is in the instrument (internal) or in a load sensor(s)
(external). The specification range for the
•
This reading is a higher resolution reading
to a 10th of a microvolt. Use this reading
to determine if the load cell is working
correctly.
You can also use this reading to determine
which load sensor is malfunctioning by
looking at each load sensor to determine
any problems (e.g. creep) in the millivolt
reading. Multiply the mV/V reading by the
sense voltage to get a mV reading with 3
decimals points.
Converting mV/V to mV use this formula:
99
CHAPTER 7
Troubleshooting
Step 5. Press the Exit button to return to the Diagnostics
display.
5 x mV/V = mV
Step 6. Press the Exit button to return to the Diagnostics
Display.
Factory Defaults
System Integrity Check and Fault Determination From the Web Browser
Diagnostics
CAUTION: IF YOU CHOOSE FACTORY DEFAULTS ALL
DATA WILL BE LOST! MAKE ABSOLUTELY SURE THAT THIS
IS WHAT YOU WANT TO DO BEFORE CHOOSING THIS
OPTION. DO NOT USE THIS FUNCTION IN AN EFFORT TO
CORRECT ANY MALFUNCTIONS IN THE OPERATION OF THE
INSTRUMENT.
Step 1. Press the “-” button until the cursor is in front of
Factory Defaults. (See Fig. 7-23)
Diagnostics is used to troubleshoot the Tension Control System. A complete Troubleshooting Guide is available in the
Service Manual. What is important for Operational purposes
is to be able to see the information about this instrument.
(See fig. 7-99) Setting Default Settings is also useful to operators.
Step 1. From the Home page click on Operation. (See Fig.
7-25) The Operations Page appears. (See Fig. 7-26)
0.00
Diagnost ics
Weight and Volt age
> Fact or y Def ault s
DeviceNet
NO
FIG. 7-23 DIAGNOSTICS MENU/FACTORY
DEFAULTS
•
•
Resetting the Default Parameters is used
when you want to return the instrument to
a factory default condition.
It is required that the security access to this
menu be High (HI).
FIG. 7-25 TENSION CONTROLLER HOME PAGE/
SELECTING OPERATION
Step 2. Press the left or right arrow button to select Yes if
you want to return the instrument to Factory
Defaults. (See Fig. 7-24)
0.00
Diagnost ics
!!!WARNING!!!
> Fact or y Def ault s
Dat a Lost
Yes
FIG. 7-26 OPERATION PAGE/SELECTING DIAGNOSTICS
Step 2. Click on Diagnostics. The Diagnostics Page
appears. (See Fig;. 7-27)
FIG. 7-24 FACTORY DEFAULTS DISPLAY
Step 3. Press the Exit button if you do not want to set the
Factory Defaults. The Diagnostics menu reappears.
Step 4. Press the Enter button if you want to set the Factory
Defaults.
HI-3300 Tension Controller
Service Manual
•
•
100
Enter the password again and click on the
Default button.
If you still cannot set the defaults, contact
you network administrator for the correct
password.
Step 6. Click on the Return to Factory Defaults button. A
message appears informing you that the Factory
Defaults are set. (See Fig. 7-30)
FIG. 7-27 OPERATION/DIAGNOSTICS PAGE
Step 3. To Set the Factory Defaults click on Set Factory
Defaults
NOTE:
There is a warning that should be read first
before setting Factory Defaults.
FIG. 7-30 FACTORY DEFAULTS SET
Step 7. Click on Back to return to the Diagnostics page.
Step 8. Click on “UDP”. The UDP pages appears with the
number of packets received from other nodes on
your network. (See Fig. 7-31) This information is
useful to determine if you are communicating with
other nodes.
FIG. 7-28 DIAGNOSTICS/FACTORY DEFAULTS
PAGE
Step 4. Click in the High Security Code field. (See Fig. 728)
Step 5. Enter the High Security Code for this instrument.
•
If the High Security Code is not correct,
when you press the Return to Factory
Default button a message appears informing you that the password is not valid,
Defaults are not set. (See Fig. 7-29)
FIG. 7-31 COUNT OF UDP PACKETS RECEIVED
FROM EACH EXTERNAL NODE ON YOUR NETWORK
Step 9. Click on Parameters. The Parameters page appears
with a list of all the parameter settings you entered
for the instrument. (See Fig. 7-32)
FIG. 7-29 HIGH SECURITY PASSWORD INVALID
NOTE:
It is a good idea to save these parameters. You
should also highlight all the parameters and
paste them in a text editor so you have a hard
101
CHAPTER 7
Troubleshooting
copy for repair and configuration purposes. This
feature allows you to save the parameter settings
for future use or reference.
Step 13. To perform the Stability Test click on Stability Test.
the
FIG. 7-34 DIAGNOSTICS/STABILITY TEST
WARNING: DO NOT PERFORM THE STABILITY TEST
WITH PRODUCT ON THE ROLLER OR SHEAVE OR WHILE THE
SYSTEM IS RUNNING.
TO DO SO CAN RESULT IN PROPERTY
DAMAGE, PRODUCT DAMAGE AND/OR PERSONAL INJURY.
MAKE SURE THE SYSTEM IS COMPLETELY STOPPED
BEFORE PERFORMING THE STABILITY TEST.
FIG. 7-32 DIAGNOSTICS/PARAMETER DUMP
Step 10. Click on the left arrow to return to the Diagnostics
page.
Step 11. Click on Alarm Log. The Alarm Log page appears
with a list of the Alarms that have been recorded
since you last cycled the power. (See Fig. 7-33)
Step 14. Click on the Channel pull down menu. (See Fig. 734)
Step 15. Click on the Channel you want.
Step 16. Click on Test.
Step 17. The Instrument goes through the Stability test, then
the Results page and an explanation of the test
appears. (See Fig. 7-35)
FIG. 7-35 STABILITY TEST RESULTS PAGE
Step 18. Click on the BACK button to return to the Diagnostics page.
Step 19. To See the force, mV, mV/V and ADC counts for
each load cell click on Weight and Voltage. The
Weight and Voltage page appears. (See Fig. 7-36)
FIG. 7-33 DIAGNOSTICS/ALARM LOG
Step 12. The Alarm Log gives you a picture of the alarms
and date and time when they occurred. Useful information to troubleshoot the tension system over
time.
HI-3300 Tension Controller
Service Manual
102
Step 22. To see if you have any C2 load cells connected to
the Tension Controller, click on C2. The C2 Data
page appears with the number of C2 Sensors in
your system. In our example there are none connected to the instrument. (See Fig. 7-38)
FIG. 7-36 DIAGNOSTICS PAGE/WEIGHTS AND
VOLTAGE
Step 20. This page provides a snapshot of the load cells and
cables. For example if you see an A/D conversion
Error it means that a load cell is not connected. The
information on this page is excellent for determining if a problem is in the load cell/cable or the
instrument.
Step 21. Click on I/O to see the status of each of the Inputs
and Relay Outputs for this instrument. (See Fig. 737)
FIG. 7-38 DIAGNOSTICS PAGE/C2 DATA
Step 23. Click on the Read Sensor button to get the data
from the C2 sensor.
Step 24. Click on the left arrow to return to the Diagnostic
page.
Step 25. Click on Home to return to the Home page.
Troubleshooting The Network Connections and Configuration with the "Ping"
Tool
Step 1. The Ping Tool is used from the root directory of the
PC. Get to the Root directory. The Root Directory is
the “C:/” Prompt.
Step 2. Click on the Start Button of the Windows Task Bar.
Step 3. Click on Run. (See Fig. 7-39)
FIG. 7-39 RUN/CMD ENTERED
Step 4. In the Run field type “cmd” without the quotation
marks.
Step 5. Click on the OK button. The Command Window
appears. (See Fig. 7-40)
FIG. 7-37 DIAGNOSTIC PAGE/INPUT AND OUTPUT
LIST AND STATUS
103
CHAPTER 7
Troubleshooting
•
If the instrument or network are configured incorrectly and cables are loose or not
connected correctly, nothing prints out
after the first line. Do the following:
1.
2.
FIG. 7-40 COMMAND WINDOW
3.
Selecting the module by number for Testing
NOTE:
You can only ping from the PC you cannot ping
from an instrument.
•
Step 1. Type PING <space>IP address of the instrument
you want to test. For Example:
C:\>PING 168.215.209.78
NOTE:
NOTE:
The IP address entered is for the test module
which is available to the outside world. You IP
Address will vary.
Step 2. Press the Enter key on the PC.
Step 3. The PING utility starts sending out 56 signals and
64 signals should return if the unit is functioning
correctly.
FIG. 7-42 SUCCESSFUL PING
If the unit is configured correctly and the
Ethernet card is functioning correctly and
the cables are the correct ones for this
application and are securely fastened, 64
signals should be returned and the print
out will reflect this fact.
NOTE: The Ping utility continues to send out signals (pings) until you exit the Ping Tool.
•
FIG. 7-41 ENTERING IP ADDRESS
Check the Network cables and connectors to be sure they are tightly fastened and the correct cables for this
application.
Check the configuration to be sure
that the instrument is configured correctly. (See Configuration IP Address
in Chapter 6)
Check the Ethernet card to be sure
that is securely seated and that it is
functioning correctly.
Simultaneously press the <Ctrl> key and
the letter <C> key to stop the signals.
Exiting the Root Directory
Step 1. Type exit at the root directory prompt.
C:/exit
Step 2. Press the Enter key.
About Solid State Relays With Light Loads
There have been installations where solid state relays have
been used and failed to shut off a solenoid or relay when deenergized. 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.
SCR SWITCHING LOAD CIRCUIT
The SCR itself presents no leakage current. Some solid state
relay manufactures specify 20mA minimum load. This is
based on the presumption a relay or solenoid will drop out
with only 4mA through it, which is not always true. That
may not be true. When switching a light load with a solid
state relay across the line, you must look at the rated dropout current of the load, and if it is less than 4mA it may not
turn off. The solution is to put a loading resistor in parallel
with the light load, to be sure leakage current is sufficiently
shunted away from the coil.
HI-3300 Tension Controller
Service Manual
104
Ordering Replacement Parts
HOT
SOLID
STATE
RELAY
Contact the Hardy Instruments Sales Department to order
replacement parts and option boards. Have your equipment
model number and serial number ready.
System Support
Technical Service is provided as follows:
•
15000 ohm
RELAY
COIL
NEEDED
SHUNT
New system start-up: Ensure that the
installation is checked and correct; instruments are calibrated, and operators
trained.
1.
NEUTRAL
2.
FIG. 7-43 SCR SWITCHING LOAD CIRCUIT
Assume a load like a relay with a coil of 15,000 ohms and of
5% of nominal drop-out. When the solid state relay is off,
there will still be 1/3 of the line voltages across the relay, so
it will not drop out. For the relay to have 5% of the line
across it, it and a parallel shunt resistor must be 20 times less
resistance than the 30K snubbing network, or 1.5K ohms.
Use less than a 1.67K ohm parallel resistor and now total
load is below 1.5K ohm or 80mA.
General Policies and Information
With over 70 years of industrial weighing experience and
products in the field, Hardy Instruments continues to design,
manufacture, install and support Hardy products worldwide.
The following paragraphs describe Hardy's customer support
services and equipment warranty.
NOTE:
Before returning any product to Hardy Instruments, call the Technical Service Department
listed below for a Return Authorization Number.
Have your company name, address, telephone,
equipment model number, S/N, and a brief
description of the problem ready to give to him.
In addition, please have Appendix A completed
and ready to FAX to us before calling.
FOR FURTHER INFORMATION CONTACT:
Technical Service Manager
Hardy Instruments, Inc.
9440 Carroll Park Drive, Suite 150
San Diego, CA 92121
Telephone: (858) 278-2900
FAX: (858) 278-6700
Web Site: http://www.hardyinst.com
E-Mail: [email protected]
Service: Engineers are trained and
qualified to provide on-site installation, calibration, and maintenance.
On-site training: A Hardy Support
Representative can be scheduled to
train your operations and maintenance
personnel. This can be as simple as
basic load cell theory or as complete
as troubleshooting techniques which
allow you to service your equipment.
Warranty
A warranty problem may be handled by returning the product to the factory for repair or replacement under warranty.
105
Glossary of Terms
GLOSSARY OF TERMS
BASIS WEIGHT
The mass per unit area of a web. Common metric units are in g/m 2. English units for
the paper industry are often lb/3000ft 2. (Need to enter the symbol.)
CD
Abbreviation for Cross (machine) Direction, sometimes also abbreviated as XMD,
which is the direction perpendicular to the material flow and material plane in a
machine. In many plants, this is referred to as TDE or Transverse Direction.
CALIPER
(THICKNESS)
The thickness of a web usually expressed in micrometers or mils (thousandths of an
inch).
CALIPER (BRAKE
TYPE)
A disc brake pad or baking mechanism involving opposing brake pads that grip a
rotating disc.
CONVERTING
The process of a web material from one form to another. Converting processes
include calendaring, coating, die cutting, embossing, laminating, printing, punching,
sheeting, slitting, treating, winding and unwinding.
CORE
A hollow tube, often of fiber, plastic or metal, upon which a roll is wound.
CORE SHAFT
A mandrel upon which rolls are wound.
DANCER
A moving roller sensor used for feedback control of web tension.
FEEDBACK
Output from a sensor which is input to a controller for maintaining a control setpoint.
FEEDFORWARD
A control technique to improve responsiveness of controls by letting the actuator know
a change is need even before its sensor detects it.
FILM
A thin polymer (plastic) web such as found in stretch wrap or garbage bags. Also a
thin liquid.
FRICTION
A force resisting motion. Friction between webs and rolls is important because it determines whether the web will track or lose traction. Friction between web and web is
important because it determines how stable a stack or wound roll will be. Friction on
machines is important because it may compromise the sensitivity of measurement or
control.
HOOKE’S LAW
A law that states that stresses equal the product of a material constant call modulus
(or Young’s modulus) and strains.
IDLER ROLLER
A roller which is driven by the web rather than by an electric motor, belt or other external means.
INTERMEDIATE ZONE
An independent tension zone typically created between two driven nip points on a
converting line. Also referred to as a Mid-Process Zone.
LOAD CELL
An electronic sensor that measures force. On converting machinery, load cells under
the ends of an undriven roller are often used to measure web tension.
MANDREL
A cylinder upon which a roll is wound.
MD
Abbreviation for Machine Direction, which is the direction of material flow through a
machine.
HI-3300 Series
Operation and Installation
106
NIP
Two parallel rolls pressed together on converting machinery between which the web
passes
PID CONTROL
An abbreviation for Proportional, Integral and Derivative control. A common threefunction algorithm found in closed-loop controllers for automatically matching the control output to a set value of interest. Most tension controllers on the market that use a
tension measurement input from transducers or load cells use PID for tension control.
DFE uses the terms “Gain”, “Stability” and “Response” to describe each component of
PID control because they are more descriptive of each.
PLI
An abbreviation for Pounds per Lineal Inch. A unit of tension measurement expressed
as the total force (in pounds) on the web in the machine direction (MD) divided by the
width (in inches) of the web. Expressing tension in PLI allows comparison of typical
tensions between various width webs or various web substrates.
RATIO
An output feature on a tension controller that multiplies (for unwind applications) or
divides (for rewind applications) the sampled control output by a factor adjustable
between 1 and 10. The feature allows an instantaneous change i control output to correspond to the roll diameter change that takes place during a flying splice.
REWIND ZONE
A tension zone, typically on converting machinery, created between a driven nip roll or
other tensioning point and the driven core onto which the web is wound.
ROLL
A web in wound roll form. This term is also used in the converting industry for rollers.
ROLLER
A rotating cylinder used for web transport. Aliases include, idler rolls, idler rollers,
drums, rolls, pipe rollers.
SAMPLE AND HOLD
A control feature that locks the tension controller output at whatever level it is at when
an external contact closes. The lock is maintained until the contact opens. Used in flying splice applications to prevent instability during the splice. Also actuated by the
Ration function.
SOFT START
A tension controller feature used in unwinds zones; soft start causes the controller
output to drop to a preset low level to prevent brake lockup when the machine start;
the feature is actuated automatically upon loss of tension below a preset trip point, by
a change in machine speed or by an external contact closure.
STRAIN GAUGE
A thin flat electrical transducer for measuring strain that is bonded to a body of interest.
SUBSTRATE
The material composition of a web.
TENSION
TRANSDUCER
A tension sensor and variation of a load cell specifically designed to measure exact
web or filament tension in processing industry.
TENSION LIMIT
SWITCH (TLS)
A controller feature that provides a relay contact closure at preset tension levels,
either high or low. TLS is often used as a web break detector or web break deterrent.
TAPER TENSION
A means of decreasing web tension as roll diameter increases in a rewind zone.
Taper tension helps produce a roll of better quality by eliminating telescoping, crushed
cores, and overly tight or loose rolls.
TENSION ZONE
A length of machine in which the web is under nominally the same tension, usually
between driven roller.
107
Glossary of Terms
TRACTION
One of the three possible web/roller interactions where there is no relative movement
between web and roller or between roll and roller. Also refers to the maximum tension
differential that can exist across a roller without slippage.
UNWIND ZONE
A tension zone created between a driven roll or driven nip and the core from which a
roll is unwound. Tension is often created by torque applied to the unwind shaft by a
pneumatic brake.
WEB
a long, thin, flexible structure. Common web materials include paper, film, foil, nonwovens and textiles.
WRAP ANGLE
The angle between the ingoing and outgoing tangent of a web on a roller, or equivalently, the angle the web deflects as it goes over a roller. High wrap angles help
ensure web/roller traction.
HI-3300 Series
Operation and Installation
108
Index
Index
Symbols
+/- Buttons 22
“Clean” Primary Line
16
Numerics
0/Char. Button 23
10/100 Base T Ethernet connection 31
10/100 BaseT Ethernet 1
14 AWG Power Line 16
2/ABC Button 22
32 Bit Integer 73
32 Bit Integer Analog Variable Types 73
3rd Party I/O 3, 4
55 Updates Per Second 27
6/MNO Button 23
8/TUV Button 23
9 Terminal Block 17
A
A - Guidelines for Instabilities on Formerly Operating
Systems 79
A Definition of Mapping 71
A/D Convert Error 77
A/D Failure Error 77
A1 - Guideline for Instablilities on Formerly Operating
Systems (Cont’d) 80
About Chapter 2 7
About Chapter 3 11
About Chapter 4 21
About Chapter 5 51
About Chapter 7 77
About Diagnostics 94
About Help 21
About Instrument ID 25
About IP Addresses 31
About LVDT Connections 17
About Mapping 63
About Misalignment Tolerance 38
About Operator ID 26
About PID 24
About Proportional Parameter 38
About Setting the Clock 29
About Soft Calibration 54
About Solid State Relays With Light Loads 103
About Splice The Level Parameter 36
About Start Level Parameter 34
About Stop The Stop Level Paramter 35
About the AutoGain Parameter 39
About the Averages Parameter 27
About the Decimal Point Parameter 26
About the Defaulted I/O? Parameter 40
About the Derivative Parameter 39
About the Ethernet Parameters 31
About The High Alarm Delay Parameter 38
About The High Alarm Parameter 37
About The Hold Level Parameter 36
About The Integral Parameter 39
About the IR Port Parameter 28
About The Low Alarm Delay Parameter 37
About The Low Alarm Parameter 37
About the MaxTension Parameter 27
About the Prod 1 Parameter 33
About the Prod 2 Parameter 33
About the Prod 3 Parameter 34
About the Sensor Type Parameter 28
About the Set LCD Contrast Parameter 32
About the Setpoint in Use Parameter 32
About the Start Multiple Parameter 35
About The Start Time Parameter 35
About The Stop Time Parameter 36
About the Swivel/Wall Mount 13
About The Taper Percent Parameter 40
About the WAVERSAVER Parameter 27
About Timezones 30
About Traditional Calibration 51
About Unit of Measure 26
About Web Width 40
-AC 4
AC Power 16
Add 73
Allen-Bradley Remote I/O 1, 3, 4
Alphanumeric Character LCD 21
Alphanumeric Entry 22, 23
Alphanumeric Value 22
Analog 1
Analog Board Configuration (Slot 1) 48
Analog Board in Slot 1 48
Analog Card Output Wiring 46
Analog Card Slot 0 46
Analog Card Slot 1 46
Analog CCA 8
Analog Equation 73
Analog Mapping 73
Analog Option Boards 49
Analog Option Card Configuration 18, 45
Analog Option Card Configuration from the Front Panel
45
Analog Out 49
Analog Out Slot 0 Chan 0 symbol (HSO5) 49
Analog Output 4, 49
Analog Output Board for Slot 1 50
Analog Output Option 4
Analog Output Option Card Configuration from the Web
Page 46
Analog Tables 73
Analog Variables 73
AND 72
Another Mapping Example 67
Application Specific Web Tension 1
HI 3300 Tension Controller
Service Manual
Approvals 8
Arrays of Variables 72
ASCII String 73
Auto 22
Auto - Instrument Controlling the Process
Auto/M Button 22
AutoGain Parameter 39
Auxiliary Devices 95
Average Reading 96, 97
Averages 7
Averages Parameter 27
23
B
B - Guidelines for Instabilities on Formerly Operating
Systems (Cont’d) 80
B1 - Guidelines for Instabilities on Former Operating
Systems (Cont’d) 81
B2 - Guidelines for Instabilities on Formerly Operating
Systems
Mechanical Stability and Configuration Settings. 81
Back 60
Backspace Function 22
Basic Load Cell Theory 104
Bi-Directional Communications 5
Binding 51
Block transfer commands 5
Boolean Equations 73
Boolean Mapping 72
Boolean Operations 73
Boolean Operations 72
Boolean Tables 72
Boolean Variables 73
Booster Power Supply 4
Brakes 1
Built-in Diagnostics 2
Button Functions 21
C
C>PING 168.215.209.78 103
C - Guidelines for Instabilities on Formerly Operating
Systems 82
C2 Cal 56
C2 Cal Error 77
C2 Cal Type 56
C2 Calibration Completed OK 59
C2 Calibration From the Front Panel 56
C2 Calibration From the Web Page 58
C2 Load Points 17
C2 Weighing System 3
C2® - Second Generation
Electronic 7
C2® Calibration 3
C2® Electronic Calibration 1
C2® Load Point Connection 17
C2® Second Generation Calibration 3
Cable Color Code 17
Cable color Code for Non-C2 Load Points 17
Cabling and Interconnecting 16
Cal Completed OK 57
CAL Failed 77
Cal Low (Zero) Calibration 53
Calibrate/7/PQRS Button 23
CALIBRATION Menu 52
Calibration Menu 56
Calibration Page 60
Calibration Procedures 51
Calibration Sub-Menu 58, 59
Calibration Techniques 7
Capacity 56
Capacity Text Field 60
Captive Screws 13
Certified Test Weight 53, 60
Chan 1 Mode 47
Chan0 Mode 47
Channel Pull Down Menu 101
Channels 18
Checking the Device Data List 94
Clear Button 22
Closed Containers 11, 77
-CN 4
Code Explanations 74
Command Interface 74
Command Window 102
Common Mode Rejection 8
Common Mode Voltage Range 8
Communication Cables 21
Compression 17
Compression Gasket 12
Configuration Mapping Setup Page 63
Configuration Menu 51
Configuration Page 59
Connectivity 3
Connector 11, 77
Control Link Float Out (EFO) 64
Control Lost 1, 77
Control of the Rack_Size and Starting_Quarter Combinations 10
Controlled Static Environment 11, 77
ControlNet 5
ControlNet Option Board 9
Core Technologies 51
Corrective Action 58
Current Loop Power 9
Cut Off Frequencies 27
D
Day-dd Field 43
-DC Power Wiring 16
DCS 1
Decimal Point Parameter 26
Default I/Os 41
Default Settings 74
Defaulted I/O? Parameter 40
Index
Derivative 24
Derivative Parameter 39
Destinations 65
Destinations and Sources 63
Device Data List 94
DeviceNet 4, 7
DeviceNet input and Output Tables 72
DeviceNet Input Table 72, 74
DeviceNet interFace 3
DeviceNet Output Table 74
DeviceNet Tables 73
DeviceNet™ 4
Diagnostic Menus 94
Diagnostics 94, 95, 99
Diagnostics Display 95, 98
Diagnostics Menus 94
Diagnostics Page 74, 99
Dimensions of the Panel Cutout 12
Disassembly 11, 77
Disassembly and Reassembly Notes and Cautions
Display Increments (Graduations) 7
Do C2 Calibration 57
Do C2 Calibration Button 59
Do Cal High Button 60
Do Cal High Calibration Completed OK 60
Do Cal Low Button 60
Do Cal Low? 53
Do Soft Cal? 56
Do Span Cal? 53
Dressed 16
Drop Out 103
Drop-Out Current 103
E
E - Non-Return to Zero 82
Electrical Check Procedures 62
Electrical Installation 16
Electrical Parts 11, 77
Electrical Plug 11, 77
Electrostatic Discharge 11, 12, 77
Embedded Web Server 3
Enclosure Front Panel 13
Enclosure Ratings
10
Enclosure Size Requirements 12
Enter Button 22
Entry Accepted 96
Environmental Requirements 8
Error in Option Slot 0 77
Error in Option Slot 1 77
Error Messages 77
ESD 11, 12, 16, 77
EST 30
Ethernet - 10/100 Base T 7
Ethernet and TCP/IP sockets 5
Ethernet IP Port 3
Ethernet Parameters 31, 41
Ethernet/IP 1
EtherNet/IP™ (Pending) 5
EtherNet/IP™ Option Card (Pending)
Example #2 Mapping an Alarm 67
Excitation Monitor 7
Excitation Voltage 7
Exit Button 22
Exiting the Root Directory. 103
Extranet 1, 31
9
F
77
F - Verify Individual Load Cell Milli-Volt Readings 83
F(a) - Verify Individual Load Cell Readings Using Diagnostics 84
Factory Defaults 99
Fail Display 97
FALSE 73
False High Alarm Level Conditions 38
False Low Alarm Level Conditions 37
Fanuc 5
Fastener Knobs 14
Field Configurable 1
Float 73
Flow Chart 77
Follow Proper Safety Procedures 12, 77
For Further Information Contact 104
Force Factor 55, 56
Force Outputs 95
Force Outputs Function 95
Force Outputs Menu 96
Front Panel 21
Front Panel Display 21
Front Panel NEMA 4 Seal 8
Function Error 58
G
G - A/D Failure Error 85
Gain/1 Button 22
GE 5
General Policies and Information 103, 104
General Troubleshooting Flow Chart Index 78
Getting Started 21, 51
Getting the Parameter Information on the Web Browser
74
GMT 30
GMT Time Adjustment 30
Greenwich Mean Time 30
Greenwich, England 30
H
H - Mechanical Inspection 86
Hardy C2® Second Generation 51
Hardy Input and Output Tables 72
Hardy Instruments C2 Certified Load Sensors 3
Hardy Instruments Web Site 18
Hardy Technical Support Technician 94
HI 3300 Tension Controller
Service Manual
Hardy Web Site 1
Hardy Web Tech 1, 3
Help 21
Help Button 21, 22
Help Dialog 21
Help Dialogs 2
HFI0 73
HFI1 73
HI 215JB-SS1 or PS1 Series 10
HI 3000 Manual 18
HI 3000-RC 4
HI 3300 1
HI 3300 Panel Mount 11
HI 3300 Tension Controller 1
HI 3300R 1
High Alarm Delay Parameter 38
High Alarm Parameter 37
High Tension 1
High Tension Alarm 77
Hold Level Parameter 36
Home 59
Hour-hh Field 43
http//www.hardyinstruments.com
Humidity Range 8
Hysteresis 94
Junction Box Wiring
K
K - Load Sharing and Load Sensor Checkout
Key Pad 1
Knurled Knobs 16
Leakage Current 103
LED Display 1
Left Arrow Button 22
LHS 73
LHS (Left Hand Side) 73
Load Cells 51
Load Point Cables 21
Load Point Connections 17
Load Sensor Number 57, 58
Load Sensors 1
Lock Washers 11, 77
Low Alarm Delay Parameter 37
Low Alarm Parameter 37
Low Tension 1
Low Tension Alarm 77
LVDT Tension Sensor - MB Series Connection
1
I/O Block 4
I/O Module 4
Individual Boolean Variable 72
Infra Red (IR) Port Parameter 28
Input 7
Input Table 74
Installation of Secure Memory Module 18
Installing Printed Circuit Boards 15
Installing the HI 3300 in a Panel 12
Installing the HI 3300 in a Swivel/Wall Mount
Installing the HI 3300 Tension Controller 12
Instrument ID 25
Instrument Local I/O 8
Instrument Setup 41
Instrument Setup Procedures 25
Integral 24
Integral Nonlinearity 9
Integral Parameter 39
Interface 4
Internet 31
Internet (World Wide Web) 1
Intranet 1, 31
IR (Infra Red) Port 1
IrDA (Infrared Data Association) 28
J - Electrical Inspection 87
J9 Terminal Block 17
-JB 4
88
L
17
M
I
J
18
13
M - Weight Reading Stops Incrementing 89
Main Board 15
Maintain a Setpoint Tension 24
Manual 22
Manual - Operator Controlling the Process 23
Map Button 65
Mapped I/O 1, 3
Mapping a Hardy Control-Link Network to a ControlNet/
DeviceNet/Profibus Network. 76
Mapping a Network Input to a Local Output 70
Mapping Multiple Sources 68
Mapping Setup 63
Mapping to a Network Output 69
Mapping to a Network Output Table 63
Max I/O Data Capacity
10
Max Offset 9
Maximum Capacity 54
MaxTension Parameter 27
-MB 4
Mean Squared Variation 97
Mechanical Calibration Setup for Traditional Calibration
51
Mechanical Installation 12
Mechanical Noise 3, 27
Memory Address (Variable) 71
Method 2
Calibration 60
Method 3
Calibration - Soft Cal 61
Index
Millivolt 98
Millivolt Reading 98
Minute-mm Field 43
Misalignment 1
Misalignment Alarm 77
Misalignment Tolerance Parameter
Mixed Mapping 73
Modbus Over TCP/IP 5
Month-mm Field 43
Mounting Kit 11
Multiple Controllers 5
Multiply 73
mV/V and Weight 98
mV/V and Weight Display 98
P
Pacific Standard Time 31
Palm OS® 28
Panel Cutout Specifications 12
Panel Mount (Model # HI 3010-PM 8
Panhead Screw 15
Parallel Resistor 104
Parallel Shunt Resistor 104
Parameter Number 74
Parameter Numbers 74
Parameter Value 73
Parameters 94
PARAMID 73, 74
Pass Display 97
-PB 4
PC Boards 16
PDA 1
Performance Diagnostics 1
Phillips Head Screw Driver 15
Physical Characteristics 8
PID Control 22
PID Control for Mid-Process (intermediate) Zone
PID Control for Rewinding Zone 2
PID Control for Unwinding Zone 2
PID Controller 1
Ping Tool 102
PING Utility 103
PLC® 1
Pocket PC 28
Pounds Force (lb) 26
Pounds Force (lbf) 38
Pounds per Linear Inch (Pli) 26
Pounds Per Linear Inch (Pli) 38
Power 8
Power and Relay Circuit Card 16
Power and Utility Requirements 7
Power Input J1 16
Power Supply 9
38
N
N - Blank Screen 90
Name of the Product 22
Neatly Bundled 16
Negate 73
NEMA 4 & 4X 12
NEMA 4X 4
Network Card 95
Network Option Card Installation 18
Network Pull Down Menu 63
Newtons (N) 26
No C2 Sensor 77
Non-C2 Load Point Connection 17
Non-Linearity 7
Nonvolatile Memory Failure 77
Normally Open 96
NOT 72
O
O - Display Stuck on a Screen 91
Offset 73
OK to Fill Input Parameter 41
OLE Technology (DCOM) 5
OLE/COM 5
On-Board Diagnostics 3
On-board Help Files 3
Online Tech Support Knowledge Base
OPC 5
Operating Mode Display 23
Operating Temperature 9
10
Operating Temperature Range 8
Operator ID 26
Options 4
OR 72
Ordering Replacement Parts 104
Original Point of Removal 11, 77
Output Alarms 1
Output Sensitivity 94
Output Types 8
Overall Depth 12
10
3
PP# = Program Part Number 94
Pre-Startup 95
Prevent Damage 37
Prime Meridian 30
Print Button 22
Printed Circuit Boards 11, 77
Process Setup 43
Process Setup Procedures 32
Prod 1 Parameter 33
Prod 2 Parameter 33
Prod 3 Parameter 34
Product Button 22
Product Menus 22
Profibus 1, 5
Profibus (Process Fieldbus) 5
Profibus Interface 4
Profibus Option Board 9
Program Version 94
2
HI 3300 Tension Controller
Service Manual
Programmable Logic Controllers (PLC)
Proportional 24
Proportional Parameter 38
Provide Feedback Link 3
5
R
R - View Input States 92
READINTEGER 74
Rear Cover 13
Reassembly 11, 77
Recommended Installation Procedures
Recommended Load Cell Cable 17
Ref Wgt 57
Reference Weight 58, 60
Reference Weight Text Field 58
Relays 4
Remote I/O 5
Removing Printed Circuit Boards 16
Repairs 11, 77
Report Any Damage 11
Resolution 7, 8, 98
Resource CD 18
Right Arrow Button 22
-RIO 4
RIO Baud Rate
16
10
RIO Option Board 10
RIO Supported Features
10
Roll Weight and Load Sensors Have Been Zeroed and
Calibrated 21
Root Directory 102
RS Networks® 3
S
S - Forcing Outputs 93
Scale Capacity Parameter 28
SCR Switching Load Circuit 103
Scratchpad 66
Screws 11, 77
Secure Memory Module 19
Secure Memory Module (SMM) 4
Security Violation 58
Selectable Predetermined 5
Selecting a Destination 63
Selecting a Source 64
Sensor Type Parameter 28
Sensor Types 56
Serial Port Parameters 41
Service Manuals 11
Set Clock Parameter 29
Set Date/Clock Parameters 43
Set LCD Contrast Parameter 32
Set the Factory Defaults 100
Set the Span Value 53
Setpoint in Use Parameter 32
Setting the P (Proportional) + I (Integral) + D (Derivative) Parameters (PID) 24
Setup Dialogs 3
Setup/3/DEF Button 23
Short Integer 73
Siemens 5
Silicon Controlled Rectifier (SCR) 103
Simple Network Mapping 69
Sliding Average 27
Slotted Head Screwdriver 13
Small Fasteners 11, 77
Small Logic Controllers (SLC 5
Smart Devices 4
SMM 4, 18
SMM (Secure Memory Module) 1
Snubbing Network 104
Soft Calibration - Wrap Angles or Force Factor 7
Soft Calibration from the Front Panel 54
Soft Calibration from the Web Page 60
Solenoid 103
Solid State Relays 103
Sources 66
Spacers 11, 77
Span Weight Field 60
Span Wgt. 53
Special (Command) Mapping) 73
Specifications 7
Specifications for I/O Option Boards 9
Specifications for Peripherals/Systems Components 10
Splice Level Parameter 36
Stability Test 96
Stand-Alone PID Closed Loop Controller 1
Standard Interfaces 7
Standard SPST (Form A) Setpoint Relays 7
Standby - Prepared and Waiting to Start 23
Standby Display 94
Start Button 21
Start Level Parameter 34
Start Multiple Parameter 35
Start Time Parameter 35
Starting Up for the First Time 23
Stop - Controller and Process are Stopped 23
Stop Button 21
Stop Level Parameter 35
Stop Time 36
Storage Temperature Range 8
Support Section 1
Swivel Bracket 13
Swivel Mount 13
Swivel Mount Brackets 13
Swivel Mounted 1
Syntax 73
System Integrity Check and Fault Determination From
the Front Panel 94
System Integrity Check and Fault Determination From
The Web Browser 99
System Support 104
Index
T
Taper Percent Parameter (Rewind Only) 40
Taper Percentage 23
Taper/4/GHI 23
Technical Support Department 1
Temperature Coefficient 8
Tension 17
Tension Control Process 24
Tension Control. Home Page 46
Tension Controller 1
Tension Controller Configuration From the Front Panel
24
Tension Controller Configuration From the Web Page
41
Tension Controller Home Page 41, 58, 59
Tension Controller system 77
Terminal Blocks 18
Test and Data Menu 94
Test Button 3
Test Weight 53
Test/9/WXYZ Button 23
Texas Instruments 5
The Process Setup is Complete 45
The Secure Memory Module 4
The WAVERSAVER® Parameter 27
Tied 16
Timezone Field 43
Traditional - Calibration with Test Weights 7
Traditional Calibration 3, 51, 52
Traditional Calibration From the Front Panel 51
Traditional Calibration From the Web Page 59
Transferring a Secure Memory Module 19
Troubleshooting 77
Troubleshooting Techniques 104
Troubleshooting The Network Connections and Configuration with the "Ping" Tool 102
TRUE 73
U
UDP 100
UDP/IP (User Datagram Protocol) 5
Unit of Measure Parameters 26
Units/5/JKL Button 23
Universal Power Supply 16
Universal Power Supply (50/60 Hz) 7
Unpacking 11
Up/Down - Left/Right Buttons 22
Update Rate 7
User Guide 11
User/./_/@ Button 23
V
Valid Ranges 74
Vibration Analysis 1
Vibratory Forces 27
View Inputs 95
View/Force Outputs 95
Voltage & Weight Displays 95
VPN 1
VPN (Virtual Private Network) 31
W
Wall Mount 13
Wall Mount (HI 3300-MB) 8
WAP Enabled Devices 3
Warranty 104
Washers 11, 77
Watts available for DeviceNet Power
WAVERSAVER 3, 7
WAVERSAVER pull down menu 42
WAVERSAVER® 1, 3, 24
WAVERSAVER® Technology 3
Web and Strand Tension Control 2
Web Browser 21
Web Width 40
Weight and Voltage 98
Wireless Connectivity 1
Wiring Harness 11, 77
Wrap Angle 1 57
Wrap Angle 2 57
WRITEFLOAT 73
WRITEINTEGER 73
WRITESTRING 73
Y
Year-yyyy Field
43
Z
Zero Cal Reference Weight
Zero Point 52
60
8
HI 3300 Tension Controller
Service Manual
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
Hard Instruments Document Number: 0596-0287-01 Rev. E
Copyright December 2004, Dynamic Instruments, All Rights Reserved. Printed in the U.S.A.
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